JP2024041103A - Manufacturing apparatus of slurry-impregnated sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing apparatus of a slurry-impregnated sheet which can manufacture a slurry-impregnated sheet in which an impregnation amount of slurry is uniform with excellent productivity.

SOLUTION: A manufacturing apparatus of a slurry-impregnated sheet according to the present invention comprises: a conveyance device which conveys a fiber sheet or a porous sheet; a first application device which applies a solvent or first slurry to the fiber sheet or the porous sheet; a second application device which weighs and applies second slurry to the fiber sheet or the porous sheet; an impregnation device which applies external force to the fiber sheet or porous sheet to impregnate particles in the fiber sheet or the porous sheet; a squeezing device which applies the external force to the fiber sheet or the porous sheet to squeeze the excessive solvent or slurry; and a returning device which returns the solvent or slurry squeezed from the sheet by the squeezing device to the first application device.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to an apparatus for manufacturing a slurry-impregnated sheet.

Fiber-reinforced composite materials (FRP), which are made by reinforcing matrix resins including thermoplastic resins and thermosetting resins with reinforcing fibers, are used in aerospace materials, automobile materials, industrial materials, pressure vessels, building materials, housings, and medical applications. It is used in a variety of fields, including applications and sports. FRP is produced by impregnating reinforcing fiber bundles with a matrix resin to obtain an intermediate base material, which is then laminated and molded, and further heat-cured if a thermosetting resin is used as the matrix resin to produce a member made of FRP. ing. In many of the above applications, flat objects or bent forms are used, and two-dimensional sheet-like objects are widely used as intermediate base materials for FRP from the viewpoint of lamination efficiency and formability when producing components. .

As the two-dimensional sheet-like intermediate base material, a prepreg is used in which a sheet-like reinforcing fiber bundle in which reinforcing fibers are arranged in one direction is impregnated with a matrix resin. The hot melt method, which is one of the methods for producing prepreg, involves melting a matrix resin, coating it on a release paper, sandwiching this between the upper and lower surfaces of a sheet-like reinforcing fiber bundle to create a laminated structure, and then heating and applying it. The matrix resin is impregnated into the inside of the sheet-shaped reinforcing fiber bundle using pressure. This method involves a large number of steps, cannot increase production speed, and has the problem of high cost.

Apart from the hot melt method, a method of manufacturing prepregs is also known called the slurry impregnation method, in which a sheet-shaped reinforcing fiber bundle is impregnated with a slurry in which resin is powdered and dispersed in a solvent, and the solvent is then removed (see, for example, Patent Document 1).

Publication of JP-A-2005-255927

In Patent Document 1, a reinforcing fiber sheet with adjusted strand width is immersed in a slurry in which thermoplastic resin powder is dispersed in an organic solvent such as alcohol, the resin powder is adhered to the sheet, and then heated. A prepreg with excellent uniformity is produced by drying the organic solvent, heating it at a high temperature to melt the thermoplastic resin, and integrating the reinforcing fiber sheet. However, since the fibers constituting the strands are twisted or intertwined, it is difficult to control the strand width to a constant value. In addition, the basis weight of the resin particles to be attached to the reinforcing fiber sheet varies not only depending on the width of the strand, but also depending on the conveying tension of the strand, the opening state, and the particle concentration in the slurry tank. It has been practically difficult to precisely control the basis weight of .

The present invention has been made in view of the above problems, and an object of the present invention is to provide a slurry-impregnated sheet manufacturing apparatus that can manufacture a slurry-impregnated sheet with a uniform amount of slurry with high productivity.

A device for producing a slurry-impregnated sheet of the present invention for achieving the above-mentioned object is a device for producing a slurry-impregnated sheet in which a fiber sheet or a porous sheet is impregnated with a slurry in which particles are dispersed in a solvent. or a conveying device that conveys a porous sheet, a first coating device that applies a solvent or a first slurry to the fiber sheet or the porous sheet, and a downstream side of the first coating device in the sheet conveyance direction; a second coating device that measures and applies a second slurry to the fiber sheet or porous sheet; and a second coating device that is located downstream of the second coating device in the conveying direction of the sheet and applies an external force to the fiber sheet or porous sheet. an impregnating device that impregnates the inside of the fiber sheet or porous sheet with particles; and an impregnating device that is located downstream of the impregnating device in the conveying direction of the sheet and applies an external force to the fiber sheet or porous sheet to remove excess solvent or slurry. The method includes a squeezing device for squeezing the sheet, and a reflux device for flowing the solvent or slurry squeezed from the sheet by the squeezing device back to the first coating device.

Further, in the above invention, the slurry-impregnated sheet manufacturing apparatus according to the present invention is characterized in that, in the sheet conveyance path from the impregnation device to the squeezing device, the center in the sheet width direction at the entrance of the impregnation device and the center in the sheet width direction at the exit of the impregnation device. The angle formed between the horizontal direction and an imaginary straight line connecting the center of The angle is 30° or more and 90° or less.

Further, in the slurry-impregnated sheet manufacturing apparatus according to the present invention, in the above invention, the reflux device has a slurry tank that stores the solvent or slurry squeezed by the squeezing device, and the first coating device It consists of a slurry tank and a mechanism for immersing the fiber sheet or porous sheet in the slurry tank, and the second coating device has a die.

Further, in the slurry-impregnated sheet manufacturing apparatus according to the present invention, in the above-mentioned invention, the slurry tank has a discharge mechanism for discharging particles settled on the bottom surface, and the dipping mechanism of the first coating device is arranged in the slurry tank. placed near the liquid level.

Further, in the slurry-impregnated sheet manufacturing apparatus according to the present invention, in the above invention, the reflux device includes a slurry tank for storing the solvent or slurry squeezed by the squeezing device, and a slurry tank for storing the solvent or slurry squeezed by the squeezing device, and a flow from the slurry tank to the first coating device. a first pump for feeding a solvent or slurry, and the first coating device and the second coating device each have a die.

Further, in the slurry-impregnated sheet manufacturing apparatus according to the present invention, in the above invention, the slurry tank includes a liquid level gauge that measures the liquid level of the solvent or slurry stored in the slurry tank, and a signal from the liquid level gauge. and a first control device that originally controls the flow rate of the first pump.

Further, in the slurry-impregnated sheet manufacturing apparatus according to the present invention, in the above invention, the reflux device includes a concentration meter that measures the concentration of the solvent or slurry to be sent, and a flow rate meter that measures the flow rate of the solvent or slurry to be sent. and a second control device that controls the amount of second slurry applied by the second coating device based on signals from the concentration meter and the flow meter.

According to the apparatus for producing a slurry-impregnated sheet of the present invention, first, a fiber sheet or the like is impregnated with a solvent or a low concentration slurry in the first coating device to facilitate impregnation of particles into the fiber sheet or the like, and then a high concentration slurry is impregnated with the fiber sheet or the like. The second coating device impregnates the fiber sheet with the slurry, and finally the squeezing device removes the excess solvent, reducing the amount of solvent applied to the fiber sheet while impregnating the particles to the inside. It becomes possible to produce a slurry-impregnated sheet.

FIG. 1 is a schematic diagram of a slurry-impregnated sheet manufacturing apparatus according to Embodiment 1 of the present invention. FIG. 2 is a schematic diagram of a slurry-impregnated sheet manufacturing apparatus according to Embodiment 2 of the present invention.

Hereinafter, the slurry-impregnated sheet manufacturing apparatus according to the present invention will be described in detail with reference to the drawings.

(Embodiment 1)
FIG. 1 is a schematic diagram of a manufacturing apparatus 100 for a slurry-impregnated sheet 1 according to Embodiment 1 of the present invention. The manufacturing apparatus 100 of the slurry-impregnated sheet 1 of the present invention includes an unwinding device 10 that unwinds the fiber sheet 1a, a conveying device 20 that conveys the fiber sheet 1a and the slurry-impregnated sheet 1, and a solvent or a first solvent applied to the fiber sheet 1a. A first coating device 30A that applies slurry; a second coating device 30B that is located downstream of the first coating device 30A in the sheet conveyance direction and that measures and applies a second slurry to the fiber sheet 1a; An impregnating device 40 is located downstream of 30B in the sheet conveyance direction and applies an external force to the fiber sheet 1a to impregnate the inside of the fiber sheet 1a with particles. , a squeezing device 50 that squeezes out excess solvent or slurry by applying an external force to the fiber sheet 1a, a reflux device 60 that refluxes the solvent or slurry squeezed from the sheet by the squeezing device 50 to the first coating device 30A, and a slurry impregnation device. It has a winding device 70 that winds up the sheet 1.

<Fiber sheet>
Examples of the fiber sheet 1a include a UD base material in the form of a sheet in which fibers are arranged in one direction, and a fiber fabric that is a woven fabric in which fibers are arranged in multiple directions. When mechanical properties are given priority, a UD base material can be preferably used. On the other hand, when producing FRP with a complex shape, a woven fabric with excellent shapeability and shape followability can be preferably used.
In the first embodiment, the fiber sheet 1a is explained as an example, but the apparatus 100 for manufacturing the slurry-impregnated sheet 1 according to the first embodiment can also be used when impregnating a porous sheet with slurry. I can do it. Examples of the porous sheet include nonwoven fabric, paper, mesh, sponge, and foamed rubber, and any material may be used as long as it can be impregnated with the slurry.

Examples of the fibers constituting the fiber sheet 1a include carbon fibers, glass fibers, metal fibers, metal oxide fibers, metal nitride fibers, organic fibers (aramid fibers, polybenzoxazole fibers, polyvinyl alcohol fibers, polyethylene fibers, etc.). I can give an example. When using the slurry-impregnated sheet 1 for FRP, it is preferable to use carbon fiber from the viewpoint of mechanical properties and light weight of the FRP.

The UD base material used as the fiber sheet 1a is one in which a plurality of fibers are arranged in one direction on a surface, and the plurality of fibers do not necessarily need to be integrated by intertwining with each other. The slurry-impregnated sheet 1 manufactured by the slurry-impregnated sheet 1 manufacturing apparatus 100 of the present invention is obtained as a sheet material impregnated with the slurry after the slurry is applied, so that the fibers are arranged and integrated. For convenience, those that are not included are also referred to as fiber sheets. Here, the thickness and width of the fiber sheet 1a are not particularly limited and can be appropriately selected depending on the purpose and use. In the case of carbon fibers, a tape-shaped collection of about 1,000 to 1,000,000 single fibers is usually called a "tow," and a fiber sheet is obtained by arranging these tows. be able to. The fiber sheet 1a preferably has an aspect ratio defined by its width/thickness of 10 or more for ease of handling.

A known method can be used to form the fiber sheet 1a, and there are no particular limitations. However, a fiber bundle in which single fibers are arranged in advance is formed, and this fiber bundle is further arranged to form the fiber sheet 1a. This is preferable from the viewpoint of improving process efficiency and making the arrangement uniform. For example, in the case of carbon fiber, a "tow" which is a tape-shaped fiber bundle is wound around a bobbin, and it is possible to arrange the tape-shaped fiber bundles pulled out from the tow to obtain the fiber sheet 1a as the UD base material. can. In addition, in the process of forming the fiber sheet 1a, it is preferable to use a fiber opening device for orderly arranging the fiber bundles pulled out from the bobbin hung on a creel and eliminating undesirable overlapping or folding of the fiber bundles of the fiber sheet 1a. . As the fiber arrangement mechanism, a known roller or comb arrangement device can be used. As the opening device, for example, those described in JP-A-2005-163223, JP-A 2004-225222, JP-A 2004-225183, etc. can be used. Note that it is preferable that the creel is provided with a tension control mechanism when drawing out the fibers. As the tension control mechanism, any known mechanism can be used, such as a brake mechanism. The tension can also be controlled by adjusting the thread guide.

Moreover, the fiber fabric as the fiber sheet 1a is made into a sheet by arranging fibers multiaxially or randomly arranging them. Specifically, in addition to woven fabrics and knitted fabrics, examples include fabrics in which fibers are arranged in a two-dimensional multiaxial manner, and fabrics in which fibers are randomly oriented such as nonwoven fabrics, mats, and paper. In this case, the reinforcing fibers can also be formed into a sheet by applying a binder, entangling, welding, fusing, or the like. As the woven fabric, in addition to basic woven structures such as plain weave, twill, and satin, non-crimp woven fabric, bias structure, leno weave, multiaxial woven fabric, and multiple woven fabric can be used. A fabric that combines a bias structure and a UD base material is a preferred form because the UD structure not only suppresses the deformation of the fabric due to tension during the coating/impregnation process, but also has pseudo-isotropy due to the bias structure. . Furthermore, the multilayer fabric has the advantage that the upper and lower surfaces of the fabric, as well as the structure and characteristics inside the fabric, can be designed individually. For knitted fabrics, warp knitting is preferred in consideration of morphological stability during coating and impregnating steps, but braided tubular knitting may also be used.

<Slurry>
The slurry used in the present invention can be appropriately selected depending on the purpose for which it is applied. For example, when it is applied to the production of sheet prepreg, a mixture of a particulate matrix resin and a dispersion medium, a suspension, etc. are exemplified. Ru.

As the matrix resin, thermoplastic resin, thermosetting resin, photocurable resin, etc. can be used.

The thermoplastic resin has a main chain selected from carbon-carbon bonds, amide bonds, imide bonds, ester bonds, ether bonds, carbonate bonds, urethane bonds, urea bonds, thioether bonds, sulfone bonds, imidazole bonds, and carbonyl bonds. Polymers with bonds can be used. Specifically, polyacrylate, polyolefin, polyamide (PA), aramid, polyester, polycarbonate (PC), polyphenylene sulfide (PPS), polybenzimidazole (PBI), polyimide (PI), polyetherimide (PEI), polysulfone (PSU), polyethersulfone (PES), polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polyamideimide (PAI), etc. can. In fields where heat resistance is required, such as aircraft applications, PPS, PES, PI, PEI, PSU, PEEK, PEKK, PAEK, etc. are suitable. On the other hand, for industrial applications, automobile applications, etc., polyolefins such as polypropylene (PP), PA, polyester, PPS, etc. are suitable in order to increase molding efficiency. These may be polymers, or oligomers or monomers may be used for low viscosity and low temperature application. Of course, these may be copolymerized depending on the purpose, or various types may be mixed and used as a polymer blend/alloy.

Examples of thermosetting resins include epoxy resins, maleimide resins, polyimide resins, resins with acetylene ends, resins with vinyl ends, resins with allyl ends, resins with nadic acid ends, and resins with cyanate ester ends. It will be done. These can generally be used in combination with a curing agent or a curing catalyst. Moreover, it is also possible to use a mixture of these thermosetting resins as appropriate.

It is also suitable to use a mixture of a thermosetting resin and a thermoplastic resin as the matrix resin. Mixtures of thermosets and thermoplastics give better results than thermosets alone. This is because thermosetting resins generally have the disadvantage of being brittle but can be molded at low pressure in an autoclave, whereas thermoplastic resins have the advantage of being tough but are difficult to mold at low pressure in an autoclave. This is because they exhibit contradictory properties, so by mixing and using them, it is possible to balance physical properties and moldability. When used as a mixture, it is preferable to contain more than 50% by mass of the thermosetting resin from the viewpoint of mechanical properties.

From the viewpoint of adhesion to the fiber sheet 1a and ease of handling, particles with a particle diameter of 0.1 μm or more and 1 mm or less can be used. A thickness of 50 μm or more can be suitably used.

Examples of the dispersion medium for the slurry include organic solvents such as alcohols, glycols, ketones, and halogenated hydrocarbons, and water. Mixtures of organic solvents and water can also be used. Examples of alcohols include methanol, ethanol, isopropyl alcohol, etc.; examples of glycols include methyl cellosolve, ethyl cellosolve, etc.; examples of ketones include acetone, methyl ethyl ketone, etc.; and examples of halogenated hydrocarbons include methylene chloride, dichloroethane, etc. be able to.

In the manufacturing apparatus 100 for the slurry-impregnated sheet 1 according to the first embodiment, the first coating device 30A applies the solvent or the first slurry to the fiber sheet 1a, and the second coating device 30B applies the second slurry to the fiber sheet 1a. Apply to sheet 1a. The first coating device 30A applies a first slurry with a low solvent or particle concentration that can be easily impregnated into the fiber sheet 1a. First, by applying a first slurry having a low solvent or particle concentration to the fiber sheet 1a using the first coating device 30A, a second slurry having a higher particle concentration than the first slurry is applied to the impregnating device 40 by the second coating device. This facilitates impregnation of particles into the fiber sheet 1a.
When applying the slurry with the first coating device 30, the proportion of particles in the first slurry is preferably 0.1% by mass or more and 10% by mass or less, and preferably 0.1% by mass or more and 5% by mass or less. More preferred. This is because the controllability of the particle weight in the second coating device 30B is improved by minimizing the basis weight of the particles applied to the fiber sheet 1a in the first coating device 30A.
It is preferable that the ratio of particles in the second slurry applied by the second coating device 30B is higher than that in the first slurry. In particular, it is preferable that the proportion of particles in the second slurry be as close as possible to the proportion of particles in the slurry contained in the slurry-impregnated sheet 1 that has passed through the squeezing device 50. In such a case, the amount of slurry applied by the second coating device 30B and the amount of slurry finally brought out by the slurry-impregnated sheet 1 become equal, and as a result, the amount of the solvent or slurry squeezed by the squeezing device 50 and the first Since the amount of solvent or slurry applied by the coating device 30A is equal, the amount stored in the slurry tank 61 does not change over time, making management easier. The ratio of particles in the slurry contained in the slurry-impregnated sheet 1 that has passed through the squeezing device 50 is determined by cutting out a part of the slurry-impregnated sheet 1 and measuring the mass of the particles and the mass of the solvent contained therein. Specifically, the proportion of particles in the second slurry applied by the second coating device 30B is preferably 1% by mass or more and 50% by mass or less, and more preferably 10% by mass or more and 30% by mass or less.

Various additives can be added to the slurry as needed. In particular, surfactants are generally used as additives to prevent particle agglomeration and ensure fluidity of the slurry. Specific examples of anionic surfactants include fatty acid salts typified by sodium oleate, sodium alkylsulfonate, sodium dialkylsulfosuccinate, sodium dialkyl diphenyl ether disulfonate, sodium alkylbenzene sulfonate, sodium alkylnaphthalene sulfonate, etc. sulfonates, sodium alkyl sulfates, sodium polyoxyethylene alkyl ether sulfates, sodium polyoxyethylene alkyl phenyl ether sulfates, etc. As nonionic surfactants, ethylene oxide polyaddition type alkylphenyl ethers, alkyl ethers, Sorbitanic acid ester ether, polyoxypropylene ether, fatty acid diethanolamide, polyhydric alcohol fatty acid ester polyoxyethylene monostearate, polyoxyethylene glycol distearate, polyoxyethylene sorbitan monooleate, as a cationic surfactant , alkyltrimethylammonium chloride, dialkyldimethylammonium chloride, and various natural or synthetic polymers that act as protective colloids such as polyvinyl alcohol, hydroxyethylcellulose, carboxymethylcellulose, water-soluble cellulose ether, casein, polyethylene oxide, and polyacrylamide. They can be used alone or in combination as dispersants.

Further, metal particles or inorganic particles may be added to the slurry. Examples of metal particles include silver, copper, gold, aluminum, nickel, and iron, and examples of inorganic particles include silica and ceramics. The average particle size of the metal particles and inorganic particles is preferably in the range of 5 to 50 μm, more preferably in the range of 7 to 40 μm, and still more preferably in the range of 10 to 30 μm.

<Unwinding device>
The unwinding device 10 unwinds the fiber sheet 1a. Instead of the unwinding device 10, a plurality of creels for unwinding fiber bundles and an arrangement device for arranging the unwound fiber bundles in one direction to obtain the fiber sheet 1a may be used.

<Transport device>
The conveying device 20 conveys the fiber sheet 1. The conveying device 20 includes a conveying roller 21 and a conveying roller 22. The conveyance roller 21 and the conveyance roller 22 are arranged to face the first coating device 30A and the second coating device 30B, respectively. As the conveyance roller 21 and the conveyance roller 22, known rollers can be used.

<Coating device>
The coating device 30 includes a first coating device 30A and a second coating device 30B. The first coating device 30A applies the solvent or the first slurry to the fiber sheet 1a, and the second coating device 30B measures and applies the second slurry to the fiber sheet 1a. The second coating device 30B is preferably one capable of metering and coating the slurry onto the fiber sheet 1a, and a die coater, roll coater, knife coater, spray coater, bar coater, etc. can be used. As the first coating device 30A, in addition to the one used as the second coating device 30B, a dip coater, a dip nip coater, etc. can also be used. In the manufacturing apparatus 100 of FIG. 1, die coaters are used as the first coating device 30A and the second coating device 30B. The second coating device 30B includes a die 31, a metering pump (not shown), and a slurry tank. The first coating device 30A includes a die 31, a first pump 62 as a metering pump, and a slurry tank 61 as a slurry tank. The first coating device 30A and the second coating device 30B can control the amount of solvent and/or slurry applied to the fiber sheet 1a by a metering pump, so that a uniform amount can be applied to the fiber sheet 1a in the longitudinal direction (conveying direction). Particles can be applied.

Examples of the metering pump to be used include diaphragm pumps, syringe pumps, screw pumps, and snake pumps.

The die 31 includes a slurry supply channel (not shown) that supplies slurry, a manifold 32 that communicates with the slurry supply channel and widens the slurry in the width direction of the fiber sheet 1a (direction perpendicular to the conveyance direction), and a manifold. 32, and has a slit 33 that uniformly discharges the supplied slurry in the width direction. The coating device 30 can uniformly coat the slurry from the slit 33 of the die 31 in the width direction of the fiber sheet 1a. In FIG. 1, the die 31 is placed close to the fiber sheet 1a and applies the slurry directly, but the slurry may be applied indirectly using a roller, a slope, or the like.

In the first coating device 30A and the second coating device 30B, the die 31 is arranged so that the flow direction of the solvent and/or slurry passing through the slit 33 is vertically downward. The die 31 may be installed so that the flow direction is a downward direction having an angle of 45 degrees or less with the vertical direction. By setting the flow direction of the slurry to be vertically downward, even if the particles in the slurry settle when the slurry is supplied from the manifold 32 to the slits 33, the particles are quickly discharged from the slits 33. As a result, the sedimented particles can be prevented from staying in the manifold 32, and the slurry can be stably supplied over a long period of time without clogging the slits 33.

Moreover, it is preferable that the interval between the slits 33 is twice or more the average particle diameter of the particles. This prevents particles from clogging the slits 33 and makes it possible to control the amount of particles applied to the fiber sheet 1a.

<Impregnation device>
The impregnating device 40 includes a roller 41, a roller 42, a roller 43, a roller 44, and a roller 45. The rollers 41, 42, 43, 44, and 45 are arranged so that the fiber sheet 1a coated with slurry runs in an S-shape. The fiber sheet 1a coated with the slurry is conveyed between rollers 41, 42, 43, 44, and 45, so that particles in the slurry impregnate the fiber sheet 1a. In the first embodiment, the rollers 41, 42, 43, 44, and 45 are arranged in an S-shape, but if slurry impregnation is possible, they may be arranged in a U-shape or V-shape. The contact length between the sheet and roller may be adjusted accordingly. The rollers 41, 42, 43, 44, and 45 may be rotated as free rolls or feed rolls, or may be fixed bars. Alternatively, the impregnation device may be configured with one or more nip rolls, and impregnation may be performed by further applying pressure to the fiber sheet 1a. In addition, when increasing the impregnation pressure of the slurry and further improving the degree of impregnation, opposing contact rolls may be added. Furthermore, as shown in FIG. 4 of International Publication No. 2015/076981, the impregnation efficiency may be improved by arranging a conveyor belt facing rollers arranged in an S-shape. Furthermore, particles are impregnated into the fiber sheet 1a by passing the plurality of fiber sheets 1a coated with slurry between ironing blades equipped with an ultrasonic generator described in JP-A-2017-154330. Good too.

<Aperture device>
The squeezing device 50 applies external force to the fiber sheet 1a to squeeze out excess solvent or slurry. The squeezing device 50 has a nip roll 51 and a nip roll 52. As the squeezing device 50, an S-shaped roll, an S-shaped bar, etc. can also be used in addition to the nip roll. By changing the roll spacing or contact pressure between the nip rolls 51 and 52, the amount of slurry applied to the fiber sheet 1a, that is, the amount of slurry squeezed out, can be adjusted. Note that when nip rolls are used as the impregnating device 40, by increasing the number of nip rolls installed, it is possible to impregnate the fiber sheet 1a with the slurry and squeeze out the excess solvent or slurry at the same time. At this time, the squeezed solvent or slurry drips from the lowermost nip roll of the impregnating device 40 to the outside of the fiber sheet 1a, so it may be received by the slurry tank 61. By squeezing the excess solvent or slurry with the squeezing device 50, it is possible to prevent the slurry from dripping from the fiber sheet 1a in the subsequent process, maintain controllability of the particle basis weight, and also prevent the slurry from dripping from the fiber sheet 1a in the subsequent process. It becomes possible to reduce the drying load when drying.

<Arrangement of impregnating device and squeezing device>
The impregnating device 40 and the squeezing device 50 are connected to a virtual straight line connecting the center of the sheet width direction at the inlet A of the impregnating device 40 and the center of the sheet width direction of the outlet B of the impregnating device 40 in the sheet conveyance path from the impregnating device 40 to the squeezing device 50. The angle formed between AB and the horizontal direction, and the angle formed between the horizontal direction and an imaginary straight line BC connecting the center of the sheet width direction of the outlet B of the impregnating device 40 and the center of the sheet width direction of the inlet C of the squeezing device 50 are 30° or more. Preferably, the angle is 90° or less. Here, the inlet A of the impregnation device 40 refers to the position where an external force is first applied to the fiber sheet 1a for impregnation with particles, and the outlet B of the impregnation device 40 refers to the position where the fiber sheet 1a is finally applied to the fiber sheet 1a for impregnation with particles. Refers to the position where external force is applied. The inlet C of the squeezing device 50 refers to the position where the squeezing device 50 and the fiber sheet 1a first come into contact with the fiber sheet 1a in order to squeeze the solvent or slurry from the fiber sheet 1a. The angle formed between the fiber sheet 1a and the horizontal direction in the impregnation device 40, that is, the angle formed between the horizontal direction and the imaginary straight line AB connecting the center in the sheet width direction at the inlet A of the impregnation device 40 and the center in the sheet width direction at the outlet B, And the impregnating device is arranged so that the angle formed between the horizontal direction and the imaginary straight line BC connecting the center of the sheet width direction at the outlet B of the impregnating device 40 and the center of the sheet width direction of the inlet C of the squeezing device 50 is 30° or more and 90° or less. 40 and the squeezing device 50, the slurry seeping out onto the surface of the fiber sheet 1a does not drip down due to the action of gravity, but stays on the surface of the fiber sheet 1a, and dripping of the slurry other than the squeezing device 50 is prevented. It can be prevented. Furthermore, by entering the squeezing device 50 while the slurry remains on the fiber sheet 1a, it becomes possible to collect the entire amount of dripping slurry in the slurry tank 61.

In the manufacturing apparatus 100 for the slurry-impregnated sheet 1 shown in FIG. The impregnating device 40 and the squeezing device are arranged so that the angle formed between the horizontal direction and the imaginary straight line BC connecting the center of the sheet width direction of the outlet B of the drawing device 40 and the center of the sheet width direction of the inlet C of the drawing device 50 is approximately 90°. 50 is arranged, but if the angle is 30° or more and 90° or less, dripping of the slurry from the slurry-impregnated sheet 1 other than the squeezing device 50 can be prevented.

<reflux device>
The reflux device 60 refluxes the solvent or slurry squeezed from the sheet by the squeezing device 50 to the first coating device 30A. The reflux device 60 includes a slurry tank 61 that stores the solvent or slurry squeezed by the squeezing device 50, a first pump 62 that sends the solvent or slurry from the slurry tank 61 to the first coating device 30A, and a solvent that sends the liquid. Alternatively, it has a densitometer 63 that measures the concentration of the slurry.

The slurry tank 61 has a liquid level gauge 64 that measures the liquid level of the solvent or slurry stored in the slurry tank 61. The manufacturing apparatus 100 includes a first control device (not shown), and the first control device controls the flow rate of the first pump 62 based on the signal from the liquid level gauge 64, that is, the flow rate of the solvent or the first It is also possible to adopt a configuration in which the amount of slurry applied is controlled. Specifically, if the flow rate of the first pump 62, that is, the amount of applied first slurry is controlled so that the liquid level height of the slurry tank 61 is constant, the solvent or slurry in the slurry tank 61 may be depleted, It can prevent overflow. Alternatively, if the solvent or slurry in the slurry tank 61 is insufficient (or excessive) depending on the first slurry application amount, the solvent or slurry is refilled (removed) in the slurry tank 61 based on the signal from the liquid level gauge 64. You may.

The first pump 62 has a flow meter. The manufacturing apparatus 100 includes a second control device (not shown), and the second control device is configured to control the amount of second slurry applied by the second coating device 30B based on signals from the concentration meter 63 and the flow meter. It is also possible to do this. Specifically, based on the flow rate of the solvent or slurry controlled by the first controller based on the signal from the liquid level gauge 64 and the signal from the concentration meter 63, the fiber sheet 1a is coated with the first coating device 30A. The basis weight of the particles to be applied can be calculated, and the second control device can control the amount of the second slurry applied so as to achieve the target particle basis weight. Even if the amount of slurry squeezed by the squeezing device 50 or the particle concentration changes over time, the change over time can be measured by the liquid level gauge 64, the concentration meter 63, and the flow meter of the first pump 62. The amount of particles applied to the fiber sheet 1a can be controlled by this. In this way, by controlling the amount of the first slurry and the second slurry applied by the first coating device 30A and the second coating device 30B by the first control device and the second control device, the coating amount of the first slurry and the second slurry is applied to the fiber sheet 1a. The accuracy of the amount of slurry applied per unit area can be further improved.

In addition, the manufacturing apparatus 100 reuses the solvent or slurry squeezed out by the squeezing device 50 in the first coating device 30A using the reflux device 60, making it possible to reduce the amount of solvent or slurry used and wasted.

<Other mechanisms>
The slurry-impregnated sheet 1 manufacturing apparatus 100 according to the present embodiment may include a drying device or a melting device after the squeezing device 50.

The drying device and the melting device can use various means such as air heating, infrared heating, far infrared heating, laser heating, contact heating, heating medium heating (steam, etc.). Preferably, the melting temperature is higher than the drying temperature. In the first embodiment, the excess solvent is removed by the squeezing device 50, so that the drying load can be reduced.

(Embodiment 2)
FIG. 2 is a schematic diagram of a manufacturing apparatus 200 for a slurry-impregnated sheet 1 according to Embodiment 2 of the present invention. The manufacturing apparatus 200 of the slurry-impregnated sheet 1 of the present invention includes an unwinding device 10 that unwinds the fiber sheet 1a, a conveying device 20 that conveys the fiber sheet 1a and the slurry-impregnated sheet 1, and a solvent or a first solvent applied to the fiber sheet 1a. A first coating device 30A' that applies a slurry, a second coating device 30B that is located downstream of the first coating device 30A' in the sheet conveyance direction and that measures and applies a second slurry to the fiber sheet 1a; an impregnation device 40 which is located downstream of the coating device 30B in the sheet conveyance direction and applies an external force to the fiber sheet 1a to impregnate particles into the fiber sheet 1a; and an impregnation device 40 which is located downstream of the impregnation device 40 in the sheet conveyance direction. a squeezing device 50 that squeezes out excess solvent or slurry by applying an external force to the fiber sheet 1a, and a reflux device 60' that refluxes the solvent or slurry squeezed from the sheet by the squeezing device 50 to the first coating device 30A. , and a winding device 70 that winds up the slurry-impregnated sheet 1. In the following description, the same components as those in Embodiment 1 are given the same numbers, and the description will be omitted. Further, since the same slurry is used, a description thereof will be omitted.

<First coating device 30A'>
The first coating device 30A' is a dip nip coater and includes a roller 34, a roller 35, a nip roller 36, a nip roller 37, and a slurry tank 61. The rollers 34 and 35 constitute a mechanism for dipping the fiber sheet 1a into the slurry tank 61. The solvent or slurry squeezed by the squeezing device 50 is stored in a slurry tank 61 and then applied to the fiber sheet 1a by the rollers 34 and 35 immersed in the slurry tank 61, so the slurry tank 61 is used for the first application. It serves both as the device 30A and the reflux device 60'. Although FIG. 2 shows an example in which two rollers are immersed in the slurry tank 61, it may be one or three or more rollers. Further, the rollers 34 and 35 may be driven rollers or driven rollers, and if friction between the fiber sheet 1a and the rollers is not a problem, non-rotating bars may be used. Nip roller 36 and nip roller 37 are arranged to face each other with fiber sheet 1a in between, and the amount of solvent or slurry adhering to fiber sheet 1a can be controlled by adjusting the distance or contact pressure between the nip roller 36 and nip roller 37. adjust. Alternatively, if there is no need to adjust the amount of solvent or slurry applied to the fiber sheet 1a by the first coating device 30A', the nip roller 36 and the nip roller 37 may be omitted. With a configuration like the first coating device 30A', the fiber sheet 1a can be coated and impregnated with a solvent or a low concentration slurry without using a die or a pump as a coating device. It is possible to have a simpler device configuration.

The second coating device 30B applies a highly concentrated slurry to the fiber sheet 1a so that the basis weight of the particles contained in the fiber sheet 1a becomes a target value. When a low concentration slurry is applied to the fiber sheet 1a by the first application device 30A', the amount of application by the second application device 30B is controlled so as to compensate for the particles lacking in the target particle basis weight. good. At this time, a fabric weight meter (not shown) may be provided between the squeezing device 50 and the winding device 70 to measure the fabric weight of the particles.

If you want to control with high precision the basis weight of the particles included in the slurry-impregnated sheet 1 with the coating amount of the second coating device 30B, the basis weight of the particles applied to the fiber sheet 1a with the first coating device 30A' should be made as small as possible. It is preferable to do so. Specifically, by arranging the rollers 34 and 35 near the liquid surface of the slurry tank 61, the supernatant in the slurry tank 61, that is, the solvent that does not contain particles, can be selectively applied to the fiber sheet 1a. can. At this time, it is preferable that the slurry tank 61 has a discharge mechanism for discharging the particles settled on the bottom surface. Further, it is preferable that the inside of the slurry tank 61 is not stirred to promote settling of particles into the slurry tank 61. By periodically discharging the particles settled in the slurry tank 61 by the discharge mechanism and reducing the particle concentration in the slurry tank 61, the basis weight of the particles applied to the fiber sheet 1a by the first coating device 30A' can be minimized. It becomes possible to control the basis weight of the particles contained in the slurry-impregnated sheet 1 only by the coating amount of the second coating device 30B. This further improves control of the amount of particles applied to the fiber sheet 1a.

As described above, according to the slurry-impregnated sheet manufacturing apparatus according to the present invention, a slurry-impregnated sheet in which a fiber sheet is uniformly impregnated with particles such as resin can be manufactured with good productivity.

The present invention applies to FRP used for aerospace applications, structural materials and interior materials for automobiles, trains, ships, etc., pressure vessels, industrial materials, sports materials, medical equipment, civil engineering and architectural applications, etc. It is useful in the production of

1 Slurry impregnated sheet 1a Fiber sheet 10 Unwinding device 20 Conveying device 21, 22 Conveying roller 30 Coating device 30A, 30A' First coating device 30B Second coating device 31 Die 32 Manifold 33 Slits 34, 35 Rollers 36, 37 Nip roller 40 Impregnation device 41, 42, 43, 44, 45 Roller 50 Squeezing device 51, 52 Nip roller 60, 60' Reflux device 61 Slurry tank 62 First pump 63 Concentration diameter 64 Level gauge 100, 200 Manufacturing device

Claims (7)

An apparatus for producing a slurry-impregnated sheet in which a fiber sheet or a porous sheet is impregnated with a slurry in which particles are dispersed in a solvent,
a conveyance device that conveys the fiber sheet or porous sheet;
a first coating device that applies a solvent or a first slurry to the fiber sheet or porous sheet;
a second coating device that is located downstream of the first coating device in the sheet conveyance direction and that measures and applies a second slurry to the fiber sheet or porous sheet;
an impregnating device that is located downstream of the second coating device in the conveying direction of the sheet and applies an external force to the fibrous sheet or porous sheet to impregnate particles into the fibrous sheet or porous sheet;
a squeezing device that is located downstream of the impregnating device in the conveying direction of the sheet and applies external force to the fiber sheet or porous sheet to squeeze out excess solvent or slurry;
a reflux device that refluxes the solvent or slurry squeezed from the sheet by the squeezing device to the first coating device;
A slurry-impregnated sheet manufacturing device having: Of the sheet conveyance path from the impregnating device to the squeezing device,
An angle formed between a horizontal direction and an imaginary straight line connecting the center in the sheet width direction at the inlet of the impregnating device and the center in the sheet width direction at the outlet, and the center in the sheet width direction at the outlet of the impregnating device and the sheet at the inlet of the squeezing device. The angle formed between the virtual straight line connecting the center in the width direction and the horizontal direction is 30° or more and 90° or less,
The apparatus for manufacturing a slurry-impregnated sheet according to claim 1. The reflux device has a slurry tank that stores the solvent or slurry squeezed by the squeeze device,
The first coating device includes the slurry tank and a mechanism for immersing the fiber sheet or porous sheet in the slurry tank,
the second coating device has a die;
The apparatus for producing a slurry-impregnated sheet according to claim 1 or 2. The slurry tank has a discharge mechanism that discharges particles settled on the bottom surface,
The dipping mechanism of the first coating device is arranged near the liquid level of the slurry tank.
The apparatus for manufacturing a slurry-impregnated sheet according to claim 3. The reflux device includes:
a slurry tank that stores the solvent or slurry squeezed by the squeezing device;
a first pump that sends a solvent or slurry from the slurry tank to the first coating device,
the first coating device and the second coating device have a die;
The apparatus for producing a slurry-impregnated sheet according to claim 1 or 2. The slurry tank is
It has a liquid level gauge that measures the liquid level of the solvent or slurry stored in the slurry tank,
The slurry-impregnated sheet manufacturing device according to claim 5, further comprising a first control device that controls the flow rate of the first pump based on a signal from the liquid level gauge. The reflux device includes:
a concentration meter that measures the concentration of the solvent or slurry to be sent;
A flow meter that measures the flow rate of the solvent or slurry to be sent,
The slurry-impregnated sheet manufacturing device includes a second control device that controls the amount of second slurry applied by the second coating device based on signals from the concentration meter and flowmeter.
The apparatus for manufacturing a slurry-impregnated sheet according to claim 5.

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