JP2020131671A - Device for manufacturing prepreg, heating unit used in device for manufacturing prepreg and method for manufacturing prepreg - Google Patents

Abstract

To efficiently heat a laminate when a prepreg is manufactured.SOLUTION: A manufacturing device 10 includes: supply means 18 that supplies a laminate L of a fiber bundle FB and a resin film 6 in a longitudinal direction of the fiber bundle; an impregnation device 50 that heats and pressurizes the laminate by a plurality of heating rolls and thereby impregnates the fiber bundle with the resin film; and heating means 65 that heats the heating rolls with infrared rays. The laminate is guided so that its surfaces on different sides are alternately brought into contact with the plurality of heating rolls arranged to the downstream side from the upstream side.SELECTED DRAWING: Figure 1

Description

The present invention relates to a prepreg manufacturing apparatus, a heating unit used in the prepreg manufacturing apparatus, and a method for producing a prepreg.

A prepreg made by impregnating a fiber bundle with a resin is widely used. Then, the uniaxial reinforcing fiber prepreg has high strength especially in the longitudinal direction of the reinforcing fiber. Examples of the resin impregnated in the fiber bundle include a thermosetting resin and a thermoplastic resin. As disclosed in Patent Document 1, when producing a prepreg, a laminate having a fiber bundle and resin films located on both sides of the fiber bundle is heated by a heating roll while applying pressure in the stacking direction. receive. At this time, the resin of the resin film melts and impregnates the fiber bundle.

The heating roll usually has a metal roll. The metal roll is formed with a large number of through holes separated in the circumferential direction. Each through hole penetrates the metal roll in a direction parallel to the rotation axis of the heating roll. Then, the outer peripheral surface of the heating roll can be heated by circulating the heat medium through the through hole of the metal roll.

JP-A-2017-43669

When producing a prepreg, it is necessary to heat the laminate to a temperature above 100 ° C. Therefore, oil or the like is used as a heat medium that circulates in the heating roll. When such a heating roll is used, the oil is first heated, then the outer peripheral surface of the heating roll is heated by the heat of the oil, and then the laminate is heated by the heat of the heating roll. Therefore, there is a problem that the heating efficiency is lowered.

The present invention has been made in consideration of the above points, and an object of the present invention is to enable efficient heating of a laminate when producing a prepreg.

[1] A supply means for supplying a laminate of a fiber bundle and a resin film in the longitudinal direction of the fiber bundle, and
An impregnation device that impregnates the fiber bundle with the resin film by heating and pressurizing the laminate with a plurality of heating rolls.
A heating means for heating the heating roll with infrared rays is provided.
A prepreg manufacturing apparatus in which the laminated body is guided so that its different side surfaces are alternately in contact with the plurality of heating rolls arranged from the upstream side to the downstream side.

[2] The prepreg manufacturing apparatus according to [1], wherein the heating means is arranged so as to face the outer peripheral surface of the heating roll and heats the outer peripheral surface with infrared rays.

[3] The heating means includes an infrared source that emits infrared rays and a reflective member that covers the infrared source.
The prepreg manufacturing apparatus according to [1] or [2], wherein the infrared source is located between the reflective member and the outer peripheral surface of the heating roll.

[4] The reflective member is located between the laminated body sent to the heating roll, at least one of the laminated bodies sent out from the heating roll, and the infrared source, [1] to [3]. ] The prepreg manufacturing apparatus according to any one of.

[5] The prepreg according to any one of [1] to [4], wherein the heating roll has a tubular member forming the outer peripheral surface and a heat insulating material provided in the tubular member. Manufacturing equipment.

[6] The prepreg manufacturing apparatus according to [5], wherein the heat insulating material contains glass fiber.

[7] The prepreg manufacturing apparatus according to [5] or [6], wherein the tubular member is made of metal.

[8] The prepreg manufacturing apparatus according to any one of [5] to [7], wherein the tubular member includes a black plating layer on its surface.

[9] The length R [mm] of the circumferential length of the outer peripheral surface of the heating roll and the length L [mm] along the circumferential direction in which the laminated body contacts the outer peripheral surface of the heating roll are as follows. The prepreg manufacturing apparatus according to any one of [1] to [8], which satisfies the relationship of.
0.3 ≤ L / R ≤ 0.7

[10] The prepreg manufacturing apparatus according to any one of [1] to [9], wherein the heating roll is a driven roll.

[11] A heating unit used in a prepreg manufacturing apparatus in which a fiber bundle is impregnated with a resin.
A heating roll that conveys the laminate of the fiber bundle and the resin film while heating and pressurizing,
A heating unit comprising a heating means for heating the heating roll with infrared rays.

[12] A step of supplying a laminate of a fiber bundle and a resin film in the longitudinal direction of the fiber bundle, and
A step of impregnating the fiber bundle with the resin film by heating and pressurizing the laminate with a plurality of heating rolls is provided.
In the step of impregnating, the laminated body moves so that its different side surfaces alternately contact the plurality of heating rolls arranged from the upstream side to the downstream side, and moves with the laminated body of each heating roll. A method of manufacturing a prepreg in which non-contact parts are heated by infrared rays.

According to the present invention, the laminate can be efficiently heated when producing the prepreg.

FIG. 1 is a diagram for explaining one embodiment, and is a schematic diagram for explaining a configuration of a prepreg manufacturing apparatus. FIG. 2 is a diagram showing an example of a heating unit that can be included in the manufacturing apparatus of FIG. FIG. 3 is a schematic diagram for explaining a heating roll that may be included in the manufacturing apparatus of FIG. FIG. 4 is a cross-sectional view taken along the line VV of FIG. 1 and is a diagram for explaining an example of the laminated body.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the drawings attached to the present specification, the scale, aspect ratio, etc. are appropriately changed from those of the actual product and exaggerated for the convenience of illustration and comprehension.

1 to 4 are diagrams for explaining one embodiment according to the present invention and a modification thereof. Of these, FIG. 1 is a side view schematically showing the configuration of a prepreg manufacturing apparatus. 2 and 3 are side views schematically showing a heating roll or heating unit. FIG. 4 is a cross-sectional view showing a laminated body fed to a heating roll or a heating unit.

In the manufacturing apparatus 10 and the manufacturing method described below, the prepreg P is manufactured by impregnating the fiber bundle FB with a resin obtained by melting the resin film 6. In particular, in the present embodiment, measures have been taken to improve the productivity of the prepreg.

First, the prepreg manufacturing apparatus 10 will be described together with the supplied materials.

As shown in FIG. 1, the prepreg manufacturing apparatus 10 includes a supply means 18 for supplying a laminate L of a fiber bundle FB and a resin film 6, and an impregnation apparatus 50 including a plurality of heating rolls 60. There is. Further, the prepreg manufacturing apparatus 10 further includes a covering sheet collecting means 45 for collecting the covering sheet 5 and a prepreg collecting means 15 for collecting the prepreg P. Further, the manufacturing apparatus 10 further includes a measuring means 52 for acquiring information regarding the tension of the fiber bundle FB. Hereinafter, each component of the manufacturing apparatus 10 will be described.

First, the supply means 18 will be described. The supply means 18 includes a fiber bundle supply means 20 for supplying the fiber bundle FB and a film supply means 30 for supplying the resin film 6. In particular, in the illustrated example, the supply means 18 further comprises a cover sheet supply means 40 that supplies the cover sheet 5.

The fiber bundle supply means 20 supplies a plurality of fiber bundle FBs. Here, the fiber bundle FB supplied from the fiber bundle supply means 20 is a long fiber bundle (toe) in which filaments are bundled in a predetermined number. The fiber is typically a fiber called a reinforcing fiber, and examples thereof include glass fiber, carbon fiber, aramid fiber, boron fiber, alumina fiber, and silicon carbide fiber. Two or more of these fibers may be mixed and used. Among these, it is preferable to use carbon fiber from the viewpoint that it is difficult to cut even if a high tension is applied in the longitudinal direction, and the finally obtained prepreg P is lightweight and has high rigidity, and a PAN system having better mechanical properties in the longitudinal direction. Carbon fiber is more preferred.

The average fiber diameter (average fiber width) of each fiber is preferably 6 μm or more, preferably 27 μm or less. The average fiber diameter of each fiber can be a value obtained by averaging the fiber diameters (maximum diameter, maximum width) of any 10 or more places.

The number of fibers contained in the fiber bundle FB is not particularly limited. When the fiber bundle FB is a bundle of carbon fibers, the number of fibers contained in the fiber bundle FB (the number of filaments contained in one strand) is preferably 1000 or more, more preferably 20000 or more, still more preferably. The number is 40,000 or more, while the upper limit can be preferably 200,000 or less, more preferably 100,000 or less, and further preferably 60,000.
In particular, the present invention is more preferably used because both impregnation property and productivity can be achieved when using a large tow having 40,000 or more fibers.
When the fiber bundle FB is a bundle of glass fibers, the number of fibers contained in the fiber bundle FB can be preferably 1000 or more, preferably 20000 or less.

The fiber bundle supply means 20 supplies the fiber bundle FB having a longitudinal direction. In this fiber bundle FB, a large number of fibers contained in the fiber bundle FB are bundled so as to have a longitudinal direction in substantially the same direction. Then, the extending direction of each fiber coincides with the longitudinal direction of the fiber bundle FB. Further, the fiber bundle supply means 20 supplies a plurality of fiber bundle FBs. As an example, the fiber bundle supply means 20 supplies 20 or more and 30 or less fiber bundles FB. For example, in the example shown in FIG. 1, the fiber bundle supply means 20 has a fiber bundle supply roll 21 formed by winding the fiber bundle FB around a bobbin or the like. In the illustrated example, the fiber bundle supply means 20 has 25 fiber bundle supply rolls 21. That is, in the illustrated example, the fiber bundle supply means 20 supplies the fiber bundle FB from each of the 25 fiber bundle supply rolls 21. In particular, in the present embodiment, the fiber bundle supply means 20 supplies a plurality of fiber bundle FBs in parallel by an induction means (for example, an induction roll) (not shown) so that the longitudinal directions of the plurality of fiber bundle FBs are aligned. .. Therefore, the plurality of fiber bundles FB are defined so as to spread (arrange) on a certain virtual surface, and more specifically, in the first direction d1 and the third direction d3 in FIG. It is supplied in parallel so that it spreads on the surface. In other words, the plurality of fiber bundles FB are supplied so as to form a fiber sheet.

The fibers contained in the plurality of fiber bundles FBs supplied in this way generally face one direction. Therefore, the finally obtained prepreg P will also be referred to as a uniaxial prepreg. The uniaxial prepreg will have high strength in the direction in which the fibers extend (longitudinal direction). In the illustrated example, the fiber bundle supply means 20 supplies each fiber bundle FB along the longitudinal direction of the fiber bundle FB. Therefore, the fiber bundle FB unwound from the fiber bundle supply means 20 has high strength in the supply direction, in other words, the transport direction, and has resistance to tension along this direction as described later.

By the way, in order to clarify the directional relationship between the drawings, in some drawings, the first direction d1, the second direction d2 and the third direction d3 are shown as common directions between the drawings. In the illustrated example, the first direction d1 and the third direction d3 are along the horizontal direction, and the second direction d2 is along the vertical direction. Further, in the illustrated example, the first direction d1 coincides with the transport directions of the plurality of fiber bundles FB and the laminate L in macroscopic observation.

As one of the indexes of the performance of the fiber sheet in which a plurality of fiber bundles FB are arranged in parallel, there is a weight per unit area (usually 1 m square), and the performance is expressed as a basis weight. The basis weight of the fiber sheet is preferably 40 g / m ² or more, more preferably 100 g / m ² or more, while the upper limit is preferably 400 g / m ² or less. When the basis weight is not more than the above lower limit, the strength of the fiber bundle is further increased. When the basis weight is not more than the above upper limit, the impregnation property of the resin becomes even higher.

During the production of prepreg P, tension is applied to the fiber bundle FB. When tension is applied to the fibers, the distance between the fibers tends to decrease. Therefore, it is preferable that the fiber bundle is treated to increase the distance between the fibers. The fiber bundle FB may include spacer particles that increase the interfiber distance. By increasing the distance between the fibers in this way, even if a high tension is applied to the fiber bundle FB, the distance between the fibers is widened in advance, so that the resin can be easily impregnated. Further, even if tension is applied to the fiber bundle FB, the distance between fibers is unlikely to be narrowed.

The material of the spacer particles is not particularly limited. The material of the spacer particles is preferably a material in which the spacer particles are not excessively deformed by the temperature and pressure at the time of impregnation. As the material of the spacer particles, a naphthoxazine resin is preferable. The naphthoxazine resin is easily carbonized and is not excessively softened even when a high temperature or pressure is applied. Therefore, a sufficient distance between fibers is secured, and the impregnation property of the resin is further improved.

Further, the spacer particles are preferably inorganic particles, and more preferably inorganic particles excluding metal particles. Regarding the above-mentioned inorganic particles, a colloidal inorganic particle dispersion may be subjected to a treatment such as salting out to aggregate the particles and adjusted to a size suitable as a spacer.

The fiber bundle supply means 20 may include a driving force source that rotationally drives the fiber bundle supply roll 21, or the fiber bundle supply roll 21 rotates according to the tension on the fiber bundle FB to rotate the fiber bundle supply roll 21. It may be a driven roll that pays out a bundle FB. Further, even if the driving force source for rotationally driving the fiber bundle supply roll 21 is configured to be capable of rotating the fiber bundle supply roll 21 in the forward direction, in the reverse direction, and in a driven rotation. Good. For example, when the tension of the delivered fiber bundle FB is an appropriate value, the driving force source may cause the fiber bundle supply roll 21 to rotate in a driven manner. When the tension of the delivered fiber bundle FB is too high, the driving force source outputs the driving torque to the fiber bundle supply roll 21 so as to rotate the fiber bundle supply roll 21 in the normal direction and promote the feeding of the fiber bundle FB. You may. When the tension of the delivered fiber bundle FB is too low, the driving force source outputs the driving torque to the fiber bundle supply roll 21 so as to reverse the fiber bundle supply roll 21 and suppress the feeding of the fiber bundle FB. May be good. The configuration for imparting the above driving force is not limited to the fiber bundle supply means 20, and the rotational drive of the film supply rolls 31A and 31B in the film supply means 30 and the coating sheet supply roll 41A in the coating sheet supply means 40, which will be described later, The same can be applied to the rotation of 41B.

Next, the film supply means 30 will be described. As shown in FIG. 1, the film supply means 30 supplies the resin film 6 to both sides of the plurality of fiber bundle FBs supplied from the fiber bundle supply means 20. In the illustrated example, the film supply means 30 has a first film supply roll 31A and a second film supply roll 31B formed by winding the resin film 6 on a bobbin or the like. As described above, the plurality of fiber bundle FBs supplied from the fiber bundle supply means 20 are in the form of fiber sheets spreading on the surface defined by the first direction d1 and the third direction d3. The first film supply roll 31A supplies the resin film 6 laminated on the fiber sheet from one side (for example, the upper side in the vertical direction) in the second direction d2. Similarly, the second film supply roll 31B supplies the resin film 6 laminated on the fiber sheet from the other side (for example, the lower side in the vertical direction) in the second direction d2.

In the illustrated example, the film feeding means 30 has a pair of nip rolls 32. The plurality of fiber bundle FBs supplied from the fiber bundle supply means 20 pass between the pair of nip rolls 32. The nip roll 32 laminates the resin film 6 supplied from the first film supply roll 31A on the plurality of fiber bundles FB. Further, the nip roll 32 laminates the resin film 6 supplied from the second film supply roll 31B on the plurality of fiber bundles FB. On the downstream side of the pair of nip rolls 32, a laminate L including the pair of resin films 6 and a plurality of fiber bundles FB located between the pair of resin films 6 is obtained.

The resin film 6 can be used by using an arbitrary thermoplastic resin as a film. In particular, the impregnation device 50 of the present embodiment is suitable for a thermoplastic resin film having a high melt viscosity because the laminated body L can be stably heated and pressed.

As the thermoplastic resin, any resin can be used depending on the physical properties of the target prepreg. Specific examples of the thermoplastic resin include polyolefin resin, polyamide resin, polycarbonate resin, polystyrene resin, vinyl chloride resin, acrylic resin, PPS resin, polyetherimide resin, polyetheretherketone resin, polyetherketoneketone resin, and polyester. Examples include resin. Examples of the polyolefin resin include polyethylene resin and polypropylene resin. Examples of the polyamide resin include aliphatic polyamide resins, and specific examples thereof include polyamide 66, polyamide 6, and polyamide 12. Examples of the polystyrene resin include styrene polymer resin, AS resin and ABS resin. Examples of the polyester resin include aromatic polyester resins such as polyethylene terephthalate, and aliphatic polyester resins such as polylactic acid, polybutylene succinate, polybutylene succinate adipate, and polyglycolic acid. A vinyl chloride resin, a polyolefin resin, and a polyetheretherketone resin are preferable from the viewpoint of excellent physical properties and the impregnation property of the resin.

The thickness of the resin film 6 supplied from the film supply means 30 can be preferably 20 μm or more, preferably 200 μm or less. When the thickness of the resin film 6 is at least the above lower limit, the impregnation property of the resin can be further increased. When the thickness of the resin film 6 is not more than the above upper limit, the resin can hardly deteriorate the performance of the fiber bundle.

Next, the covering sheet supply means 40 will be described. As shown in FIG. 1, the covering sheet supplying means 40 supplies the covering sheets 5 on both sides of the laminated body L. In the illustrated example, the covering sheet supplying means 40 has a first covering sheet supply roll 41A and a second covering sheet supply roll 41B formed by winding the covering sheet 5 around a bobbin or the like. The first covering sheet supply roll 41A supplies the covering sheet 5 laminated on the fiber sheet from one side (for example, the upper side in the vertical direction) in the second direction d2. Similarly, the second coating sheet supply roll 41B supplies the coating sheet 5 laminated on the fiber sheet from the other side in the second direction d2 (for example, the lower side in the vertical direction).

In the illustrated example, the covering sheet supplying means 40 has a pair of nip rolls 42. The laminate L passes between the pair of nip rolls 42. The nip roll 42 laminates the covering sheet 5 supplied from the first covering sheet supply roll 41A on the laminated body L. Further, the nip roll 42 laminates the covering sheet 5 supplied from the second covering sheet supply roll 41B on the laminated body L. On the downstream side of the pair of nip rolls 42, as shown in FIG. 4, the laminate L is composed of a pair of coating sheets 5, a pair of resin films 6 located between the pair of coating sheets 5, and a pair of resin films 6. It comes to include a plurality of fiber bundles FB located between.

The covering sheet 5 is not essential for the production of the prepreg P. Therefore, in the manufacturing apparatus 10 (supply means 18), the covering sheet supply means 40 is not essential. However, the covering sheet 5 is a pair of resin films from the viewpoint of improving the handleability of the laminated body L, preventing contamination of rolls and the like, and effectively impregnating the fiber bundle FB with resin. It is preferable to coat one of the resin films 6, and it is more preferable to coat both of the pair of resin films 6.

The coating sheet 5 preferably has strength even when heated to a high temperature. Examples of the material of the coating sheet 5 include fluororesin, polyimide resin, polyethylene terephthalate (PET) resin, and the like. The thickness of the coating sheet 5 is preferably 50 μm or more, preferably 100 μm or less. When the thickness of the covering sheet 5 is at least the above lower limit, the strength of the covering sheet 5 becomes even higher. When the thickness of the covering sheet 5 is not more than the above upper limit, the heating efficiency and the cooling efficiency of the laminated body are further increased, and the heating and cooling costs are further suppressed.

Next, the impregnation device 50 will be described. The impregnation device 50 heats and pressurizes the supplied laminate L to melt the resin film 6 and impregnate the fiber bundle FB with the melted resin. Therefore, the impregnation device 50 has a heating unit 55 for heating and pressurizing the laminated body L.

As shown in FIG. 1, the impregnation device 50 has a plurality of heating rolls 60 arranged in order from the upstream side to the downstream side. Further, for example, as shown in FIG. 2, the impregnation device 50 has a heating means 65 for heating the heating roll 60. In the illustrated example, the heating means 65 is provided for each heating roll 60. In this example, one heating unit 55 is composed of each heating roll 60 and the heating means 65 provided corresponding to the heating roll 60. That is, the heating unit 55 has a heating roll 60 and a heating means 65. In the example shown in FIG. 1, the impregnation device 50 further has a pair of induction rolls 53 provided on the upstream side and the downstream side of the plurality of heating rolls 60, respectively.

The "upstream side" means the upstream side along the movement path of the fiber bundle FB, respectively. Further, the “downstream side” means the downstream side along the movement path of the fiber bundle FB, respectively.

Further, the plurality of heating rolls 60 guide the movement of the laminated body L from the upstream side to the downstream side in order. Each heating roll 60 has a cylindrical side surface outer peripheral surface 60S. The laminated body L is conveyed from the upstream side to the downstream side while contacting the heating rolls 60 of the plurality of heating rolls 60 and changing the direction.

In the present embodiment, the laminated body L is guided by the heating rolls 60 so that the surfaces on different sides of the laminated body L alternately contact a plurality of heating rolls 60 arranged from the upstream side to the downstream side. To. In other words, in the laminate L guided by the plurality of heating rolls 60, one surface and the other surface of the laminate L come into contact with each of the plurality of heating rolls 60 arranged from the upstream side to the downstream side in order. Will be. Therefore, one surface of the laminated body L contacts the odd-numbered heating roll 60 counting from the upstream side, and one surface of the laminated body L contacts the even-numbered heating roll 60 counting from the upstream side. Then, the long laminated body L being conveyed is supported by a plurality of heating rolls 60 so as to be folded in a zigzag manner.

In other words, the heating roll 60 is used as a reference. In the present embodiment, the plurality of heating rolls 60 guide the laminated body L so as to pass different sides of the rotation axis RA in the second direction d2 in order from the upstream side to the downstream side. Therefore, the laminated body L passes through one side of the odd-numbered heating roll 60 in the second direction d2 (upper in the vertical direction in the illustrated example) counting from the upstream side, and the even-numbered heating roll counting from the upstream side. It passes through the other side in the second direction d2 of 60 (the lower side in the vertical direction in the illustrated example).

In the present embodiment, when tension is applied to the laminated body L, the laminated body L is pressed against the outer peripheral surface 60S of the heating roll 60. As a result, the laminated body L is pressurized in the normal direction to the outer peripheral surface 60S, that is, in the thickness direction of the laminated body L, in other words, in the laminating direction of the laminated body L. As a result, heat exchange between the laminate L and the outer peripheral surface 60S of the heating roll 60 is promoted, and impregnation of the resin into the fiber bundle FB by pressurization is also promoted.

In the illustrated example, the laminate L passes through one side of the odd-numbered heating roll 60 in the second direction d2 (upper in the vertical direction in the illustrated example) counting from the upstream side, and is an even number counting from the upstream side. It passes through the other side of the second heating roll 60 in the second direction d2 (the lower side in the vertical direction in the illustrated example). Further, the odd-numbered heating roll 60 counted from the upstream side is located on one side in the second direction d2 (upper side in the vertical direction in the illustrated example) with respect to the even-numbered heating roll 60 counted from the upstream side. There is. On the contrary, the even-numbered heating roll 60 counting from the upstream side is located on the other side (vertically downward side in the illustrated example) in the second direction d2 than the odd-numbered heating roll 60 counting from the upstream side. are doing. As a result, as shown in FIG. 3, the circumferential direction in which the laminated body L (fiber bundle FB) contacts the outer peripheral surface 60S of the heating roll 60 with respect to the length R [mm] of the peripheral surface 60S of the heating roll 60. The value (L / R) of the ratio of the length L [mm] along the line can be increased. The length R is the length of the circumferential length of the outer peripheral surface 60S of the heating roll 60 along the circumferential direction.

By increasing the ratio value (L / R), heat exchange between the laminate L and the outer peripheral surface 60S of the heating roll 60 is promoted, and the impregnation of the resin into the fiber bundle FB by pressurization is also promoted. .. Specifically, the ratio value (L / R) is preferably 0.3 or more from the viewpoint of realizing a significant promotion of impregnation and a significant improvement in productivity. Further, the ratio value (L / R) is preferably 0.7 or less from the viewpoint of equipment restrictions, in particular, from the viewpoint of realizing efficient heating of the heating roll 60 by the heating means. Further, by lengthening the contact length L [mm] of the laminated body L (fiber bundle FB) with the outer peripheral surface 60S of the heating roll 60, the moving speed (linear speed) of the laminated body L (fiber bundle FB) is increased. can do. Thereby, the productivity of the prepreg P can be improved.

Further, the contact length L [mm] of the laminated body L (fiber bundle FB) with the outer peripheral surface 60S of the heating roll 60 is the second direction d2 of the two heating rolls 60 adjacent to the laminated body L along the movement path. It can also be lengthened by shortening the separation interval along the line. In the example shown in FIG. 3, the separation interval D along the second direction d2 of the two adjacent heating rolls 60 is smaller than the sum of the radii r1 and r2 of the two heating rolls 60. According to this example, the laminated body L (fiber bundle FB) can come into contact with the outer peripheral surface 60S over a length of more than half of the peripheral length R [mm] of the outer peripheral surface 60S of the heating roll 60.

In the illustrated example, the heating roll 60 is a driven roll. That is, the heating roll 60 is not a roll to which a rotational force is input by a driving force source. The heating roll 60 rotates due to friction with the laminated body L as the laminated body L moves. Since the heating roll 60 functions as a driven roll instead of a driving roll, the laminated body L can stably receive pressure in the stacking direction when it is located on the outer peripheral surface 60S of the heating roll 60. .. Further, it is possible to effectively prevent the laminated body L from slipping on the outer peripheral surface 60S of the heating roll 60, thereby efficiently exchanging heat between the outer peripheral surface 60S of the heating roll 60 and the laminated body L. can do.

Next, the heating means 65 will be described. The heating means 65 is a means for heating the heating roll 60. In particular, the heating means 65 is a means for heating the outer peripheral surface 60S of the heating roll 60 that comes into contact with the laminated body L and guides the laminated body L. The outer peripheral surface 60S of the heating roll 60 is preferably heated to 120 ° C. or higher by the heating means 65. By heating the outer peripheral surface 60S of the heating roll 60 to 120 ° C. or higher, the impregnation of the resin into the fiber bundle FB can be stabilized. In addition, the transport speed of the laminated body L can be improved to improve the productivity of the prepreg P.

Further, depending on the melting point of the resin contained in the resin film 6, for example, when the resin film 6 contains a heat-resistant resin such as polyetheretherketone, the outer peripheral surface 60S of the heating roll 60 is 300 by the heating means 65. It is preferable to heat the temperature above ° C.

Here, an example of the heating means 65 will be described with reference to FIG. The heating means 65 shown in FIG. 2 heats the heating roll 60 with infrared rays. That is, the heating roll 60 heats the heating roll 60 by irradiating the heating roll 60 with infrared rays. Here, infrared rays are electromagnetic waves having a wavelength of 780 nm or more. The infrared rays emitted from the heating means 65 may be near infrared rays having a wavelength of approximately 780 nm to 2 μm, mid-infrared rays having a wavelength of approximately 2 μm to 4 μm, and far infrared rays having a wavelength of approximately 4 μm to 1000 μm.

In the illustrated example, the heating means 65 is provided so as to face the outer peripheral surface 60S of the heating roll 60. The heating means 65 can directly heat the outer peripheral surface 60S of the heating roll 60 by emitting infrared rays from a position facing the outer peripheral surface 60S. Since the outer peripheral surface 60S of the heating roll 60 that exchanges heat with the laminated body L is directly heated in this way, it is excellent in terms of energy efficiency. Further, since the heating means 65 can be arranged outside the heating roll 60, the degree of freedom in designing the heating roll 60 and the heating means 65 is increased, and the configuration of the heating roll 60 and the heating means 65 can be simplified. ..

The heating means 65 shown in FIG. 2 has an infrared source 66 that emits infrared rays and a reflective member 67 that covers the infrared source 66. The infrared source 66 is located between the reflective member 67 and the outer peripheral surface 60S of the heating roll 60. In other words, the infrared source 66 is arranged in the space partitioned by the reflective member 67 and the outer peripheral surface 60S of the heating roll 60. A part of the infrared rays emitted from the infrared source 66 is directly applied to the heating roll 60. Most of the other infrared rays are reflected by the reflecting member 67 and then irradiated to the heating roll 60. That is, since the infrared rays emitted from the infrared source 66 can be directed to the outer peripheral surface of the heating roll 60 by the reflecting member 67, it is preferable from the viewpoint of energy efficiency.

Various infrared lamps can be used as the infrared source 66. As an example, an infrared halogen lamp can be used as the infrared source 66. The infrared halogen lamp is a highly efficient lamp having a peak in the infrared wavelength region. Further, for example, when a tungsten filament is used as a heat source, infrared rays can be emitted at almost the maximum output immediately after the start of operation of the infrared source 66, and the emission of infrared rays can be stopped immediately after the operation of the infrared source 66 is stopped. it can.

As shown in FIG. 2, the reflective member 67 is located between at least one of the laminated body L sent to the heating roll 60 and the laminated body L sent out from the heating roll 60 and the infrared source 66. According to such an arrangement of the reflecting member 67, it is possible to effectively prevent the infrared rays emitted from the infrared source 66 from being directly irradiated to the laminated body L by the reflecting member 67. As a result, the reflective member 67 promotes that the infrared rays emitted from the infrared source 66 are applied to the outer peripheral surface 60S of the heating roll 60. As a result, the laminate L is not only heated by the heating roll 60, but is also heated while being pressurized. That is, if the laminate L is heated at a timing deviated from the pressurization timing, a loss due to heat dissipation until impregnation occurs, but according to the illustrated example, this loss can be effectively avoided. it can. Therefore, it is possible to promote the impregnation of the resin into the fiber bundle FB in the laminate L.

In the heating unit 55 shown in FIG. 2, the configuration of the heating roll 60 is devised according to the configuration of the heating means 65. That is, as shown in FIG. 2, the heating roll 60 has a tubular member 61 forming the outer peripheral surface 60S and a heat insulating material 62 provided in the tubular member 61. The heat insulating material 62 is a member having a lower thermal conductivity than the tubular member 61. Since the heat insulating material 62 is arranged inside the tubular member 61, it is possible to effectively prevent the heat of the tubular member 61 from moving to the inner side of the heating roll 60. Therefore, the infrared source 66 may emit heat that heats only the tubular member 61, not the entire heating roll 60. As a result, the heat of the tubular member 61 forming the outer peripheral surface 60S can be efficiently transferred to the laminated body L. The thickness of the tubular member 61 is preferably thin from the viewpoint of suppressing the output from the infrared source 66, and is preferably 1 cm or less, for example.

The heat insulating material 62 may contain glass fibers. Since the glass fiber is relatively inexpensive, the heating roll 60 having excellent heat exchange efficiency with the laminate L can be made simple, inexpensive, and lightweight. On the other hand, the tubular member 61 may be made of metal. The metal heating roll 60 can receive the heat from the heating means 65 to the outer peripheral surface 60S with high efficiency, and can efficiently heat the laminated body L in contact with the outer peripheral surface 60S. Further, as shown in the illustrated example, the tubular member 61 may include a black plating layer as the surface layer 61A forming the outermost surface thereof, that is, as the surface layer 61A forming the heating roll 60. The surface layer 61A formed by the black plating layer can efficiently absorb the infrared rays emitted from the infrared source 66 of the heating means 65. In the illustrated example, the heating roll 60 has a surface layer 61A and a tubular main body 61B that supports the surface layer 61A. The tubular body portion 61B may be, for example, a metal tubular portion.

Next, the covering sheet collecting means 45 will be described. The covering sheet collecting means 45 is provided on the downstream side of the impregnation device 50. The covering sheet collecting means 45 is an apparatus for recovering the covering sheet 5 from the laminate L in which the resin impregnation of the fiber bundle FB is completed.

In the illustrated example, the covering sheet collecting means 45 has a first covering sheet collecting roll 46A and a second covering sheet collecting roll 46B for winding up and collecting the covering sheet 5. The first covering sheet recovery roll 46A recovers the covering sheet 5 located on one side in the second direction d2 from the laminated body L. Similarly, the second coated sheet recovery roll 46B recovers the coated sheet 5 located on the other side in the second direction d2 from the laminated body L. The first coated sheet recovery roll 46A and the second coated sheet recovery roll 46B are rotationally driven, for example, according to the transport speed of the laminated body L or the like, or so that a constant tension is applied to the coated sheet 5.

In the illustrated example, the covering sheet collecting means 45 has a pair of nip rolls 47. The laminated body L passes between the pair of nip rolls 47. The nip roll 47 guides one covering sheet 5 toward the first covering sheet recovery roll 46A and guides the other covering sheet 5 toward the second covering sheet recovery roll 46B. By peeling the pair of coating sheets 5 from the laminate L, a prepreg P formed by impregnating the fiber bundle FB with the resin of the resin film 6 can be obtained on the downstream side of the pair of nip rolls 47.

In the illustrated example, a measuring means 52 for acquiring information on tension is provided at a position between the impregnation device 50 and the covering sheet collecting means 45. As the measuring means 52, various types of tension meters such as a contact type and a non-contact type can be used. As a specific example of the contact-type measuring means 52, a sensor that specifies the tension based on the amount of deflection of the measuring object generated when the measuring object is pressed with a constant force in a direction orthogonal to the moving direction is used. Can be done.

A plurality of measuring means 52 may be provided so as to correspond to each fiber bundle FB, for example, as many as the number of fiber bundle FBs contained in the laminate L, or only one may be provided. Further, in the illustrated example, the measuring means 52 is provided on the downstream side of the plurality of heating rolls 60 included in the impregnation device 50, but the measuring means 52 is not limited to this, and the measuring means 52 is upstream of the plurality of heating rolls 60. It may be provided on the side, or may be provided in the middle of the plurality of heating rolls 60. Further, the measuring means 52 may be provided at a plurality of positions along the moving path of the laminated body L. When the plurality of heating rolls 60 are all driven rolls, the tension applied to the laminate L (fiber bundle FB) is constant and does not change significantly while being guided by the plurality of heating rolls 60. Absent.

Next, the prepreg collecting means 15 will be described. The prepreg collecting means 15 is provided on the downstream side of the covering sheet collecting means 45. The prepreg recovery means 15 is a device for recovering the prepreg P produced by impregnating the fiber bundle FB with the resin of the resin film 6.

In the illustrated example, the prepreg recovery means 15 has a prepreg recovery roll 16 that winds up and recovers the prepreg P. The prepreg recovery roll 16 is rotationally driven, for example, so that a constant tension is applied to the laminated body L. More specifically, the prepreg recovery roll 16 is rotationally driven based on the information regarding the tension of the laminated body L acquired by the measuring means 52. For example, if the tension applied to the laminated body L is too high, the drive torque input for the rotation of the prepreg recovery roll 16 is reduced. If the tension applied to the laminated body L is too low, the drive torque input for the rotation of the prepreg recovery roll 16 is increased.

Next, an example of a method of manufacturing the prepreg P by using the prepreg manufacturing apparatus 10 described above will be described.

First, the fiber bundle FB is unwound from the fiber bundle supply means 20 of the supply means 18. The fiber bundle supply means 20 has a large number, for example, 25 fiber bundle supply rolls 21 formed by winding the fiber bundle FB around a bobbin or the like. The fiber bundle FB is unwound from each fiber bundle supply roll 21. The fiber bundle supply means 20 supplies a plurality of fiber bundle FBs having a longitudinal direction in a state of being arranged in parallel on a virtual surface so that the longitudinal directions are aligned. That is, a plurality of fiber bundle FBs are supplied from the fiber bundle supply means 20, and the supplied plurality of fiber bundle FBs are spread in a sheet shape like a fiber sheet and along the longitudinal direction of each fiber bundle FB. Will move.

Next, the resin film 6 is supplied from the first film supply roll 31A and the second film supply roll 31B of the film supply means 30 of the supply means 18. The resin film 6 is laminated on the resin film 6 from both sides along the normal direction to the virtual surface on which the plurality of fiber bundles FB are arranged. The nip roll 32 of the film supply means 30 presses the pair of resin films 6 toward each other with a plurality of fiber bundles FB arranged between them. In this way, a laminate L having a plurality of fiber bundles FB and the resin film 6 is obtained.

After that, the laminated body L proceeds to the covering sheet supply means 40 of the supply means 18. The coating sheet 5 is supplied from the first coating sheet supply roll 41A and the second coating sheet supply roll 41B of the coating sheet supply means 40. The covering sheet 5 is laminated on the laminated body L from both sides along the normal direction (laminated direction) to the laminated body L. The nip roll 42 of the coating sheet supply means 40 presses the pair of coating sheets 5 toward each other with a plurality of fiber bundles FB and a pair of resin films 6 arranged between them. In this way, a laminate L (see FIG. 4) having a plurality of fiber bundles FB, a resin film 6, and a coating sheet 5 is obtained. The supply means 18 supplies the laminated body L in the longitudinal direction of the fiber bundle FB contained in the laminated body L. The laminate L then moves along the longitudinal direction of the fiber bundle FB.

The covering sheet 5 forming the outermost layer of the laminated body L in the laminating direction does not form a part of the prepreg P. Therefore, it is not essential for the production of prepreg P. The coating sheet 5 is provided for the purpose of coating and protecting the resin film 6 and the fiber bundle FB.

Next, the laminated body L proceeds to the impregnation device 50. The laminated body L is guided to a plurality of heating rolls 60 by the induction roll 53 on the upstream side. In the illustrated example, the impregnation device 50 has a first heating roll 60A, a second heating roll 60B, a third heating roll 60C, and a fourth heating roll 60D in this order from the upstream side to the downstream side. The outer peripheral surface 60S of the heating roll 60 is preheated by the heating means 65, for example, to a temperature of 120 ° C. or higher. The laminate L is guided while being heated and pressurized in this order by the first heating roll 60A, the second heating roll 60B, the third heating roll 60C, and the fourth heating roll 60D. The fiber bundle FB and the resin film 6 are covered with the coating sheet 5 to protect them from damage caused by heating and pressurizing. Further, by covering the resin film 6 with the coating sheet 5, it is possible to effectively avoid contamination of the heating roll 60 by the molten resin.

As shown in FIG. 1, the laminated body L moves so that its surfaces on different sides alternately contact each of the plurality of heating rolls 60 arranged from the upstream side to the downstream side. The laminated body L passes through different sides of the rotation axis RA of each heating roll 60 in order from the upstream side to the downstream side. That is, the long laminated body L is supported by a plurality of heating rolls 60 so as to be folded in a zigzag manner in the impregnation device 50. Then, the laminated body L is pressed against the outer peripheral surface 60S of each heating roll 60 by applying tension in its longitudinal direction (moving direction). Further, the heating means 65 heats the outer peripheral surface 60S of the heating roll 60 while the laminated body L is moving in the impregnation device 50, and maintains the temperature at, for example, 120 ° C. or higher. Therefore, the laminated body L is heated by each heating roll 60 and is pressurized in the laminating direction on the outer peripheral surface 60S of each heating roll 60. The resin film 6 of the laminate L is heated to a melting point or higher by contact with the outer peripheral surface 60S of the heating roll 60, so that the resin of the resin film 6 is melted. Further, the molten resin of the resin film 6 impregnates the fiber bundle FB by pressurizing the laminate L in the lamination direction by the tension on the laminate L. In this way, the impregnation device 50 impregnates the fiber bundle FB with the resin film 6.

From the viewpoint of stably impregnating the molten resin of the resin film 6, each fiber bundle FB contained in the laminate L is at least 8 [kgf / bundle] or more for at least a period of time while being guided by the plurality of heating rolls 60. It is preferable that the tension of 10 [kgf / bundle] or more is applied, and it is more preferable that the tension of 15 [kgf / bundle] or more is applied. The tension applied to the laminated body L can be controlled, for example, by adjusting the magnitude of the drive torque input for rotationally driving the prepreg recovery roll 16 of the prepreg recovery means 15. Further, the tension applied to the fiber bundle FB can be controlled based on the information acquired by the measuring means 52.

Further, the laminated body L supported so as to be folded in a zigzag by a plurality of heating rolls 60 secures a large contact length L [mm] (see FIG. 3) of each heating roll 60 with respect to the outer peripheral surface 60S. can do. Then, the laminated body L is guided by the plurality of heating rolls 60 so as to alternately pass different sides of the rotation axis RA of the heating rolls 60 from the upstream side to the downstream side, and 8 [kgf] is applied to the fiber bundle FB. By applying a tension of [/ bundle] or more, the impregnation of the resin into the fiber bundle FB can be promoted, and as a result, the moving speed of the laminate L (the linear velocity of the fiber bundle FB) can be increased. It will be possible. Specifically, as demonstrated in Examples described later, while the laminate L (fiber bundle FB) is guided by the plurality of heating rolls 60, the laminate L (fiber bundle FB) is 0.4. It was possible to move at a linear speed of [m / min] or higher. That is, the prepreg P can be produced in a short time, and the productivity of the prepreg P can be significantly improved.

As described above, the prepreg P can be produced by impregnating the fiber bundle FB with the resin film 6 in the impregnation device 50.

After that, the produced prepreg P proceeds to the covering sheet collecting means 45. The covering sheet collecting means 45 peels off the covering sheet 5 from both sides of the prepreg P and collects it on the first covering sheet collecting roll 46A and the second covering sheet collecting roll 46B. Next, the prepreg P is wound around the prepreg recovery roll 16 of the prepreg recovery means 15.

In one embodiment described above, the laminated body L is guided so that its surfaces on different sides alternately contact a plurality of heating rolls 60 arranged from the upstream side to the downstream side, and the laminated body L is guided. The fiber bundle FB of the above is subjected to a tension of 8 [kgf / bundle] or more for at least a period of time while being guided by a plurality of heating rolls 60. In the present embodiment, the longitudinal directions of the fibers contained in the fiber bundle FB of the laminated body L are aligned. The laminate L has high strength in the longitudinal direction of the fiber bundle FB. Therefore, when the fiber bundle FB is impregnated with the resin of the resin film 6, a high tension can be applied to the laminate L. On the other hand, the laminated body L meanders from the upstream side to the downstream side so as to pass through different sides of the rotation axis RA of each heating roll 60. That is, the long laminated body L is supported by a plurality of heating rolls 60 so as to be folded in a zigzag manner. The ninety-nine folded laminate L can come into contact with the outer peripheral surface 60S of the heating roll 60 in a large area. In addition, when high tension is applied to the laminated body L, the laminated body L receives a strong pressure on the outer peripheral surface 60S of each heating roll 60 in the normal direction to the outer peripheral surface 60S, that is, in the laminating direction of the laminated body L. become. In particular, in the present embodiment, each fiber bundle FB of the laminate L is subjected to a tension of 8 [kgf / bundle] or more by the heating roll 60 for at least a period of time while being guided by the plurality of heating rolls 60. It will be heated. Therefore, the laminated body L is efficiently heated from the outer peripheral surface 60S of the heating roll 60 while receiving high pressure in the laminating direction. As a result, the time required for impregnation can be shortened. As a result, the transport speed of the laminated body L can be improved, and the productivity of the prepreg P can be effectively improved.

In one specific example of the above-described embodiment, the fiber bundle FB contains carbon fibers and the resin film 6 contains a thermoplastic resin. Since the carbon fiber has high strength, it is possible to apply high tension to the laminate L containing the fiber bundle FB. Further, since the resin film 6 contains a thermoplastic resin, the resin of the resin film 6 can be stably impregnated into the fiber bundle FB by heating the laminate L with the heating roll 60.

In one specific example of the above-described embodiment, the fiber bundle FB can move at a linear velocity of 0.4 [m / min] or more while being guided by a plurality of heating rolls 60 in the impregnation step. That is, by applying a tension of 8 [kgf / bundle] or more to each fiber bundle FB, the resin can be stably impregnated into the fiber bundle FB while moving the fiber bundle FB at high speed.

In one specific example of the above-described embodiment, the plurality of heating rolls 60 include four or more heating rolls. That is, in the impregnation step, the laminate L is guided by at least four or more heating rolls. By providing four or more heating rolls 60, it is possible to stabilize the impregnation of the resin into the fiber bundle FB. Further, the transport speed of the laminated body L can be improved, and the productivity of the prepreg P can be effectively further improved.

In one specific example of the above-described embodiment, the outer peripheral surface 60S of the heating roll 60 is heated to 120 [° C.] or higher. By heating the outer peripheral surface 60S of the heating roll 60 to 120 [° C.] or higher, the impregnation of the resin into the fiber bundle FB can be stabilized. Further, the transport speed of the laminated body L can be improved, and the productivity of the prepreg P can be effectively further improved.

In one specific example of the above-described embodiment, the length R [mm] of the peripheral surface 60S of the heating roll 60 and the circumferential direction in which the fiber bundle FB contacts the outer peripheral surface 60S of the heating roll 60 are aligned. The length L [mm] satisfies the following relationship.
0.3 ≤ L / R ≤ 0.7
According to this specific example, since a large area of the outer peripheral surface 60S of the heating roll 60 comes into contact with the laminated body L, the laminated body L can be efficiently heated by the heating roll 60. Further, the transport speed of the laminated body L can be improved, and the productivity of the prepreg P can be effectively further improved.

In one specific example of the above-described embodiment, the prepreg manufacturing apparatus 10 includes a measuring means 52 for measuring the tension of the fiber bundle FB. Therefore, in the step of impregnation, the tension of the fiber bundle FB can be actually specified. By specifying the tension of the fiber bundle FB, impregnation of the resin into the fiber bundle FB can be stably realized.

In one specific example of the above-described embodiment, the plurality of heating rolls 60 are driven rolls. Therefore, the magnitude of the tension acting on each fiber bundle FB of the laminated body L can be made substantially constant while being guided by the plurality of heating rolls 60. As a result, the heating and pressurizing action on the laminated body L on each heating roll 60 is stable, and the impregnation of the resin into the fiber bundle FB can be realized more stably.

In one specific example of the above-described embodiment, the heating means 65 can heat the heating roll 60 by infrared heating. Therefore, the heating means 65 can directly irradiate the heating roll 60 with infrared rays to efficiently heat the heating roll 60. Further, the laminated body L is
The surfaces on the different sides move so as to alternately contact the plurality of heating rolls 60 arranged from the upstream side to the downstream side. That is, the long laminated body L is supported by a plurality of heating rolls 60 so as to be folded in a zigzag manner. The ninety-nine folded laminate L can come into contact with the outer peripheral surface of the heating roll 60 in a large area. In addition, when high tension is applied to the laminated body L, the laminated body L receives a strong pressure on the outer peripheral surface 60S of each heating roll 60 in the normal direction to the outer peripheral surface 60S, that is, in the laminating direction of the laminated body L. become. From these points, heat exchange can be efficiently performed between the outer peripheral surface 60S of the heating roll 60 and the laminated body L. From the above, according to the present embodiment, it is possible to efficiently heat the laminated body L when manufacturing the prepreg P. As a result, the productivity can be improved so that the prepreg P can be produced in a short time.

In the conventional heat medium circulation type heating roll described in the background technology column, since it is necessary to handle the high temperature heat medium with high accuracy, the structure of the apparatus has become complicated and large. Further, there have been problems such as damage to the moving parts of the device and clogging of the heat medium flow path. In addition, for these reasons, the manufacturing cost and maintenance cost of the heat medium circulation type heating roll are also high. On the other hand, the heating means 65 of the present embodiment can solve these conventional problems.

In one specific example of the above-described embodiment, the heating means 65 is arranged to face the outer peripheral surface 60S of the heating roll 60, and the outer peripheral surface 60S is heated by infrared rays. According to this specific example, since the outer peripheral surface 60S of the heating roll 60 that exchanges heat with the laminated body L is directly heated, it is excellent in terms of energy efficiency. Further, since the heating means 65 can be arranged outside the heating roll 60, the configuration of the heating roll 60 and the heating means 65 can be simplified.

In one specific example of the above-described embodiment, the heating means 65 includes an infrared source 66 that emits infrared rays and a reflective member 67 that covers the infrared source 66. The infrared source 66 is located between the reflective member 67 and the outer peripheral surface 60S of the heating roll 60. According to this specific example, the infrared rays emitted from the infrared source 66 by the reflecting member 67 can be directed to the outer peripheral surface 60S of the heating roll 60, which is excellent in terms of energy efficiency.

In one specific example of the above-described embodiment, the reflective member 67 is located between at least one of the laminated body L sent to the heating roll 60 and the laminated body L sent out from the heating roll 60 and the infrared source 66. are doing. According to this specific example, the reflective member 67 can prevent the infrared rays emitted from the infrared source 66 from heading toward the laminated body L. Therefore, the laminated body L is efficiently heated by the outer peripheral surface 60S of the heating roll 60 in a state of being located on the outer peripheral surface 60S of the heating roll 60 and receiving pressure in the stacking direction. As a result, the fiber bundle FB can be stably impregnated with the resin.

In one specific example of the above-described embodiment, the heating roll 60 has a tubular member 61 forming the outer peripheral surface 60S and a heat insulating material 62 provided in the tubular member 61. According to such a specific example, since the heat insulating material 62 is arranged inside the tubular member 61, the heat of the tubular member 61 is effectively prevented from being transferred to the inner side of the tubular member 61. can do. As a result, the heat of the tubular member 61 forming the outer peripheral surface 60S can be efficiently transferred to the laminated body L.

In one specific example of the above-described embodiment, the heat insulating material 62 includes glass fibers. According to such a specific example, the heating roll 60 having excellent heat exchange efficiency with the laminated body L can be made simple, inexpensive, and lightweight.

In one specific example of the above-described embodiment, the tubular member 61 is made of metal. Such a heating roll 60 can receive heat from the heating means 65 on its outer peripheral surface 60S with high efficiency, and can efficiently heat the laminated body L in contact with the outer peripheral surface 60S.

In one specific example of the above-described embodiment, the tubular member 61 includes a black plating layer on its surface. The black plating layer forming the outer peripheral surface 60S of the heating roll 60 can receive the heat from the heating means 65 with high efficiency.

In one specific example of the above-described embodiment, the length R [mm] of the peripheral surface 60S of the heating roll 60 and the circumferential direction in which the fiber bundle FB contacts the outer peripheral surface 60S of the heating roll 60 are aligned. The length L [mm] satisfies the following relationship.
0.3 ≤ L / R ≤ 0.7
According to such a specific example, since a large area of the outer peripheral surface 60S of the heating roll 60 comes into contact with the laminated body L, the laminated body L can be efficiently heated by the heating roll 60. Further, when the outer peripheral surface 60S of the heating roll 60 is heated by infrared rays, unnecessary heat dissipation from the outer peripheral surface 60S of the heated heating roll 60 can be effectively suppressed.

In one specific example of the above-described embodiment, the heating roll 60 is a driven roll. Since the heating roll 60 functions as a driven roll instead of a driving roll, the laminated body L can stably receive pressure in the stacking direction when it is located on the outer peripheral surface 60S of the heating roll 60. .. Further, it is possible to effectively prevent the laminated body L from slipping on the outer peripheral surface 60S of the heating roll 60, thereby efficiently exchanging heat between the outer peripheral surface 60S of the heating roll 60 and the laminated body L. can do.

Although one embodiment has been described by a plurality of specific examples, these specific examples are not intended to limit one embodiment. The above-described embodiment can be implemented in various other specific examples, and various omissions, replacements, and changes can be made without departing from the gist thereof.

Hereinafter, an example of modification will be described with reference to the drawings. In the following description and the drawings used in the following description, the same reference numerals as those used for the corresponding parts in the above-mentioned specific examples are used for the parts that can be configured in the same manner as the above-mentioned specific examples, and the same reference numerals are used, and duplicate explanations are given. Is omitted.

In the specific example of the above-described embodiment, the prepreg is recovered so as to wind up the laminate L and the fiber bundle FB in a state where one end of the laminate L and the fiber bundle FB is fixed to the prepreg recovery roll 16 of the prepreg recovery means 15. By rotationally driving the roll 16, tension can be applied to the laminate L and the fiber bundle FB. Then, the tension acting on the laminate L and the fiber bundle FB can be controlled by adjusting the drive torque input for rotationally driving the prepreg recovery roll 16. However, the control of the tension acting on the laminate L and the fiber bundle FB is not limited to such an example, and can be realized by various configurations and methods. For example, in the above-mentioned example, the prepreg manufacturing apparatus 10 pulls the means for applying back tension to the laminate L and the fiber bundle FB, in other words, the laminate L and the fiber bundle FB to the upstream side of the impregnation apparatus 50. You may have a means of applying force. For example, the tension of the fiber bundle FB may be controlled by outputting a driving torque that opposes the feeding of the fiber bundle FB to the fiber bundle supply roll 21 of the fiber bundle supply means 20.

Further, in the specific example of the above-described embodiment, an example in which the impregnation device 50 has four heating rolls 60 is shown, but the present invention is not limited to this example. The impregnation device 50 may have less than four heating rolls 60, or may include five or more heating rolls 60.

Although some modifications to the above-described embodiments have been described above, it is naturally possible to apply a plurality of modifications in combination as appropriate.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to these Examples.

The prepreg P was manufactured by the above-mentioned manufacturing method using the prepreg manufacturing apparatus 10 shown in FIG. The moving speed of the laminated body L (supply speed of the fiber bundle FB) and the tension applied to the laminated body L (fiber bundle FB) were changed, and it was confirmed whether there was a problem in impregnation.

As the fiber bundle FB, 24,000 carbon fibers (product name TC35 24K manufactured by Formosa Plastics Group) were used. Twenty fiber bundle FBs were supplied in parallel from the fiber bundle supply means 20. The longitudinal direction of the carbon fibers contained in the fiber bundle FB was made to coincide with the moving direction of the fiber bundle FB. A resin film 6 containing a thermoplastic resin was supplied from the film supply means 30 to both sides of the 20 fiber bundle FBs supplied in parallel. The resin film 6 was a polypropylene film having a thickness of 80 μm. The coating sheet 5 was supplied from the coating sheet supply means 40 so as to sandwich the fiber bundle FB and the pair of resin films from both sides. The coating sheet 5 was a sheet made of polyethylene terephthalate resin having a thickness of 100 μm.

The impregnation device 50 was made to include four heating rolls 60. The four heating rolls 60 guide the laminated body L so as to pass through different sides of the rotation axis RA in order from the upstream side to the downstream side. The circumference R of the outer peripheral surface 60S of each heating roll 60 was 480 mm. Further, the length L along the circumferential direction in which the laminated body L contacts the outer peripheral surface 60S of the heating roll 60 was 240 mm.

The heating means 65 heats the outer peripheral surface 60S of the heating roll 60 to 190 ° C. As the heating means 65 of the heating unit 55 included in the prepreg manufacturing apparatus 10, the heating means by infrared heating shown in FIG. 2 was used.

The laminated body L heated and pressurized in the impregnation device 50 was then removed by the covering sheet collecting means 45, and then recovered by the prepreg collecting roll 16 by the prepreg collecting means 15.

While measuring the tension of each fiber bundle FB by the measuring means 52, the driving torque applied to the prepreg recovery roll 16 for winding the prepreg P was adjusted. The measuring means 52 was arranged at a position immediately downstream of the fourth heating roll 60, which is the most downstream side. The tension of each fiber bundle FB measured by the measuring means 52 was substantially the same as the value obtained by dividing the total length force applied to the laminated body L by 20, which is the number of fiber bundle FBs. As shown in Table 1, the tension applied to one fiber bundle FB was changed to 6 kgf, 8 kgf, 10 kgf, 15 kgf and 20 kgf.

The rotation speed of the prepreg recovery roll 16 was controlled to control the moving speed of the laminated body L (fiber bundle FB). The moving speed of the laminated body L (fiber bundle FB) was changed to 0.4 m / min, 0.6 m / min, and 0.8 m / min.

As described above, the tension applied to one fiber bundle FB and the moving speed of the laminated body L (fiber bundle FB) are changed, and three randomly selected places of the manufactured fiber bundle FB after impregnation are optically selected. It was magnified 100 times with a microscope, and the presence or absence of voids, which were resin-impregnated sites, was confirmed. In the photograph, those in which voids were observed even in one place were marked with "x" as insufficient impregnation, and those in which no voids were observed were marked with "○" as complete impregnation.

As shown in Table 1, a prepreg having no voids is manufactured by setting the tension applied to one fiber bundle FB to 8 kgf or more and the moving speed to the laminate L (fiber bundle FB) to 0.4 m / min. It became clear that it could be done. It is known that such a prepreg without voids can obtain high mechanical properties.
It was also found that by increasing the tension applied to one fiber bundle FB from 8 kgf to 20 kgf, a prepreg without voids can be obtained even if the moving speed (linear speed) is increased to 0.8 m / min.
Therefore, it has been clarified that the method of the present invention can produce a prepreg having high productivity and excellent mechanical properties as compared with the conventional method for producing a prepreg.

5 Coating sheet 6 Resin film 10 Manufacturing equipment 15 Prepreg recovery means 16 Prepreg recovery roll 20 Fiber bundle supply means 21 Fiber bundle supply roll 30 Film supply means 31A First film supply roll 31B Second film supply roll 32 Nip roll 40 Coating sheet supply means 41A 1st coated sheet supply roll 41B 2nd coated sheet supply roll 42 Nip roll 45 Covered sheet recovery means 46A 1st coated sheet recovery roll 46B 2nd coated sheet recovery roll 47 Nip roll 50 Impregnation device 52 Measuring means 53 Induction roll 55 Heating unit 60 Heating roll 60A 1st heating roll 60B 2nd heating roll 60C 3rd heating roll 60D 4th heating roll 60S Outer peripheral surface 61 Cylindrical member 61A Surface layer 61B Cylindrical body 62 Insulation material 65 Heating means 66 Infrared source 67 Reflective member P Prepreg L Laminated body FB Fiber bundle d1 1st direction d2 2nd direction d3 3rd direction RA Rotation axis D Separation interval r1 Radius r2 Radius HM Heat medium

Claims (12)

A supply means for supplying the laminate of the fiber bundle and the resin film in the longitudinal direction of the fiber bundle,
An impregnation device that impregnates the fiber bundle with the resin film by heating and pressurizing the laminate with a plurality of heating rolls.
A heating means for heating the heating roll with infrared rays is provided.
A prepreg manufacturing apparatus in which the laminated body is guided so that its different side surfaces are alternately in contact with the plurality of heating rolls arranged from the upstream side to the downstream side. The prepreg manufacturing apparatus according to claim 1, wherein the heating means is arranged so as to face the outer peripheral surface of the heating roll and heats the outer peripheral surface with infrared rays. The heating means includes an infrared source that emits infrared rays and a reflective member that covers the infrared source.
The prepreg manufacturing apparatus according to claim 1 or 2, wherein the infrared source is located between the reflective member and the outer peripheral surface of the heating roll. The production of the prepreg according to claim 3, wherein the reflective member is located between the laminate fed to the heating roll, at least one of the laminates delivered from the heating roll, and the infrared source. apparatus. The prepreg manufacturing apparatus according to any one of claims 1 to 4, wherein the heating roll has a tubular member forming an outer peripheral surface and a heat insulating material provided in the tubular member. The prepreg manufacturing apparatus according to claim 5, wherein the heat insulating material contains glass fiber. The prepreg manufacturing apparatus according to claim 5 or 6, wherein the tubular member is made of metal. The prepreg manufacturing apparatus according to any one of claims 5 to 7, wherein the tubular member includes a black plating layer on its surface. The length R [mm] of the peripheral surface of the heating roll and the length L [mm] along the circumferential direction in which the laminated body contacts the outer peripheral surface of the heating roll have the following relationship. The prepreg manufacturing apparatus according to any one of claims 1 to 8, wherein the prepreg manufacturing apparatus is satisfied.
0.3 ≤ L / R ≤ 0.7 The prepreg manufacturing apparatus according to any one of claims 1 to 9, wherein the heating roll is a driven roll. A heating unit used in a prepreg manufacturing apparatus in which a fiber bundle is impregnated with resin.
A heating roll that conveys the laminate of the fiber bundle and the resin film while heating and pressurizing,
A heating unit comprising a heating means for heating the heating roll with infrared rays. A step of supplying a laminate of a fiber bundle and a resin film in the longitudinal direction of the fiber bundle, and
A step of impregnating the fiber bundle with the resin film by heating and pressurizing the laminate with a plurality of heating rolls is provided.
In the step of impregnating, the laminated body moves so that its different side surfaces alternately contact the plurality of heating rolls arranged from the upstream side to the downstream side, and moves with the laminated body of each heating roll. A method of manufacturing a prepreg in which non-contact parts are heated by infrared rays.

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