JP2022150681A - Scraper and unidirectional fiber-reinforced resin sheet manufacturing apparatus - Google Patents

Abstract

To provide a scraper that can efficiently scrape off adherent materials, such as pieces of reinforcing fibers, attached to an impregnating body for impregnating resin into reinforcing fibers.SOLUTION: A scraper is positioned adjacent to an impregnated material to impregnate a reinforcing fiber with resin. The scraper has a scraping part that scrapes off adhered material on a surface of the impregnated material and a holder that holds the scraping part, and a maximum deflection of the scraping part at a load of 30 N is 0.04 mm or less when the scraper is held by the holder.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a scraper and a manufacturing apparatus for a unidirectional fiber reinforced resin sheet.

A thin film-like fiber reinforced resin (hereinafter simply referred to as "Uni-Direction (UD) Also called "sheet".) is known.

Patent Document 1 describes a method for manufacturing a UD sheet, in which reinforcing fibers fed from a roll body are brought into contact with an impregnating roller carrying a resin material on the surface thereof to impregnate the reinforcing fibers with the resin material. there is

Japanese Patent Publication No. 2001-525749

According to new findings of the present inventors, when a UD sheet is produced by the method described in Patent Document 1, scraps of reinforcing fibers and the like may be mixed into the produced UD sheet. This is because the chips generated when contacting the impregnating roller remain on the impregnating roller, are mixed in the resin material newly supplied to the impregnating roller, and are subsequently conveyed together with the resin material. This is considered to be due to impregnation of the reinforcing fibers.

Therefore, the present inventors attached a commercially available resin scraper to the impregnation roller and attempted to scrape and remove the scraps, but the scraps could not be sufficiently removed.

The present invention has been made in view of the above problems of the prior art, and is a scraper capable of efficiently scraping off deposits such as cut pieces of reinforcing fibers adhering to an impregnating body for impregnating reinforcing fibers with resin. , and an apparatus for manufacturing a unidirectional fiber-reinforced resin sheet having the scraper.

A scraper relating to one embodiment of the present invention for solving the above problems is a scraper arranged adjacent to an impregnation body for impregnating reinforcing fibers with a resin. The scraper has a scraping part for scraping off deposits adhering to the surface of the impregnated body, and a holder for holding the scraping part. The maximum deflection at a load of 30N is 0.04 mm or less.

According to the present invention, there is provided a scraper capable of efficiently scraping off deposits such as cut pieces of reinforcing fibers adhering to an impregnation body for impregnating reinforcing fibers with resin, and a unidirectional fiber-reinforced resin having the scraper. A sheet manufacturing apparatus is provided.

FIG. 1 is a schematic diagram showing an exemplary configuration of a fiber-reinforced resin manufacturing apparatus according to one embodiment of the present invention. FIG. 2A is a schematic perspective view showing the configuration of a scraper used in one embodiment of the present invention, and FIG. 2B is a schematic perspective view showing a disassembled scraper. FIG. 3 is a top view of the scraper shown in FIG. 2A. FIG. 4A and FIG. 4B are schematic diagrams for explaining the length l by which the protrusion protrudes from the holder. FIG. 5 is a cross-sectional view of the protrusion perpendicular to the direction in which the protrusion protrudes from the holder to indicate the lengths indicated by d, t, s and b.

FIG. 1 is a schematic diagram showing an exemplary configuration of a fiber-reinforced resin manufacturing apparatus according to one embodiment of the present invention.

A fiber-reinforced resin manufacturing apparatus 100 includes a bobbin 112 arranged in a yarn supplying section 110, a guide path 120 for moving reinforcing fibers 200 drawn out from the bobbin, a spread section 130, an impregnated body 140, and a recovery roll 150. .

The yarn supplying section 110 supplies reinforcing fibers that are impregnated with the resin in the impregnation body 140 to constitute the fiber-reinforced resin. The yarn supplying section 110 may be, for example, a creel having a plurality of spindles, and a bobbin 112 around which the reinforcing fibers 200 are wound may be rotatably installed on each spindle.

In this embodiment, the reinforcing fibers 200 are carbon fibers. However, the reinforcing fibers 200 may be any fibers used in fiber reinforced resins, such as glass fibers and aramid fibers.

The guide path 120 guides the reinforcing fibers 200 supplied from the yarn supplying section 110 to the constituent sections of the spread section 130, the impregnated body 140 and the collection roll 150 in this order. The guide path 120 has a plurality of guide rolls 122 and a feeder 124 composed of two rolls facing each other with the reinforcing fiber 200 interposed therebetween. The two rolls that make up the feeder 124 rotate in opposite directions to sandwich the reinforcing fibers, thereby moving the reinforcing fibers 200 on the moving path formed by the guide rolls 122 .

The reinforcing fibers 200 are continuously fed out from the bobbin 112 and moved by the feeder 124 so that the reinforcing fibers 200 continue to move on the guide path 120 without interruption.

The reinforcing fibers 200 are continuously fed out from the bobbin 112 and moved by the feeder 124 so that the reinforcing fibers 200 continue to move on the guide path 120 without interruption.

At this time, the feeder 124 applies a predetermined tension to the reinforcing fibers 200 . The tension causes the reinforcing fibers to be oriented linearly in the moving direction. By impregnating the impregnation body 140 with resin in this state, a UD sheet having a plurality of reinforcing fibers 200 arranged in one direction and a matrix resin impregnated in the reinforcing fibers 200 is manufactured. .

The fiber-spreading section 130 spreads the reinforcing fibers 200 . The structure of the fiber-spreading portion 130 is not particularly limited, and the reinforcing fibers 200 may be spread by contact (rubbing) with a rotating roller or bar, or the reinforcing fibers 200 may be spread in a sizing liquid stored in a sizing tank. may be immersed. At the same time, ultrasonic waves may be used to apply vibration to the reinforcing fibers.

The impregnation body 140 impregnates the opened reinforcing fibers 200 with resin (thermoplastic resin).

In this embodiment, impregnation body 140 is a rotating impregnation roller. A molten resin 144 extruded from an extruder 142 adheres to the rotating surface of the impregnated body 140 and rotates. In addition, the impregnated body 140 is heated to a temperature at which the reinforcing fibers 200 are impregnated with the molten resin 144 by the heating unit shown in the accompanying drawings.

The reinforcing fibers 200 moving along the guide path 120 are pressed by a guide roller 146 against the rotating surface of the impregnated body 140, which is an impregnation roller, on which the resin 144 is adhered, and while being in contact with the surface of the impregnated body roller, the surface move along. Due to the contact and movement, the reinforcing fibers 200 are impregnated with the molten resin 144 .

Thereafter, the reinforcing fibers 200 impregnated with the resin 144 are separated from the impregnated body 140 and moved by the guide path 120, cooled, and after the resin 144 is solidified, are wound around the collection roll 150 and collected.

During the contact and movement, some of the reinforcing fibers may be cut and adhere to the surface of the impregnation roller. Alternatively, fluff generated on the reinforcing fibers 200 during the contact and movement described above may separate from the reinforcing fibers 200 and adhere to the surface of the impregnation roller.

When the reinforcing fibers 200 attached to the surface of the impregnation roller by cutting and detachment (hereinafter also simply referred to as "fragments") remain on the impregnation roller, the above-mentioned fragments are added to the resin 144 newly supplied to the impregnation roller. is mixed in. If the cut pieces are impregnated with the resin 144 as they are into the subsequently conveyed reinforcing fibers 200, the manufactured UD sheet will be mixed with the cut pieces.

Therefore, in this embodiment, in the rotation direction of the impregnation roller, after the reinforcing fibers 200 are separated from the surface and before the resin 144 is newly supplied, the impregnation is performed by the scraper 300 arranged adjacent to the impregnation roller. Scrape off the pieces adhering to the surface of the roller.

By the way, according to the findings of the present inventors, even if the scraps are scraped using a general-purpose resin scraper, the scraps attached to the surface of the impregnation roller cannot be sufficiently removed, and the UD that is still produced The contamination of the scraps in the sheet was not eliminated.

The present inventors have made intensive studies on the above problem, and have found that in conventional scrapers, the scraping portion of the scraper for scraping off the scraps is slightly deformed (deflected) due to the scraps of the reinforcing fiber with high hardness. Found it. Then, the inventors have found that the deformation causes a minute gap between the scraper and the impregnated body 140, so that the scrap cannot be sufficiently removed. Based on the above knowledge, various methods of improving the removal efficiency of the scraps by making the scraper more difficult to deform were investigated. The present inventors have conceived that the removal of scraps can be sufficiently performed by using a material, and have completed the present invention. From the above viewpoint, the maximum deflection is preferably 0.03 mm or less, more preferably 0.02 mm or less. Although the lower limit of the maximum deflection is not particularly limited, it can be 0 mm.

FIG. 2A is a schematic perspective view showing the configuration of the scraper 300 used in this embodiment based on the above findings, and FIG. 2B is a schematic perspective view showing the scraper 300 disassembled. FIG. 3 is a top view of the scraper 300 shown in FIG. 2A.

The scraper 300 has a scraping portion 310 that scrapes the scrap and a holder 320 that holds the scraping portion 310 . The holder 320 has an insertion hole 322 into which a portion of the scraping portion 310 is inserted.

The scraping portion 310 has a flat plate portion 312 having a rectangular shape when viewed from above, and a pair of ribs 314 arranged at both ends of the flat plate portion 312 .

One end of the rectangular plate portion 312 is an insertion portion 312 a inserted into the insertion hole 322 of the holder 320 , and is held by the holder 320 by inserting the insertion portion 312 a into the insertion hole 322 . The other end opposite to the one end inserted into the insertion hole 322 is a protruding portion 312b that protrudes from the holder 320 when held by the holder 320. As shown in FIG. The scraper 300 is arranged such that the protruding part 312b protrudes from the holder 320 toward the impregnated body 140 when the scraper 300 is attached to the manufacturing apparatus 100 . Then, the tip 312c of the protruding portion 312b comes into contact with and scrapes off the scrap adhering to the surface of the impregnated body 140 that rotates.

The ribs 314 are arranged at both ends of the flat plate portion 312 (both ends of the surface of the flat plate portion 312 in the direction perpendicular to the direction in which the protruding portion 312b protrudes) so as to be substantially parallel to the direction in which the protruding portion 312b protrudes. Also, it is a member protruding from the surface of the flat plate portion 312 . The scraper 300 is on the side opposite to the direction in which the impregnated body 140 rotates (in general terms, the direction in which the surface of the impregnated body 140 moves relative to the scraper 300) when attached to the manufacturing apparatus 100. The ribs 314 are arranged so as to protrude from the flat plate portion 312 in the direction of . The ribs 314 reinforce both ends of the flat plate portion 312 to suppress deformation (deflection) of the flat plate portion 312 . The insertion hole 322 of the holder 320 is shaped so that the rib 314 can also be inserted. is also inserted into the insertion hole 322 at the same time.

The holder 320 holds the scraping portion 310 by inserting the insertion portion 312 a of the flat plate portion 312 into the insertion hole 322 . The insertion hole 322 has an opening having substantially the same shape and size as the cross-sectional shape of the flat plate portion 312 and the rib 314, and extends in the depth direction of the holder 320 from the opening with substantially the same shape and size. be. The shape, size and material of the holder 320 and the size and depth of the opening of the insertion hole 322 are not particularly limited as long as they can withstand the stress when scraping off the scrap.

Note that the holder 320 can change the insertion amount of the scraping portion 310 and the insertion portion 312a (and part of the corresponding rib 314), and by changing the insertion amount, the projection amount of the projecting portion 312b is changed. be able to.

The scraper 300 has a maximum deflection of 0.04 mm or less at a load of 30 N of the scraping portion 310 when the scraping portion 310 is held by the holder 320 . The maximum deflection is the direction in which stress is applied to the entire tip 312c of the flat plate portion 312 at normal temperature when scraping off the scrap in a state where the scraping portion 310 is held by the holder 320 (FIGS. 2A and 2B It may be a value obtained by measuring the length of deformation (deflection) at the center of the tip 312c when a load of 30 N is applied toward the bottom of the figure in FIG. 3, or a value obtained from calculation There may be.

The maximum deflection can be obtained by the following formula.

In the formula (1), P is the load applied to the tip 312c of the flat plate portion 312, which is assumed to be 30N when the scraper 300 is actually used.

l is the length by which the protruding portion 312b of the flat plate portion 312 protrudes from the holder 320 (see FIG. 3). FIGS. 4A and 4B are schematic diagrams for explaining the length l by which the protruding portion 312b protrudes from the holder 320. FIG. 4A and 4B only show the impregnated body 140 and the scraper 300 for easy understanding. As shown in FIG. 4A, when the length of the flat plate portion 312 that is in contact with the holder 320 is the same between the upper surface and the lower surface of the flat plate portion 312, the protrusion length of either the upper surface side or the lower surface side is measured. You may use it as l. On the other hand, as shown in FIG. 4B, when the length of the flat plate portion 312 in contact with the holder 320 differs between the upper surface and the lower surface of the flat plate portion 312, the direction in which the impregnated body 140 rotates (the surface of the impregnated body 140 Let l be the length of protrusion 312b of flat plate portion 312 protruding from holder 320 on the downstream side in the direction of relative movement with respect to scraper 300). That is, in the embodiment of FIG. 4B, the tip 312c of the flat plate portion 312 is used as a force point during scraping, and the point where the downstream surface first contacts the holder 320 is used as a fulcrum. is subjected to flexural stress. Therefore, l is the length by which the projecting portion 312b protrudes on the downstream side, which is the distance between the force point and the fulcrum.

In this specification, as the Young's modulus value, a Young's modulus known for each material of the projecting portion 312b (material of the flat plate portion 312) may be used. When the Young's modulus is unknown, it can be obtained by measuring it according to JISZ 2241 (2011) for metals.

In Equation (1), I is the geometrical moment of inertia of the protrusion 312b. The moment of inertia of area can be obtained by calculation by a known method. For example, the geometrical moment of inertia of the projecting portion 312b having the flat plate portion 312 and the pair of ribs 314 arranged at both ends thereof, shown in FIGS. 2A and 2B, can be obtained by the following formula.

In the formulas ( ₂ ) to ( ₄ ), e1 is the distance from the centroid to the tip of the rib 314 in the cross section perpendicular to the direction in which the projecting portion 312b protrudes from the holder 320, and e2 is the flat plate portion from the centroid in the above cross section. The distance to the lower end of 312, I, is the area moment of inertia. Also, d is the height of the rib 314, t is the width of the rib 314, s is the thickness of the flat plate portion 312, and b is the width of the flat plate portion 312, respectively. Note that the units of d, t, s and b are all mm (millimeters). The lengths indicated by d, t, s and b are shown in FIG.

In addition, when the shape of the projecting portion 312b is a shape other than the above, it may be calculated by a calculation formula according to the shape. In addition, when the shape of the projecting portion 312b changes from the holder 320 to the tip 312c, the geometrical moment of inertia I is obtained as an integrated value of the geometrical moment of inertia ΔI calculated from the minute length Δl of the value of the projection length l. may

The material and shape of the scraping portion 310 are limited as long as the maximum deflection of the projecting portion 312b at a load of 30 N of the scraping portion 310 when the scraping portion 310 is held by the holder 320 is 0.04 mm or less. not.

For example, scraping portion 310 is preferably formed by molding a material having a Young's modulus of 70000 MPa or more. By using a harder material for the scraping portion 310 (increasing the Young's modulus in formula (1)), the maximum deflection can be made smaller. From the above viewpoint, the material of the scraping portion 310 preferably has a Young's modulus of 70000 MPa or more, more preferably 100000 MPa or more, and particularly preferably 150000 MPa or more.

Examples of materials for the scraping portion 310 include various resins and metals. Among these, metals, which are materials having a higher Young's modulus, are preferred. Examples of the above metals include iron, copper, nickel, gold, silver, platinum, cobalt, zinc, titanium, chromium, aluminum, manganese, and alloys thereof (e.g., steel (such as stainless steel), brass, phosphor bronze, etc.). and so on. Of these, iron-based metals and aluminum-based metals are preferred because of their availability, and iron-based metals are more preferred because of their higher Young's modulus.

Also, the shape of the scraping portion 310 may be designed so that the second moment of area of the projecting portion 312b is increased. For example, by adjusting the lengths d, t, s, b and l of the protrusion 312b having the plate portion 312 and the pair of ribs 314 disposed at both ends thereof, as shown in FIGS. 2A and 2B, By increasing the geometrical moment of inertia of the protruding portion 312b, the maximum deflection may be reduced.

2A and 2B, the height d of the rib 314 is preferably 0.1 mm or more and 20 mm or less, more preferably 0.2 mm or more and 10 mm or less.

From the above viewpoint, in the configuration shown in FIGS. 2A and 2B, the width t of the rib 314 is preferably 0.05 mm or more and 10.0 mm or less, and more preferably 0.1 mm or more and 5.0 mm or less. is more preferred.

2A and 2B, the thickness s of the flat plate portion 312 is preferably 0.05 mm or more and 5.0 mm or less, and more preferably 0.07 mm or more and 1.0 mm or less. more preferred. When the thickness s is equal to or less than the above upper limit, the amount of resin on the impregnation roller can be precisely adjusted, which is preferable. Moreover, it is preferable that the thickness s is equal to or more than the above lower limit value, because the amount of deflection tends to be further reduced.

2A and 2B, the width b of the flat plate portion 312 is preferably 200 mm or more and 2000 mm or less, more preferably 300 mm or more and 1500 mm or less.

In the configuration shown in FIGS. 2A and 2B, l, which is the length by which the projecting portion 312b of the flat plate portion 312 protrudes from the holder 320, is preferably 1.0 mm or more and 100 mm or less, and 3.0 mm or more and 45 mm or less. is more preferable.

[Materials, etc.]
The material of the reinforcing fiber is not particularly limited. For example, carbon fiber, glass fiber, aramid fiber, alumina fiber, silicon carbide fiber, boron fiber, metal fiber, and the like can be used as the reinforcing fiber.

The reinforcing fibers preferably have an average diameter of 1 μm or more and 20 μm or less, more preferably 4 μm or more and 10 μm or less, from the viewpoint of sufficiently enhancing the strength improvement effect of the reinforcing fibers.

Further, the reinforcing fibers may be sized with a sizing agent.

Although the sizing agent is not particularly limited, it is preferably modified polyolefin, and more preferably modified polyolefin containing a carboxylic acid metal salt. The modified polyolefin is obtained by, for example, grafting a carboxylic acid group, a carboxylic acid anhydride group, or a carboxylic acid ester group to the polymer chain of the unmodified polyolefin, and forming a salt between the functional group and the metal cation. It is a thing.

The unmodified polyolefin is an ethylene polymer in which the content of structural units derived from ethylene is 50 mol% or more, or a propylene polymer in which the content of structural units derived from propylene is 50 mol% or more. is preferred. Examples of the ethylene-based polymer include ethylene homopolymers and copolymers of ethylene and α-olefins having 3 to 10 carbon atoms. Examples of the propylene-based polymer include propylene homopolymers and copolymers of propylene and ethylene or α-olefins having 4 to 10 carbon atoms. The unmodified polyolefin is preferably homopolypropylene, homopolyethylene, ethylene/propylene copolymer, propylene/1-butene copolymer, or ethylene/propylene/1-butene copolymer.

Further, the reinforcing fibers may be bundled to form a fiber bundle. At this time, the number of single yarns per bundled reinforcing fiber bundle is preferably 100 or more and 100,000 or less, more preferably 1,000 or more and 50,000 or less.

The material of the matrix resin is not particularly limited, and may be a thermoplastic resin or a thermosetting resin. Examples of the thermoplastic resin include polyolefin resins including polypropylene resins and polyethylene resins, polyamide resins, polyester resins, polycarbonate resins, polyacetal resins, polyetherketone resins, polyetheretherketone resins, and polysulfone resins. is included. Among these, polypropylene-based resins and polyamide-based resins are preferred. Moreover, from the viewpoint of enhancing affinity with reinforcing fibers sized with the sizing agent, the matrix resin may contain the above-described modified polyolefin.

[Other embodiments]
It should be noted that each of the above-described embodiments is an example of the present invention, and the present invention is not limited to the above-described embodiments. It goes without saying that embodiments are also possible.

For example, in the above-described embodiment, the scraper scrapes off pieces of the reinforcing fibers, but other deposits attached to the surface of the impregnated body (such as fine dust and the surface of the impregnated body without impregnating the reinforcing fibers Residual resin, lumps of sizing agent, etc.) may be scraped off.

Further, in the above-described embodiment, the impregnated body is a rotating roller, and the scraper scrapes off deposits (such as scraps of reinforcing fibers) attached to the surface of the roller. It may be in a shape other than a roller as long as it can be in contact with and the cut ends of the reinforcing fibers can adhere to the surface.

Further, in the above-described embodiments, the scraper is manufactured so that the rib protrudes from the flat plate portion in the direction opposite to the direction in which the impregnated body rotates (the direction in which the surface of the impregnated body moves relative to the scraper). placed in the device. However, the mounting direction of the scraper is not limited to this, and it is arranged in the manufacturing device so that the rib protrudes from the flat plate portion in the direction in which the impregnated body rotates (the direction in which the surface of the impregnated body moves relative to the scraper). may be Likewise, when the scraper does not have ribs, there is no particular limitation on the direction in which the flat plate portion is arranged with respect to the impregnated body.

UD seats manufactured by the above manufacturing equipment are used for automobile parts, notebook computers, mobile phones, including various modules such as instrument panels, door beams, undercovers, lamp housings, pedal housings, radiator supports, spare tire covers, and front ends. Electric/electronic parts including telephones, digital still cameras, PDAs, and plasma displays, as well as telephones, facsimiles, VTRs, copiers, televisions, microwave ovens, audio equipment, toiletries, laser discs (registered trademark), refrigerators, It can be used for home/office electric product parts such as air conditioners. UD sheets can also be further molded and used for pipes, pressure vessels, and the like.

Specific examples of the above applications include primary structural members including main wings, vertical and horizontal stabilizers, etc., secondary structural members including ailerons, rudders and elevators, etc., interior materials including seats and tables, power units, and hydraulic cylinders. , and components of general air vehicles such as aircraft and helicopters, including composite brakes, etc., rocket components including nozzle cones and motor cases, antennas, structures, solar panels, battery cases and telescopes, etc. Artificial satellite parts, machine parts including frames, shafts, rollers, leaf springs, machine tool heads, robot arms, transfer hands and synthetic fiber pots, high-speed rotating body parts including centrifuge rotors and uranium enrichment cylinders , parabolic antennas, battery parts, radars, acoustic speaker cones, computer parts, printer parts, electronic and electrical parts including computer housings and tablet housings, frame parts, semi-structural parts, outer panel parts, interior and exterior parts, power Devices, other equipment - hydraulic cylinders, brakes, battery cases, drive shafts, engine parts, spoilers, racing car bodies, crash cones, chairs, tablets, phone covers, under covers, side covers, transmission covers, battery trays, rear steps, Vehicle parts including spare tire containers, bus body walls and truck body walls, interior materials, floor panels, ceiling panels, linear motor car bodies, Shinkansen and railroad bodies, window wipers, bogies and seats, etc. Parts, ship hulls including yachts, cruisers and boats, masts, rudders, propellers, rigid sails, screws, military ship fuselages, submarine fuselages and deep-sea exploration vessels, etc. pressure vessel parts and materials including tanks, CNG tanks and oxygen tanks; scientific equipment parts and materials including agitator blades, pipes, tanks, pit floors and plant piping; wind power including blades, skins, frameworks and de-icing systems, etc. Power generation parts, X-ray diagnostic equipment parts, wheelchairs, artificial bones, prosthetic legs/arms, crutches, nursing aids/robots (power assist suits), walkers and nursing care beds, etc. CF composite cables, concrete reinforcing members, guardrails, bridges, tunnel walls, hoods, cables, tension rods, Strand rods, flexible pipes, and other civil engineering and infrastructure components; marine risers, flexible jumpers, flexible risers, and drilling risers, fishing rods, reels, golf clubs, tennis rackets, badminton rackets, and skis. Sports and leisure equipment including boards, poles, snowboards, ice hockey sticks, snowmobiles, bows, kendo shinais, baseball bats, diving boards, sports equipment for the disabled and sports helmets, frames, disc wheels, rims, handles and Bicycle parts including saddles, daily necessities including glasses, bags, umbrellas and ballpoint pens, plastic pallets, containers, distribution materials, resin molds, furniture, umbrellas, helmets, pipes, scaffolding boards, safety shoes, protectors, fuel This includes parts and supplies for other industrial applications including battery covers, drone blades, frames, jigs and jig frames.

The present invention will be described in detail based on examples, but the present invention is not limited to these examples.

1. Production of reinforcing fiber bundle A carbon fiber bundle (manufactured by Mitsubishi Chemical Corporation, trade name Pyrofil TR50S12L, number of filaments 24000, strand strength 5000 MPa, strand elastic modulus 242 GPa) is immersed in acetone, subjected to ultrasonic waves for 10 minutes, and then The carbon fiber bundle was pulled up, washed with acetone three times, and dried at room temperature for 8 hours to obtain a carbon fiber bundle from which the adhering sizing agent was removed.

2. Preparation of sizing agent Shore D hardness is 52, 100 parts by mass of propylene-butene copolymer (weight average molecular weight Mw measured by GPC is 350,000) and 10 parts by mass of maleic anhydride-modified propylene resin ( The weight average molecular weight Mw measured by GPC is 20,000, the acid value is 45 mgKOH / g, the maleic anhydride content is 4% by mass, the melting point is 140 ° C.), and 3 parts by mass of potassium oleate as a surfactant. , were mixed.

This mixture is supplied from the hopper of a twin screw extruder (manufactured by Ikegai Iron Works, PCM-30, L/D = 40) at a rate of 3000 g / hour, and 20% was continuously extruded at a heating temperature of 210° C. while continuously supplying an aqueous solution of potassium hydroxide at a rate of 90 g/hour.

The extruded resin mixture was cooled to 110° C. with a jacketed static mixer installed at the mouth of the extruder, and then put into warm water of 80° C. to obtain an emulsion for a sizing agent. The resulting emulsion had a solid concentration of 45% (by mass).

The maleic anhydride-modified propylene resin contains 96 parts by mass of a propylene-butene copolymer, 4 parts by mass of maleic anhydride, and 0.4 parts by mass of a polymerization initiator (manufactured by NOF Co., Ltd., product It is a modified resin obtained by mixing the name Perhexy 25B) and modifying it at a heating temperature of 160° C. for 2 hours.

3. Preparation of Scraper Using SUS304 or Al5083, 12 types of scrapers having shapes shown in FIGS. 2A and 2B were prepared and installed in a holder. At this time, the shape of each scraper and the projection length of the flat plate portion from the holder were changed to set the maximum deflection amounts at a load of 30 N to different values.

4. Production of UD Sheet Each scraper was installed in the production apparatus shown in FIG. 1 to produce a UD sheet. Specifically, 50 carbon fiber bobbins were placed on a guide, adjusted so that a tension of 1200 cN was applied to each tow by an unloading device, and aligned into a sheet. The fibrous sheet was fed to impregnation rolls after being opened by contact with the opening bar.

At the same time, polypropylene (manufactured by Prime Polymer Co., Ltd., trade name J108M, MFR (ASTM D 1238, 230 ° C., load 2.16 kg) = 45 g / 10 minutes) and maleic anhydride-modified polypropylene resin (manufactured by Mitsui Chemicals, product Admer QE800, MFR (ASTM D 1238, 230°C, 2.16 kg load) = 9.1 g/10 min) were blended at a weight ratio of 90/10 and melt mixed in an extruder with a T-die. Then, this resin was extruded from a T-die onto the peripheral surface of a rotating impregnation roller. The temperature of the extruder and the T-die was 260°C, and the temperature of the impregnation roller was also adjusted to 260°C. The amount of resin supplied was adjusted so that the mass ratio of carbon fiber bundles to resin was 67/33.

The manufacturing apparatus was operated continuously for 6 hours to obtain a long UD sheet. After completion of molding, the surface of the impregnated roll was observed, and the scraping performance of each scraper was evaluated according to the following evaluation criteria.
〇 Carbon fiber fragments were not found adhering. △ Adherence of carbon fiber fragments was observed on the surface of the UD sheet after the operation was completed. Cracks occurred due to the occurrence of non-impregnated parts

For each scraper, material and its Young's modulus, shape (rib height d, rib width t, flat plate thickness s, flat plate width b, and projection length l), cross section 2 Tables 1 and 2 show the following moment, the maximum deflection at a load of 30 N, and the evaluation results of scraping properties. The geometrical moment of inertia and the maximum deflection at a load of 30 N in Tables 1 and 2 are values obtained by calculation using formulas (1) to (4).

As is clear from Tables 1 and 2, using a scraper with a maximum deflection of 0.04 mm or less at a load of 30 N at the scraping portion while being held by the holder effectively suppresses the contamination of scraps of reinforcing fibers. We were able to.

By using the scraper according to the present invention, it is possible to suppress the contamination of pieces of reinforcing fibers during the production of the UD sheet. Improved performance and improved productivity of the UD sheet can be achieved. Therefore, the present invention is expected to improve the performance and productivity of UD sheets and contribute to the development of various fields using UD sheets.

REFERENCE SIGNS LIST 100 Fiber-reinforced resin manufacturing apparatus 110 Yarn feeding unit 112 Bobbin 120 Guide path 122 Guide roll 124 Feeder 130 Spreading unit 140 Impregnated body 142 Extruder 144 Molten resin 146 Guide roller 150 Recovery roll 200 Reinforcing fiber 300 Scraper 310 Scraping unit 312 flat plate portion 312a insertion portion 312b protrusion 312c tip 314 rib 320 holder 322 insertion hole

Claims (4)

A scraper disposed adjacent to an impregnating body for impregnating reinforcing fibers with resin,
a scraping unit for scraping off deposits adhering to the surface of the impregnated body;
a holder for holding the scraping part,
The maximum deflection of the scraping portion at a load of 30 N while held by the holder is 0.04 mm or less.
scraper. The scraper according to claim 1, wherein the scraping portion has a flat plate portion and ribs arranged at both ends of the flat plate portion. 2. The scraper according to claim 1, wherein said scraping portion is formed by molding a material having a Young's modulus of 70000 MPa or more. a conveying unit that conveys reinforcing fibers;
an impregnation body for impregnating the reinforcing fibers conveyed by the conveying unit with a resin;
The scraper according to any one of claims 1 to 3, which is disposed adjacent to the impregnated body and scrapes off deposits attached to the impregnated body;
A device for manufacturing a unidirectional fiber reinforced resin sheet.

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