JP2020132390A - Manufacturing method of sheet-like material and molded article - Google Patents
Manufacturing method of sheet-like material and molded article Download PDFInfo
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- JP2020132390A JP2020132390A JP2019030318A JP2019030318A JP2020132390A JP 2020132390 A JP2020132390 A JP 2020132390A JP 2019030318 A JP2019030318 A JP 2019030318A JP 2019030318 A JP2019030318 A JP 2019030318A JP 2020132390 A JP2020132390 A JP 2020132390A
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- 239000000463 material Substances 0.000 title claims abstract description 100
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 claims abstract description 60
- 230000001681 protective effect Effects 0.000 claims description 28
- 229920005989 resin Polymers 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 6
- 239000012783 reinforcing fiber Substances 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000001514 detection method Methods 0.000 claims description 2
- 238000011282 treatment Methods 0.000 claims description 2
- 238000000465 moulding Methods 0.000 claims 1
- 238000003672 processing method Methods 0.000 abstract description 3
- 230000007547 defect Effects 0.000 abstract 1
- 238000004804 winding Methods 0.000 description 15
- 238000006073 displacement reaction Methods 0.000 description 11
- 239000005011 phenolic resin Substances 0.000 description 4
- 229920000049 Carbon (fiber) Polymers 0.000 description 3
- 239000004917 carbon fiber Substances 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000012778 molding material Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- -1 polyethylene Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- QTWJRLJHJPIABL-UHFFFAOYSA-N 2-methylphenol;3-methylphenol;4-methylphenol Chemical compound CC1=CC=C(O)C=C1.CC1=CC=CC(O)=C1.CC1=CC=CC=C1O QTWJRLJHJPIABL-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 229930003836 cresol Natural products 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 150000003739 xylenols Chemical class 0.000 description 1
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Abstract
Description
本発明は、巻出軸に巻き付けられたシート状物を巻き出し、引取工程を介して搬送する工程を有するシート状物の製造方法およびその製造装置に関する。 The present invention relates to a method for manufacturing a sheet-like material having a step of unwinding the sheet-like material wound around a winding shaft and transporting the sheet-like material through a take-up step, and a manufacturing apparatus thereof.
従来、連続したシート状物を加工する上で、巻出工程から巻取工程の間で、例えば平板プレスのようなバッチサイクルを持つ加工を行う場合は、前記加工工程へ間欠的にシート状物を供給し、加工後製品をまた間欠的に引き取る方式の連続加工法が知られている（例えば特許文献１参照）。 Conventionally, in processing a continuous sheet-like material, when processing with a batch cycle such as a flat plate press is performed between the unwinding process and the winding process, the sheet-like material is intermittently transferred to the processing process. There is known a continuous processing method in which the product is supplied and the processed product is taken back intermittently (see, for example, Patent Document 1).
しかし、前記加工工程における処理内容によって、例えばシート状物を加熱して軟化させる処理や、あるいは加工中の工程張力の変動によって、シート状物が破断したり、伸びが生じたりする問題点がある。ここで、連続的なシート搬送工程において、巻出工程と加工工程の間にシート状物のループを形成し、ループ位置を一定に保つよう制御を行うことで巻出張力を無張力とする方法が提案されている（例えば特許文献２参照）。
特許文献２に記載の製造工程では、巻出工程の後に間欠的な引取工程を有していない。間欠的な引取工程においてはループ位置が引取に合わせて常に大きく変動するため、特許文献２記載の発明のように、単にループ位置を一定に保つような制御方法では、巻出軸の回転数の変動が大きくなりすぎ、急回転と急停止とを繰り返し、慣性で過剰にたるみを生成して、シート状物が折れたり、巻出軸に巻かれているシート状物が巻き崩れて折れたりする等、シート状物がダメージを受けるため、安定して搬送することが困難である。 The manufacturing process described in Patent Document 2 does not have an intermittent pick-up process after the unwinding process. In the intermittent pick-up process, the loop position always fluctuates greatly according to the pick-up. Therefore, in the control method for simply keeping the loop position constant as in the invention described in Patent Document 2, the rotation speed of the unwinding shaft is increased. The fluctuation becomes too large, and sudden rotation and sudden stop are repeated, and excessive slack is generated by inertia, and the sheet-like material breaks or the sheet-like material wound around the unwinding shaft collapses and breaks. Since the sheet-like material is damaged, it is difficult to transport it stably.
本発明の目的は、このような従来の搬送方法による連続加工法の欠点を改良し、シート状物に破断や伸びを生じさせずに巻き取ることができるシート状物の製造方法およびその製造装置を提供することにある。 An object of the present invention is a method for producing a sheet-like material and an apparatus for producing the same, which can improve the drawbacks of the continuous processing method by such a conventional transport method and wind the sheet-like material without causing breakage or elongation. Is to provide.
上記目的を達成するために、本発明は、巻出軸に巻き付けられたシート状物を巻き出し、引き取るサイクルを間欠的に繰り返して搬送する工程を有する、シート状物の製造方法であって、前記巻き出しから引き取りまでの間には前記シート状物のたるみが存在し、前記各サイクルにおけるたるみ量のうち、引取完了時点のみのたるみ量を一定範囲に保持する制御を行い、前記制御を、前記シート状物の巻出軸からの巻出量が、前記引取工程による引取量と実質的に同等となるように前記巻出軸を回転させることにより行う、シート状物の製造方法を提供する。 In order to achieve the above object, the present invention is a method for producing a sheet-like material, which comprises a step of unwinding and transporting the sheet-like material wound around the unwinding shaft by intermittently repeating a take-up cycle. There is slack in the sheet-like material between the unwinding and the pick-up, and the slack amount in each cycle is controlled to be maintained in a certain range only at the time when the pick-up is completed. Provided is a method for producing a sheet-like material, which is carried out by rotating the unwinding shaft so that the amount of the sheet-like material unwound from the unwinding shaft is substantially equal to the amount of the sheet-like material taken up by the taking-up step. ..
本発明により、巻出工程から引取工程までのシート状物を実質無張力にすることができ、安定したシート搬送が実現できるので、シート状物に破断や伸びを生じさせずに巻き取ることができる。 According to the present invention, the sheet-like material from the unwinding process to the take-up process can be made substantially untensioned, and stable sheet transfer can be realized. Therefore, the sheet-like material can be wound without causing breakage or elongation. it can.
本発明のシート状物の製造方法において、巻出量、引取量とは、それぞれ、巻出軸に巻き付けられたシート状物を巻き出し、引き取る１サイクル内の巻出長さ、引取長さを指す。巻出量は、より具体的には、１サイクル内に巻出軸を回転させて基材を巻き出す長さであり、必ずしも引取量と同量ではないが、巻出量と引取量とが実質的に同等とすることを目的として制御を行うことが本発明のポイントである。また、後述する巻出速度、引取速度は、それぞれ、巻き取り、引取の工程における単位時間あたりに走行する基材の長さを指す。 In the method for producing a sheet-like material of the present invention, the unwinding amount and the take-up amount are the unwinding length and the take-up length within one cycle of unwinding and taking out the sheet-like material wound around the unwinding shaft, respectively. Point to. More specifically, the unwinding amount is the length of unwinding the base material by rotating the unwinding shaft within one cycle, and is not necessarily the same amount as the unwinding amount, but the unwinding amount and the unwinding amount are different. It is a point of the present invention to perform control for the purpose of making them substantially equivalent. Further, the unwinding speed and the take-up speed, which will be described later, refer to the length of the base material traveling per unit time in the take-up and take-up steps, respectively.
本発明は、例えば巻出工程と引取工程の間の加工工程において、前記シート状物が加工される過程で強度が弱くなり、実質無張力で搬送しないと前記シート状物が破断するような場合に有利である。従って、前記シート状物を構成する材料が、強化繊維に加えて、前記加工工程において軟化するような熱硬化性樹脂である場合に特に有利である。 In the present invention, for example, in the processing step between the unwinding process and the taking-up process, the strength of the sheet-like material is weakened in the process of being processed, and the sheet-like material is broken unless it is conveyed with substantially no tension. It is advantageous to. Therefore, it is particularly advantageous when the material constituting the sheet-like material is a thermosetting resin that softens in the processing step in addition to the reinforcing fibers.
前記シート状物を構成する材料のうち、熱硬化性樹脂としてはフェノール樹脂（フェノールの代わりにクレゾール、キシレノール、アルキルフェノール等のフェノール類を用いた樹脂を含む）、エポキシ樹脂、不飽和ポリエステル樹脂、メラミン樹脂、ポリイミド等いずれでもよい。フェノール樹脂は、加工工程において軟化する現象が確認されており、本発明を適用することが好ましい例として特に挙げられる。熱硬化性樹脂には、黒鉛粉末、カーボンブラックなどの粒状物質を含んでもよい。また、強化繊維としては、炭素繊維、ガラス繊維や有機繊維などの繊維材料が好ましい。成形材料は、プレス機などの加工工程の設備に接着することを防止するため、離型用の紙やフィルム等に挟んで加工工程に送ることが好ましい。 Among the materials constituting the sheet-like material, the thermosetting resin includes phenolic resin (including resin using phenols such as cresol, xylenol, and alkylphenol instead of phenol), epoxy resin, unsaturated polyester resin, and melamine. Either resin, polyimide, etc. may be used. It has been confirmed that the phenolic resin softens in the processing process, and it is particularly preferable to apply the present invention. The thermosetting resin may contain particulate matter such as graphite powder and carbon black. Further, as the reinforcing fiber, a fiber material such as carbon fiber, glass fiber or organic fiber is preferable. In order to prevent the molding material from adhering to equipment in the processing process such as a press machine, it is preferable to sandwich the molding material between paper or film for mold release and send it to the processing process.
前記強化繊維が短繊維である場合、前記加工工程での強度低下の問題が更に顕著になるため、本発明の製造方法がより有利となり好ましい。 When the reinforcing fiber is a short fiber, the problem of strength decrease in the processing step becomes more remarkable, so that the production method of the present invention becomes more advantageous and preferable.
次に、前記シート状物の巻出軸からの巻出量が、前記引取工程による引取量と実質的に同等となるように巻出軸を回転させ、引取完了した際の前記シート状物のたるみ量を一定範囲に保持する具体的な方法について述べる。 Next, the unwinding shaft is rotated so that the unwinding amount of the sheet-like material from the unwinding shaft is substantially the same as the unwinding amount of the sheet-like material in the taking-up step, and the sheet-like material when the take-up is completed. A specific method for keeping the amount of slack in a certain range will be described.
第一の方法は、前記巻出軸をフリーロールとする場合である。ここでフリーロールとは、軸に回転動力源、増減速ギア、クラッチ等の機構部品が接続されておらず、ベアリング等によって軸の保持だけを行い、保持している部品の摩擦力のみで回転力にブレーキがかかる状態であって、外力により軸が回転力を受けると自由に回転する状態、またはその状態となり得る軸体のことを言う。準備段階として、前記巻出軸に予め前記シート状物を保護フィルムとともに二層として巻き付けておく。次に、保護フィルムを前記シート状物とは別の独立したパスラインに通し、巻き取る。前記保護フィルムが巻き取られる際の張力によって巻出軸に回転し、保護フィルムと同じ長さ分のシート状物が巻き出される。このとき、保護フィルムの引取速度を、あらかじめ算出して得られた引取工程による引取速度の平均速度に設定することで、巻出工程におけるシート状物の巻取量が引取工程における引取量と実質的に同等か、近い範囲となるように巻出軸が回転し、巻き出される。前記巻出軸と前記引取工程との間に形成される前記シート状物のたるみ量がある範囲を超えると、巻出工程から引取工程までの間にシート状物に張力がかかるが、前記保護フィルムの伸びや前記保護フィルムと前記シート状物との層間のずれにより、わずかに前記たるみ量が増減し引取誤差が生じる場合がある。この誤差を補正するため、本発明では、引取完了時のみ、すなわち、引取工程において１サイクルの引取が完了して最もたるみ量が小さくなるとき（以下、いう。）を含む時点のみにおいて、前記たるみ量の変動が一定範囲となるよう、前記保護フィルムの引取速度を調整する。
ここで、前記シート状物のたるみ量は、引取工程の引取動作に合わせて絶えず増減するため、引取中のたるみ量を常に一定にする制御方法は、前記保護フィルムの引取速度の変動が大きくなり、巻出軸からの巻出量が安定せず、張力がかかって前記シート状物が破断したり、過剰に巻き出されたりするため好ましくない。言い換えれば、上記特許文献２のように、１サイクルにおける引取完了時以外の他の時点において、たるみ量を一定範囲に保持する制御を行うと、例えば巻出軸の回転数の変動が大きくなりすぎ、急回転と急停止とを繰り返し、シート状物がダメージを受けることから、制御対象を上記引取完了時のみとする。ただし、引取完了時のみのたるみ量を制御して結果的に１サイクルにおけるたるみ量が一定範囲に保持されていたとしても、本発明に含まれるものとする。また、「引取完了時のみ」とは必ずしもわずかな時間を意図するものではなく、上記のようなシート状物へのダメージにつながる動作とならない範囲で、引取完了の瞬間を含む前後の時間、たるみ量の変動を制御することがあってもよい。
第二の方法として、前記第一の方法における前記巻出工程の巻出軸を動力による駆動式とする方法が挙げられる。この方法では、前記巻出軸に巻き付けられている前記シート状物および保護フィルムのロール表面の巻出速度が、前記引取工程の引取平均速度となるように定常的に回転させる。この方法でも同様に前記引取誤差が生じるため、前記引取工程におけるたるみ量の最小点においてたるみ量の変動が一定範囲となるよう、前記巻出軸の回転速度を調整する。
第二の方法においても、１サイクルの間中シート状物のたるみ量を制御する方法は同様に好ましくない。前記巻出軸の回転数の変動量が大きくなったときに巻出量が安定せず、やはり同じように張力がかかって前記シート状物が破断したり、過剰に巻き出されたりするためである。
ここで、前記シート状物の前記たるみ量を検出する検出工程を設け、検出した引取誤差を自動調整すると、前記引取誤差を吸収できるため、更に安定した搬送を実施することができる。前記たるみ量を検出する手法としては、前記シート状物に張力をかけないような非接触タイプのものが好ましい。たとえば、レーザー変位センサなどの光学センサや、超音波変位センサなどを選択することが更に好ましい。検出された前記たるみ量の情報は、前記第一の方法では前記フィルム引取速度へ、前記第二の方法では前記巻出軸の回転速度へ、それぞれフィードバックすることで、前記引取誤差を吸収する。
The first method is a case where the unwinding shaft is free-rolled. Here, free roll means that mechanical parts such as a rotational power source, acceleration / deceleration gear, and clutch are not connected to the shaft, only the shaft is held by bearings, etc., and rotation is performed only by the frictional force of the held parts. It refers to a state in which the force is braked, and the shaft rotates freely when the shaft receives a rotational force due to an external force, or a shaft body that can be in that state. As a preparatory step, the sheet-like material is previously wound around the unwinding shaft as two layers together with a protective film. Next, the protective film is passed through an independent pass line separate from the sheet-like material and wound up. The protective film is rotated by the unwinding shaft due to the tension when it is wound up, and a sheet-like material having the same length as the protective film is unwound. At this time, by setting the take-up speed of the protective film to the average speed of the take-up speed obtained by the take-up process obtained in advance, the take-up amount of the sheet-like material in the unwinding process is substantially the same as the take-up amount in the take-up process. The unwinding shaft is rotated so as to be in the same or close range. When the amount of slack in the sheet-like material formed between the unwinding shaft and the take-up process exceeds a certain range, tension is applied to the sheet-like material between the unwinding process and the take-up process, but the protection The amount of slack may slightly increase or decrease due to the elongation of the film or the displacement between the layers of the protective film and the sheet-like material, which may cause a take-back error. In order to correct this error, in the present invention, the slack is described only when the pick-up is completed, that is, when the pick-up process completes one cycle and the amount of slack is the smallest (hereinafter referred to as “sag”). The take-up speed of the protective film is adjusted so that the fluctuation of the amount is within a certain range.
Here, since the amount of slack in the sheet-like material constantly increases or decreases in accordance with the picking operation of the picking process, the control method for keeping the amount of slack during picking always constant causes a large fluctuation in the picking speed of the protective film. The amount of unwinding from the unwinding shaft is not stable, and tension is applied to the sheet-like material, which is not preferable because the sheet-like material is broken or excessively unwound. In other words, if control is performed to keep the amount of slack within a certain range at a time other than the time when the take-up is completed in one cycle as in Patent Document 2, for example, the fluctuation of the rotation speed of the unwinding shaft becomes too large. , Sudden rotation and sudden stop are repeated, and the sheet-like object is damaged. Therefore, the control target is limited to the time when the above-mentioned collection is completed. However, even if the amount of slack in one cycle is maintained within a certain range by controlling the amount of slack only when the collection is completed, it is included in the present invention. In addition, "only when the collection is completed" does not necessarily mean a short time, and the time before and after including the moment when the collection is completed and the slack within the range that does not lead to damage to the sheet-like object as described above. You may control the variation in quantity.
As a second method, there is a method in which the unwinding shaft of the unwinding step in the first method is driven by power. In this method, the roll surface of the sheet-like material and the protective film wound around the unwinding shaft is constantly rotated so as to be the average take-up speed of the take-up step. Since the take-up error also occurs in this method, the rotation speed of the unwinding shaft is adjusted so that the fluctuation of the slack amount is within a certain range at the minimum point of the slack amount in the take-up step.
In the second method as well, a method of controlling the amount of slack in the sheet-like material during one cycle is also not preferable. This is because the unwinding amount is not stable when the fluctuation amount of the rotation speed of the unwinding shaft becomes large, and the same tension is applied to the sheet-like material to break or excessively unwind. is there.
Here, if a detection step for detecting the amount of slack in the sheet-like material is provided and the detected take-back error is automatically adjusted, the take-back error can be absorbed, so that more stable transport can be performed. As a method for detecting the amount of slack, a non-contact type that does not apply tension to the sheet-like material is preferable. For example, it is more preferable to select an optical sensor such as a laser displacement sensor, an ultrasonic displacement sensor, or the like. The detected information on the amount of slack is fed back to the film take-up speed in the first method and to the rotation speed of the unwinding shaft in the second method to absorb the take-back error.
以下、図面に示す実施例に基づいて本発明を更に詳しく説明する。
図１は、本発明の方法の実施の一例を示すもので、巻出工程Ａ、加工工程Ｂ、引取工程Ｃ、巻取工程Ｄ、シート状物Ｅから構成される。前記シート状物Ｅは図１左側から右側に向かって搬送される。
巻出工程Ａでは、前記シート状物Ｅが巻き付けられた巻出軸Ａ１が巻出方向に回転することで、たるみ量Ａ２が設けられる。たるみ量Ａ２は変位センサＡ３を用いて測定することができる。前記シート状物Ｅとともに前記保護シートＡ４が供巻きされている場合は保護フィルム巻取ニップロールを介して保護フィルム巻取軸Ａ６に巻き取ることができる。また、巻出量を厳密にコントロールするため、巻出軸Ａ１に巻径変位センサＡ７を設置し、巻径を測定し、巻出軸Ａ１への回転数にフィードバックすることもできる。
加工工程Ｂでは、前記シート状物Ｅに加熱及び加圧（プレス）などの処理を加えて、成形品とすることができる。ただし、引取工程Ｃにより間欠的に引き取られシート状物Ｅが送られる際には、引取に抗するような加工外力はなく、実質無張力となっている。また、加工機Ｂ１にシート状物Ｅが貼り付く懸念がある場合は、離型フィルムや離型紙等を介して加工することもできる。
引取工程Ｃでは、図２に示すように引取機Ｃ１がシート状物Ｅをクランプしたまま（図２−１）引取開始位置から一定距離を走行した後に停止し（図２−２）、クランプを解除し（図２−３）、解除した状態でスタート地点まで戻る（図２−４）ことで間欠的な引取サイクルを成立させる。引き取られたシート状物Ｅは、ニップロールＣ２により巻取工程Ｄに搬送される。ここで引取完了した際のたるみ量とは、図３における引取開始位置Ｃ３から引取完了位置Ｃ４に引取機が移動した直後のたるみ量Ａ２であり、引取サイクルの中で最小のたるみ量を示す。
巻取工程Ｄでは、加工されたシート状物Ｅが巻取軸Ｄ１に巻き取られる。巻取軸Ｄ１での巻取張力を一定にする場合は、前記引取工程のニップロールＣ２と巻取軸Ｄ１との間に張力計を設置することもできる。
Hereinafter, the present invention will be described in more detail based on the examples shown in the drawings.
FIG. 1 shows an example of carrying out the method of the present invention, and is composed of an unwinding process A, a processing process B, a taking-up process C, a winding process D, and a sheet-like material E. The sheet-like material E is conveyed from the left side to the right side in FIG.
In the unwinding step A, the slack amount A2 is provided by rotating the unwinding shaft A1 around which the sheet-like object E is wound in the unwinding direction. The amount of slack A2 can be measured using the displacement sensor A3. When the protective sheet A4 is wound together with the sheet-like material E, it can be wound around the protective film winding shaft A6 via the protective film winding nip roll. Further, in order to strictly control the unwinding amount, a winding diameter displacement sensor A7 can be installed on the unwinding shaft A1, the winding diameter can be measured, and the number of rotations to the unwinding shaft A1 can be fed back.
In the processing step B, the sheet-like material E can be subjected to treatments such as heating and pressurization (pressing) to obtain a molded product. However, when the sheet-like material E is intermittently picked up by the pick-up step C, there is no external processing force to resist the pick-up, and the tension is substantially zero. Further, when there is a concern that the sheet-like material E sticks to the processing machine B1, it can be processed via a release film, a release paper, or the like.
In the pick-up step C, as shown in FIG. 2, the pick-up machine C1 stops after traveling a certain distance from the pick-up start position while the sheet-like object E is clamped (FIG. 2-1), and clamps the clamp. An intermittent take-back cycle is established by releasing (Fig. 2-3) and returning to the starting point in the released state (Fig. 2-3). The taken-up sheet-like material E is conveyed to the winding step D by the nip roll C2. Here, the slack amount when the pick-up is completed is the slack amount A2 immediately after the pick-up machine moves from the pick-up start position C3 to the pick-up completion position C4 in FIG. 3, and indicates the minimum slack amount in the pick-up cycle.
In the winding step D, the processed sheet-like material E is wound around the winding shaft D1. When the take-up tension on the take-up shaft D1 is kept constant, a tension gauge may be installed between the nip roll C2 in the take-up step and the take-up shaft D1.
以下、本発明の実施例を、図面を参照しながら説明するが、本発明は以下の実施態様に限られるものではない。
［実施例１］
巻出軸Ａ１にシート状物Ｅを巻いて準備した。シート状物Ｅには、炭素短繊維を抄紙した炭素繊維紙（目付３０ｇ／ｍ2）にフェノール樹脂を含浸した材料（シート状物の目付に対するフェノール樹脂付着率５０質量％）を使用した。シート状物Ｅの上に保護フィルムＡ４（ポリエチレンフィルム厚み１０μｍ）を供巻きした。
巻出軸Ａ１をフリーロールとし、保護フィルムＡ４をシート状物Ｅとは別の独立したパスラインに通し巻き取った。このとき、保護フィルムＡ４の引取速度（保護フィルムニップロールＡ５）を、あらかじめ算出した引取機Ｃ１の平均速度に設定し、シート状物Ｅの巻出速度が引取機Ｃ１の平均引取速度と実質的に同等となるように回転させた。僅かに生じる引取誤差の修正のため、たるみ量変位センサＡ３を用いてたるみ量をモニターし、引取機Ｃ１が引き取った直後の最もたるみ量が小さくなる点におけるたるみ量のみが一定範囲となるよう、前記保護フィルムの引取速度にフィードバックをかけた。その結果、シート状物Ｅは加工工程において無張力を保ったまま安定して搬送され、巻取軸Ｄ１に巻き取られた。
［実施例２］
巻出軸Ａ１にシート状物Ｅを巻いて準備した。シート状物Ｅには実施例１と同じ材料を使用した。シート状物Ｅには保護フィルムを供巻きしなかった。
巻出軸Ａ１をサーボモータによりシート状物Ｅの巻出速度が引取機Ｃ１の平均引取速度と実質的に同等となるように回転させた。僅かに生じる引取誤差の修正のため、たるみ量変位センサＡ３を用いてたるみ量をモニターし、引取機Ｃ１が引き取った直後の最もたるみ量が小さくなる点におけるたるみ量のみが一定範囲となるよう、巻出軸Ａ１の回転速度にフィードバックをかけた。その結果、シート状物Ｅは加工工程において無張力を保ったまま安定して搬送され、巻取軸Ｄ１に巻き取られた。
［比較例１］
巻出軸Ａ１にシート状物Ｅを巻いて準備した。シート状物Ｅには実施例１と同じ材料を使用した。シート状物Ｅに保護フィルムＡ４（ポリエチレンフィルム厚み１０μｍ）を供巻きした。
巻出軸Ａ１をフリーロールとし、保護フィルムＡ４をシート状物Ｅとは別の独立したパスラインに通し巻き取った。このとき、保護フィルムＡ４の引取速度（保護フィルムニップロールＡ５）を、たるみ量変位センサＡ３を用いてモニターされるたるみ量を一定にするようフィードバックをかけた。その結果、引取機Ｃ１の引取の動きに合わせて巻出軸Ａ１が急回転、急停止を繰り返した。フリーロールである巻出軸Ａ１が慣性で過剰に回転し、巻出量が過剰となり、たるみ量が過多となってシート状物Ｅがつづら折れとなった。折れ箇所が加工機Ｂ１に入るとシート状物Ｅは破断した。
［比較例２］
巻出軸Ａ１にシート状物Ｅを巻いて準備した。シート状物Ｅには実施例１と同じ材料を使用した。シート状物Ｅに保護フィルムを供巻きしなかった。
巻出軸Ａ１をサーボモータによりたるみ量変位センサＡ３を用いてモニターしたたるみ量を一定にするようフィードバックをかけた。その結果、引取機Ｃ１の引取の動きに合わせて巻出軸Ａ１が急回転、急停止を繰り返した。急停止の影響で巻出軸Ａ１は次第に巻き緩み、巻き崩れが発生し、ひずみが生じた箇所でシート状物Ｅに折れが発生した。折れ箇所が加工機Ｂ１に入るとシート状物Ｅは破断した。
Hereinafter, examples of the present invention will be described with reference to the drawings, but the present invention is not limited to the following embodiments.
[Example 1]
A sheet-like material E was wound around the unwinding shaft A1 to prepare. For the sheet-like material E, a material (a phenol resin adhesion rate of 50% by mass based on the grain size of the sheet-like material) was used in which carbon fiber paper (grain 30 g / m2) obtained by papermaking short carbon fibers was impregnated with phenol resin. A protective film A4 (polyethylene film thickness 10 μm) was wound on the sheet E.
The unwinding shaft A1 was used as a free roll, and the protective film A4 was wound through a pass line separate from the sheet-like material E. At this time, the take-up speed of the protective film A4 (protective film nip roll A5) is set to the average speed of the take-up machine C1 calculated in advance, and the unwinding speed of the sheet-like material E is substantially equal to the average take-up speed of the take-up machine C1. It was rotated so that it would be equivalent. In order to correct the slight slack amount, the slack amount is monitored by using the slack amount displacement sensor A3, and only the slack amount at the point where the slack amount is the smallest immediately after the pick-up machine C1 is picked up is within a certain range. Feedback was applied to the take-back speed of the protective film. As a result, the sheet-like material E was stably conveyed in the processing process while maintaining no tension, and was wound around the winding shaft D1.
[Example 2]
A sheet-like material E was wound around the unwinding shaft A1 to prepare. The same material as in Example 1 was used for the sheet E. No protective film was wrapped around the sheet E.
The unwinding shaft A1 was rotated by a servomotor so that the unwinding speed of the sheet-like object E was substantially equal to the average take-up speed of the take-up machine C1. In order to correct the slight slack amount, the slack amount is monitored by using the slack amount displacement sensor A3, and only the slack amount at the point where the slack amount is the smallest immediately after the pick-up machine C1 is picked up is within a certain range. Feedback was applied to the rotation speed of the unwinding shaft A1. As a result, the sheet-like material E was stably conveyed in the processing process while maintaining no tension, and was wound around the winding shaft D1.
[Comparative Example 1]
A sheet-like material E was wound around the unwinding shaft A1 to prepare. The same material as in Example 1 was used for the sheet E. A protective film A4 (polyethylene film thickness 10 μm) was wound around the sheet E.
The unwinding shaft A1 was used as a free roll, and the protective film A4 was wound through a pass line separate from the sheet-like material E. At this time, feedback was applied to the take-up speed of the protective film A4 (protective film nip roll A5) so that the amount of slack monitored by the slack displacement sensor A3 was constant. As a result, the unwinding shaft A1 repeatedly suddenly rotated and suddenly stopped in accordance with the pick-up movement of the pick-up machine C1. The unwinding shaft A1, which is a free roll, rotates excessively due to inertia, the unwinding amount becomes excessive, the slack amount becomes excessive, and the sheet-like material E is zigzag. When the broken part entered the processing machine B1, the sheet-like material E broke.
[Comparative Example 2]
A sheet-like material E was wound around the unwinding shaft A1 to prepare. The same material as in Example 1 was used for the sheet E. No protective film was wrapped around the sheet E.
Feedback was applied to the unwinding shaft A1 so as to keep the amount of slack monitored by the servomotor using the slack displacement sensor A3. As a result, the unwinding shaft A1 repeatedly suddenly rotated and suddenly stopped in accordance with the pick-up movement of the pick-up machine C1. Due to the effect of the sudden stop, the unwinding shaft A1 was gradually unwound and unwound, and the sheet-like material E was broken at the place where the strain was generated. When the broken part entered the processing machine B1, the sheet-like material E broke.
本発明によれば、引取工程において間欠的にシート状物を引き取る工程であればどのような工程にも応用することができ、その応用範囲はこれらに限られるものではない。 According to the present invention, it can be applied to any step as long as it is a step of intermittently picking up a sheet-like material in the picking process, and the range of application thereof is not limited to these.
Ａ 巻出工程
Ｂ 加工工程
Ｃ 引取工程
Ｄ 巻取工程
Ｅ シート状物
Ａ１ 巻出軸
Ａ２ たるみ量
Ａ３ たるみ量変位センサ
Ａ４ 保護フィルム
Ａ５ 保護フィルム巻取ニップロール
Ａ６ 保護フィルム巻取軸
Ａ７ 巻径変位センサ
Ｂ１ 加工機
Ｃ１ 引取機
Ｃ２ 巻取ニップロール
Ｃ３ 引取開始位置
Ｃ４ 引取完了位置
Ｄ１ 巻取軸
A Unwinding process B Machining process C Taking-up process D Winding process E Sheet-like material A1 Unwinding shaft A2 Slack amount A3 Slack amount displacement sensor A4 Protective film A5 Protective film winding nip roll A6 Protective film winding shaft A7 Winding diameter displacement sensor B1 Processing machine C1 Take-up machine C2 Take-up nip roll C3 Take-up start position C4 Take-up completion position D1 Take-up shaft
Claims (8)
前記巻き出しから引き取りまでの間には前記シート状物のたるみが存在し、
前記各サイクルにおけるたるみ量のうち、引取完了時点のみのたるみ量を一定範囲に保持する制御を行い、
前記制御を、前記シート状物の巻出軸からの巻出量が、前記引取工程による引取量と実質的に同等となるように前記巻出軸を回転させることにより行う、シート状物の製造方法。 A method for manufacturing a sheet-like material, which comprises a step of unwinding and transporting the sheet-like material wound around the unwinding shaft by intermittently repeating a take-up cycle.
There is slack in the sheet-like material between unwinding and picking up.
Of the slack amount in each cycle, control is performed to keep the slack amount only at the time of completion of collection within a certain range.
The control is performed by rotating the unwinding shaft so that the unwinding amount of the sheet-shaped material from the unwinding shaft is substantially the same as the unwinding amount of the sheet-shaped material in the taking-up step. Method.
前記巻出軸に前記シート状物が保護フィルムとともに二層に巻き付けられており、
前記保護フィルムを巻き出すことによって前記巻出軸を回転させる、請求項１〜３のいずれかに記載のシート状物の製造方法。 The unwinding shaft is a free roll,
The sheet-like material is wound in two layers together with a protective film on the unwinding shaft.
The method for producing a sheet-like material according to any one of claims 1 to 3, wherein the unwinding shaft is rotated by unwinding the protective film.
After the unwinding step and before the picking step, there is a molding step of subjecting the sheet-like material according to any one of claims 1 to 7 to a heating and pressurizing treatment to obtain a molded product. , Manufacturing method of molded products.
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