JP2024074453A - Paint nozzle and prepreg manufacturing equipment - Google Patents

Abstract

[Problem] To provide a coating nozzle and prepreg manufacturing apparatus capable of uniformly (or approximately uniformly) adhering resin powder to a sheet-like fiber substrate. [Solution] A coating nozzle used in a prepreg manufacturing apparatus for manufacturing a prepreg by adhering resin powder to a sheet-like fiber substrate, the coating nozzle comprises an air nozzle including a first resin powder outlet having a slit shape extending in the width direction of the sheet-like fiber substrate, a second resin powder outlet having a slit shape extending in the width direction of the sheet-like fiber substrate, a supply pipe for supplying the air and resin powder sprayed from the first resin powder outlet and sprayed from the second resin powder outlet toward the sheet-like fiber substrate to the second resin powder outlet, and a plurality of top mixers arranged in the supply pipe. [Selected Figure] Figure 5

Description

This disclosure relates to a coating nozzle and prepreg manufacturing device that can apply resin powder uniformly (or approximately uniformly) to a sheet-like fiber substrate.

A prepreg manufacturing device is known that is configured to attach charged resin powder to a sheet-like fiber substrate by the Coulomb force of an electric field formed between an electrode (high-voltage plate) to which a high voltage is applied and the sheet-like fiber substrate being transported, and by the transport force of air sprayed from an air nozzle (see, for example, Patent Document 1).

Patent No. 6121978

However, in Patent Document 1, the resin powder is sprayed non-uniformly (non-uniformly in the longitudinal direction of the slit) from the air nozzle (slit), which makes it difficult to adhere the resin powder uniformly (or roughly uniformly) to the sheet-like fiber substrate.

Other objects and novel features will become apparent from the description of this specification and the accompanying drawings.

The coating nozzle according to one embodiment is a coating nozzle used in a prepreg manufacturing device that produces prepregs by attaching resin powder to a sheet-like fiber substrate, and includes an air nozzle including a first resin powder outlet having a slit shape extending in the width direction of the sheet-like fiber substrate, a second resin powder outlet having a slit shape extending in the width direction of the sheet-like fiber substrate, a supply pipe that supplies the air and resin powder to be sprayed from the first resin powder outlet and sprayed from the second resin powder outlet toward the sheet-like fiber substrate to the second resin powder outlet, and a plurality of top mixers arranged in the supply pipe, and the plurality of top mixers are arranged so that the resin powder sprayed from the first resin powder outlet is finally uniformed or approximately uniformed in the width direction of the sheet-like fiber substrate by repeatedly colliding with the top mixers, being diverted by the collision, and merging after the diverged flow multiple times in the supply pipe, and is sprayed uniformly or approximately uniformly from the second resin powder outlet.

According to the above-described embodiment, it is possible to provide a coating nozzle and a prepreg manufacturing device that can uniformly (or approximately uniformly) apply resin powder to a sheet-like fiber substrate.

FIG. 1 is a plan view showing an outline of the configuration of a prepreg manufacturing apparatus according to an embodiment of the present disclosure. FIG. 1 is a side view showing an outline of the configuration of a prepreg manufacturing apparatus according to an embodiment of the present disclosure. 3 is a view taken along the line AA in FIG. 2. FIG. 2 is a diagram for explaining a method for producing a prepreg using the prepreg production apparatus of the reference example. FIG. 2 is a perspective view of the coating nozzle 100. 6A is a view of the air nozzle 41 as seen in the direction of the arrow AR4 in FIG. 5, and FIG. 6B is a cross-sectional view taken along line BB of FIG. 6A. 6 is a view of the coating nozzle 100 as seen from the direction of the arrow AR8 in FIG. 5 . 8 is an enlarged view of the frame mixer rows 1 and 2 extracted from FIG. 7. 13A is a graph showing the distribution of resin powder sprayed from the air nozzle 41 (first slit SL1) in simulation 1, and FIG. 13B is a graph showing the results of simulation 1 (distribution of resin powder sprayed from the second slit SL2). 13A is a graph showing the distribution of resin powder sprayed from the air nozzle 41 (first slit SL1) in simulation 2, and FIG. 13B is a graph showing the results of simulation 2 (distribution of resin powder sprayed from the second slit SL2). (a) is an oblique view of the top mixer 110 used in experiment 1; (b) is an oblique view of the top mixer 110 used in experiment 1 with one half cut off; (c) is a plan view of the top mixer 110a which constitutes the upper and middle top mixer rows; and (d) is a plan view of the top mixer 110b which constitutes the lower top mixer row. 6 is a view of the coating nozzle 100 as seen from the direction of the arrow AR8 in FIG. 5 . 1 is a graph showing the results of Experiment 1, showing the resin deposition uniformity in the width direction of the prototype woven fabric base material m1 (prepreg). 1A is an example of a top mixer rocking mechanism 160, FIG. 1B is a diagram showing the top mixer 110 rocking, and FIG. 1C is a diagram showing the top mixer 110 rocking. 11 is a flowchart of an example of control of the frame mixer 110 (frame mixer control process).

<Reference Example>
A prepreg manufacturing apparatus according to a reference example will be described with reference to Figs.

The prepreg manufacturing device of the reference example is a device that manufactures prepreg by attaching resin powder 30 to a sheet-like fiber substrate 50 such as carbon fiber fabric or UD tape, and as shown in Figures 1 and 2, it mainly comprises two chambers 31, 32 provided on the left and right with the sheet-like fiber substrate 50 in between, supply pipes 37, 38 provided in the chambers 31, 32, respectively, flat-type air nozzles 41, 42 connected to the ends of the supply pipes 37, 38, respectively, and powdered resin charging units 43, 44 provided in the supply pipes 37, 38, respectively.

The chambers 31, 32 have rectangular outer shells 31a, 32a and roughly rectangular inner shells 31b, 32b with rounded corners that are provided inside the outer shells 31a, 32a.

The sheet-like fiber substrate 50 side of the outer shells 31a, 32a, i.e., the right end (front surface) of the left chamber 31 and the left end (front surface) of the right chamber 32, are open, and the sheet-like fiber substrate 50 to which the resin powder 30 is attached is placed between them. In addition, exhaust ports 35, 36 are formed on the opposite side of the sheet-like fiber substrate 50 side of the outer shells 31a, 32a, i.e., the left end (rear surface) of the left chamber 31 and the right end (rear surface) of the right chamber 32. Dust collectors 53, 54 that collect the resin powder 30 discharged from the exhaust ports 35, 36 are attached to the exhaust ports 35, 36.

In addition, openings 33, 34 are formed at the front positions of the inner shells 31b, 32b facing the sheet-like fiber substrate 50, i.e., at the right end (front) of the inner shell 31b of the left chamber 31 and the left end (front) of the inner shell 32b of the right chamber 32. High-voltage plates 51, 52 are installed around the openings 33, 34 so as to completely surround them.

The inner shells 31b, 32b of the chambers 31, 32 are provided in a partitioned state without intersecting with the outer shells 31a, 32a, and between the outer shells 31a, 32a and the inner shells 31b, 32b, flow paths (gaps) 45, 46 are formed so that the resin powder 30 discharged together with air from the openings 33, 34 on the top, bottom, left and right sides and that does not adhere is discharged from the discharge ports 35, 36 to the outside of the chambers 31, 32.

The supply pipes 37, 38 are provided at approximately the center height within the inner shells 31b, 32b of the two chambers 31, 32, respectively, and one end of each extends approximately horizontally to the openings 33, 34. The other ends of the supply pipes 37, 38 are connected to flat air nozzles 41, 42.

The flat air nozzles 41, 42 have main bodies 41a, 42a that extend in the width direction of the two chambers 31, 32 (the front-to-back direction of the paper in FIG. 2), and a first slit SL1 (see FIG. 4) in the shape of a long hole that extends in the width direction of the chambers 31, 32 like the main bodies 41a, 42a is formed at the end of the main bodies 41a, 42a on the sheet-like fiber base material 50 side, and air is sprayed from the first slit SL1 in the shape of a curtain. The first slit SL1 is an example of a first resin powder discharge port of the present disclosure.

The base end of the main body 41a, 42a of the flat air nozzle 41, 42 is connected to one end of an input tube 47, 48 having an input port 47a, 48a through which the resin powder 30 is input. The other end of the input tube 47, 48 enters the inner shell 31b, 32b of the chamber 31, 32, but one end of the input tube 47, 48 is located outside the chamber 31, 32, and a fixed amount of resin powder 30 is continuously input from the input port 47a, 48a provided at the one end by a fixed amount feeder or the like.

Compressors 39, 40 are connected to the approximate center of the inlet pipes 47, 48 via an air amplifier T. As a result, the compressed air sent from the compressors 39, 40 has its flow rate further increased by the air amplifier T, and is mixed with the resin powder 30 supplied from the inlets 47a, 48a by a quantitative feeder or the like, and is forced into the flat air nozzles 41, 42 as a high-pressure gas-solid two-phase flow.

The powdered resin charging sections 43, 44 are provided approximately in the center of the supply pipes 37, 38, and charge the resin powder 30 together with the air negatively (or positively), providing a high amount of charge to the resin powder 30.

The resin powder 30 is generally a thermosetting resin, but may be a thermoplastic resin or natural resin. The sheet-like fiber substrate 50 may be made of metal fibers, mineral fibers, glass fibers, or synthetic fibers other than carbon fibers.

The sheet-like fiber substrate 50 is also connected to ground, and a high-voltage electric field is applied between it and the high-voltage plates 51, 52 installed around the openings 33, 34 formed in the inner shells 31b, 32b of the chambers 31, 32.

A method for manufacturing prepreg using the prepreg manufacturing device configured in this manner will be described.

When a fixed amount of resin powder 30 is continuously fed into the feed ports 47a, 48a of the feed pipes 47, 48 by a fixed amount feeder or the like, the resin powder 30 is mixed inside the feed pipes 47, 48 with high-pressure air, the flow rate of which is further increased by the air amplifier T, which is compressed air sent from the compressors 39, 40, and then the resin powder 30 is forced into the flat air nozzles 41, 42.

As a result, the air speed is made uniform inside the supply pipes 37, 38 from the injection slits of the flat air nozzles 41, 42, and a solid-gas two-phase flow of the resin powder 30 and air is sent in the form of an air curtain, while both the resin powder 30 and the air are negatively charged by the powdered resin charging units 43, 44 installed in the supply pipes 37, 38.

Then, the solid-gas two-phase flow in which the charged resin powder 30 and air are mixed is discharged from the openings 33, 34 of the chambers 31, 32 (an example of the second resin powder discharge port of the present disclosure. See FIG. 4. Hereinafter, also referred to as the second slit SL2) and sprayed onto the sheet-like fiber substrate 50. At this time, a high-voltage electric field is applied between the openings 33, 34 and the grounded sheet-like fiber substrate 50 by the high-voltage plates 51, 52 installed around the openings 33, 34, and a negative high voltage is applied to the openings 33, 34 side. The negatively charged resin powder 30 is vigorously discharged from the openings 33, 34 toward the sheet-like fiber substrate 50 and adheres to the sheet-like fiber substrate 50 with strong adhesive force, and a prepreg is produced.

When the resin powder 30 is positively charged by the powder resin charging units 43 and 44, a positive high voltage is applied to the openings 33 and 34 by the high voltage plates 51 and 52.

In this specification, prepreg includes semipreg.

The resin powder 30 that is not attached to the sheet-like fiber base material 50 flows through the flow paths 45, 46 formed between the outer shells 31a, 32a and the inner shells 31b, 32b of the two chambers 31, 32 to the rear side of the outer shells 31a, 32a, and is discharged from the discharge ports 35, 36 to the outside of the two chambers 31, 32.

The discharged resin powder 30 is collected by dust collectors 53, 54 connected to the discharge ports 35, 36 so that it can be reused. In this embodiment, as shown in FIG. 1, the resin powder 30 collected by the dust collectors 53, 54 is again fed into the feed ports 47a, 48a of the feed pipes 47, 48 via a quantitative feeder or the like, and is pushed into the flat air nozzles 41, 42 together with air via the compressors 39, 40.

According to this, chambers 31, 32 consisting of outer shells 31a, 32a and inner shells 31b, 32b are provided on the left and right sides of the sheet-like fiber substrate 50, and flat air nozzles 41, 42 are provided in the inner shells 31b, 32b of the chambers 31, 32, respectively, so that the entire device is made compact and space-saving, and resin powder 30 can be simultaneously applied to both sides of the sheet-like fiber substrate 50.

Furthermore, by employing the flat-type air nozzles 41, 42, the resin powder 30 is mixed with air and pushed in from the rear side of the supply pipes 37, 38 at high pressure and at a uniform flow rate, so that the flow rate of the solid-gas two-phase flow consisting of the charged resin powder 30 and air inside the supply pipes 37, 38 is fast and uniform, making the straightening device and blower that are normally used unnecessary, which also makes it possible to miniaturize the entire device.

In this reference example, the sheet-like fiber substrate 50 is fixed between the two chambers 31, 32 and the resin powder 30 is simultaneously applied to both sides of the substrate. However, by further providing a conveying device capable of continuously conveying the sheet-like fiber substrate 50 itself in an upward or downward direction, the resin powder 30 can be continuously applied to both sides of the sheet-like fiber substrate 50 over a wide area in a short period of time.

In addition, in this reference example, high-voltage plates 51, 52 are installed around the openings 33, 34 of the chambers 31, 32 to allow the resin powder 30 to adhere more firmly to the sheet-like fiber substrate 50, but the resin powder 30 can be adhered to the sheet-like fiber substrate 50 even if the high-voltage plates 51, 52 and the powder resin charging sections 43, 44 are omitted.

Next, we will explain the manufacturing method for producing prepreg using the prepreg manufacturing device of the above reference example.

Figure 4 is a diagram to explain the manufacturing method for manufacturing prepreg using the prepreg manufacturing device of the reference example.

In the following, a woven fabric substrate is used as the sheet-like fiber substrate 50. The woven fabric substrate refers to a sheet-like fiber substrate composed of fibers corresponding to the weft and warp. Hereinafter, it will be referred to as woven fabric substrate m1. For the sake of simplicity, FIG. 4 shows only the opening 33 (second slit SL2) and omits the opening 34. The following explanation will also focus on the operation of the second slit SL2, and will omit the operation of the opening 34.

As shown in FIG. 4, the woven fabric substrate m1 is continuously pulled out from a roll M1, which is formed by winding the woven fabric substrate m1 into a roll, and is hung on driven rollers R1 and R2 and connected to a winding shaft A. The woven fabric substrate m1 is transported (transported in the direction indicated by arrows AR1 to AR3 in FIG. 4) by the winding shaft A being rotated by a motor (not shown), and passes through a second slit SL2 disposed between the driven rollers R1 and R2, a resin deposition heater 60, and a film thickness meter 80 (fixed-point film thickness meter) disposed after the resin deposition heater 60, in that order.

A high-voltage power supply 70 is electrically connected to the high-voltage plate 51 (electrode plate), and a high voltage V (e.g., several tens of KV) is applied. Therefore, a corona discharge occurs from the high-voltage plate 51 toward the grounded woven substrate m1. Therefore, the resin powder sprayed together with the air from the second slit SL2 is charged by ions generated by the corona discharge when passing through the high-voltage plate 51. This charged resin powder adheres to the woven substrate m1 (front or back) passing through the second slit SL2 due to the Coulomb force caused by the electric field formed between the high-voltage plate 51 and the woven substrate m1 and the conveying force of the air sprayed from the second slit SL2 (the principle of electrostatic powder coating). The air and resin powder sprayed from the second slit SL2 toward the woven substrate m1 are supplied to the second slit SL2 by the supply pipe 37 and sprayed from the second slit SL2.

As described above, the woven fabric base material m1 with the resin powder attached thereto is heated by the resin deposition heater 60 as it passes through the resin deposition heater 60. As a result, the resin powder attached to the woven fabric base material m1 is fused to the woven fabric base material m1, and the prepreg m2 (see FIG. 4) is produced.

When the manufactured prepreg m2 passes through the thickness meter 80, the thickness is measured by the thickness meter 80. Then, the quantitative feeder 90 (amount of resin powder supplied) is controlled (feedback controlled) so that the measured thickness becomes the target thickness.

The prepreg m2 produced in the above manner is wound up on a winding shaft A, which is rotated by a motor (not shown), via a driven roller R2.

<Embodiment>
First, a problem that the present inventors have found in the method for producing prepreg using the prepreg production apparatus of the above-mentioned Reference Example will be described.

The inventors have found that in the above reference example, the resin powder is sprayed non-uniformly (non-uniformly in the longitudinal direction of the first slit SL1) from the air nozzle 41 (first slit SL1), and this non-uniformly sprayed resin powder is supplied to the second slit SL2 by the supply pipe 37 and sprayed non-uniformly (non-uniformly in the longitudinal direction of the second slit SL2) from the second slit SL2, making it difficult to uniformly (or approximately uniformly) adhere the resin powder to the woven substrate m1.

Next, as an embodiment, an example in which a configuration example for solving the above problem is applied to the above reference example will be described. Hereinafter, an example using a top mixer (diffuser) will be described as a configuration example for solving the above problem. Note that the same components as those in the above reference example will be given the same reference numerals and will not be described as appropriate. Note that the flat air nozzles 41 and 42 have the same configuration and operation, so to simplify the description, an example using the flat air nozzle 41 and the supply pipe 37 will be described as a representative below, and an example using the flat air nozzle 42 and the supply pipe 38 will be omitted.
<Painting nozzle 100>
FIG. 5 is a perspective view of the paint nozzle 100.

5, the air nozzle 41 and the supply pipe 37 constitute a coating nozzle 100. A plurality of top mixers 110 are disposed within the supply pipe 37. The top mixers 110 will be described in detail later.
<Air nozzle 41>
First, a description will be given of the air nozzle 41. This air nozzle 41 has the same configuration as that of the above-mentioned reference example.

Figure 6(a) is a view of the air nozzle 41 as seen from the direction of the arrow AR4 in Figure 5, and Figure 6(b) is a cross-sectional view taken along line B-B in Figure 6(a).

As shown in FIG. 6(b), the air nozzle 41 is a flat-type air nozzle including an air nozzle body 120 with a first slit SL1 and an input tube 47 that supplies air and resin powder (high-pressure air mixed with resin powder) to the air nozzle body 120. The air and resin powder (high-pressure air mixed with resin powder) supplied to the air nozzle body 120 via the input tube 47 pass through the internal space of the air nozzle body 120 and are sprayed from the first slit SL1, as described below.

The configuration of the air nozzle 41 will now be explained in more detail.

As shown in FIG. 6(b), the air nozzle body 120 is a cylindrical body with a rectangular cross section that extends in the width direction of the woven fabric substrate m1 (left-right direction in FIG. 6(a)). The cross section of the air nozzle body 120 may be a cross section other than rectangular (e.g., hexagonal). Both ends of the air nozzle body 120 in the longitudinal direction are closed by walls 107 and 108, respectively (see FIG. 5 and FIG. 6(a)).

The air nozzle body 120 is formed with a first slit SL1 (see FIG. 5, FIG. 6(a), FIG. 6(b)). As shown in FIG. 6(a), the first slit SL1 is a horizontally elongated rectangular slit having a length L _SL1 ×slit width W _SL1 extending in the width direction of the woven substrate m1. The length L _SL1 is, for example, 400 mm, and the slit width W _SL1 is, for example, 20 mm. The input tube 47 is provided on the opposite side of the first slit SL1 and in the center of the longitudinal direction of the air nozzle body 120 (see FIG. 5). The input tube 47 and the first slit SL1 communicate with each other through the internal space of the air nozzle body 120. The internal space of the air nozzle body 120 is sealed except for the input tube 47 and the first slit SL1. The arrangement of the input tube 47 is different from that of the above-mentioned reference example (see FIG. 1), but the function of the input tube 47 is the same as that of the above-mentioned reference example.

As shown in FIG. 6(b), a first diffusion plate 140 and a second diffusion plate 150 are disposed in the internal space of the air nozzle body 120. The first diffusion plate 140 and the second diffusion plate 150 divide the internal space of the air nozzle body 120 into first to fourth internal spaces S1 to S4.

Next, the configuration of the first diffuser plate 140 will be described.

As shown in FIG. 6(b), the first diffusion plate 140 is composed of first to third plate-shaped portions 141 to 143. The first to third plate-shaped portions 141 to 143 each extend in the width direction of the woven fabric substrate m1 (the left-right direction in FIG. 6(a)). One end of each of the first to third plate-shaped portions 141 to 143 reaches the wall portion 107. A sealant (not shown) is disposed between one end of each of the first to third plate-shaped portions 141 to 143 and the wall portion 107. Meanwhile, the other end of each of the first to third plate-shaped portions 141 to 143 reaches the wall portion 108. A sealant (not shown) is disposed between the other end of each of the first to third plate-shaped portions 141 to 143 and the wall portion 108.

The second plate-shaped portion 142 extends from one long side of the first plate-shaped portion 141 to a corner at the upper rear of the air nozzle body 120 (see FIG. 6(b)). A sealant (not shown) is disposed between the second plate-shaped portion 142 and the upper rear corner. Similarly, the third plate-shaped portion 143 extends from the other long side of the first plate-shaped portion 141 to a corner at the lower rear of the air nozzle body 120 (see FIG. 6(b)). A sealant (not shown) is disposed between the third plate-shaped portion 143 and the lower rear corner.

As shown in FIG. 6(b), the second plate-shaped portion 142 has a plurality of through holes 142a. The through holes 142a are arranged, for example, in a row in the width direction of the woven fabric base material m1 (see arrow AR5 in FIG. 5). Similarly, the third plate-shaped portion 143 has a plurality of through holes 143a. The through holes 143a are arranged, for example, in a row in the width direction of the woven fabric base material m1 (see arrow AR5 in FIG. 5). The diameter of the through holes 142a, 143a is, for example, about 10 mm.

Next, the configuration of the second diffuser plate 150 will be described.

As shown in FIG. 6(b), the second diffusion plate 150 is composed of fourth to sixth plate-shaped portions 151 to 153. The fourth to sixth plate-shaped portions 151 to 153 each extend in the width direction of the woven fabric substrate m1 (the left-right direction in FIG. 6(a)). One end of each of the fourth to sixth plate-shaped portions 151 to 153 reaches the wall portion 107. A sealant (not shown) is disposed between one end of each of the fourth to sixth plate-shaped portions 151 to 153 and the wall portion 107. Meanwhile, the other end of each of the fourth to sixth plate-shaped portions 151 to 153 reaches the wall portion 108. A sealant (not shown) is disposed between the other end of each of the fourth to sixth plate-shaped portions 151 to 153 and the wall portion 108.

The fifth plate-shaped portion 152 extends from one long side of the fourth plate-shaped portion 151 to a corner at the upper front of the air nozzle body 120 (see FIG. 6(b)). A sealant (not shown) is disposed between the fifth plate-shaped portion 152 and the upper front corner. Similarly, the sixth plate-shaped portion 153 extends from the other long side of the fourth plate-shaped portion 151 to a corner at the lower front of the air nozzle body 120. A sealant (not shown) is disposed between the sixth plate-shaped portion 153 and the lower front corner.

As shown in FIG. 6(b), the fifth plate-shaped portion 152 has a plurality of through holes 152a. Similarly, the sixth plate-shaped portion 153 has a plurality of through holes 153a. The through holes 152a, 153a are arranged, for example, in a line in the width direction of the woven fabric base material m1 (see arrow AR5 in FIG. 5). The diameters of the through holes 152a, 153a are smaller than the diameters of the through holes 142a, 143a formed in the second plate-shaped portion 142 and the third plate-shaped portion 143.

The first diffusion plate 140 (first plate-shaped portion 141) and the second diffusion plate 150 (fourth plate-shaped portion 151) of the above configuration are fixed (e.g., fixed by screws).

In the air nozzle 41 configured as above, the air and resin powder (high-pressure air mixed with resin powder) supplied to the air nozzle body 120 via the input tube 47 passes through the internal spaces S1 to S4 of the air nozzle body 120 and is sprayed from the first slit SL1.

Specifically, the air and resin powder (high-pressure air mixed with resin powder) supplied to the air nozzle body 120 through the input tube 47 are first supplied to the internal space S1. The air and resin powder supplied to the internal space S1 are diffused and compressed in the width direction of the woven fabric substrate m1 (see arrow AR5 in FIG. 5) in the internal space S1, and then supplied to the internal space S2 through the through holes 142a (multiple) formed in the first diffusion plate 140 (second plate-shaped portion 142), and supplied to the internal space S3 through the through holes 143a (multiple) formed in the first diffusion plate 140 (third plate-shaped portion 143).

Next, the air and resin powder supplied to the internal space S2 are further compressed in the internal space S2, and then supplied to the internal space S4 via the through holes 152a (multiple) formed in the second diffusion plate 150 (fifth plate-shaped portion 152). Similarly, the air and resin powder supplied to the internal space S3 are further compressed in the internal space S3, and then supplied to the internal space S4 via the through holes 153a (multiple) formed in the second diffusion plate 150 (sixth plate-shaped portion 153).

Next, the air and resin powder supplied to the internal space S4 as described above are further compressed in the internal space S4 and then sprayed from the first slit SL1. At this time, the air is sprayed uniformly (uniformly in the longitudinal direction of the first slit SL1) from the first slit SL1, but the resin powder is sprayed non-uniformly (non-uniformly in the longitudinal direction of the first slit SL1) from the first slit SL1.
<Supply pipe 37>
Next, a description will be given of the supply pipe 37. The supply pipe 37 has the same structure as in the above-mentioned embodiment.

As shown in FIG. 5, the supply pipe 37 is a pipe having a rectangular cross section and is composed of plate-shaped portions 37a to 37d. The plate-shaped portions 37a and 37c are parallel to each other and are arranged at a predetermined interval. Similarly, the plate-shaped portions 37b and 37d are parallel to each other and are arranged at a predetermined interval. The height H ₃₇ of the supply pipe 37 is, for example, 20 mm, the width W ₃₇ is, for example, 400 mm, and the length L ₃₇ is, for example, 500 mm. The base end 37e side (open end) of the supply pipe 37 is fixed to the air nozzle 41 in a state surrounding the first slit SL1. At that time, a seal material (not shown) is arranged between the base end 37e side (open end) of the supply pipe 37 and the air nozzle 41. Meanwhile, the second slit SL2 is arranged on the tip end 37f side of the supply pipe 37. 3, the second slit SL2 is a horizontally elongated rectangular slit extending in the width direction of the woven fabric base material m1 and having a length L _SL2 ×slit width W _SL2 . The length L _SL2 is, for example, 400 mm, and the slit width W _SL2 is, for example, 20 mm.

The air and resin powder (high-pressure air mixed with resin powder) sprayed non-uniformly from the air nozzle 41 (first slit SL1) of the above configuration are supplied to the second slit SL2 by the supply pipe 37. At that time, the resin powder sprayed non-uniformly from the air nozzle 41 (first slit SL1) is made uniform (or roughly uniform) in the width direction of the woven fabric substrate m1 (longitudinal direction of the second slit SL2) by the top mixers 110 (multiple) arranged in the supply pipe 37. As a result, the resin powder is sprayed uniformly (or roughly uniformly) from the second slit SL2.
<Frame Mixer 110>
Next, the frame mixer 110 will be described.

First, we will explain the principle of how the resin powder sprayed unevenly from the air nozzle 41 (first slit SL1) is made uniform (or roughly uniform) in the width direction of the woven fabric substrate m1 (the longitudinal direction of the second slit SL2) by the top mixers 110 (multiple).

Figure 7 is an arrow view of the paint nozzle 100 as seen from the direction of the arrow AR8 in Figure 5.

As shown in FIG. 7, the top mixer rows 1 to N1 are arranged in a staggered pattern in multiple stages within the supply pipe 37. N1 may be an integer of 2 or greater. Each top mixer row is composed of N2 top mixers 110 arranged in the width direction of the woven fabric base material m1 (the longitudinal direction of the second slit SL2). N2 may be an integer of 2 or greater. Note that the top mixers 110 at both ends of the even-numbered top mixer rows are configured with one half cut off in relation to the plate-shaped portions 37b and 37d that constitute the supply pipe 37.

The top mixer 110 is configured in a cylindrical shape (see FIG. 7). The top mixer 110 is not limited to a cylindrical shape. That is, the top mixer 110 is simply used in a simple cylindrical shape to easily explain the principle of homogenizing (or roughly homogenizing) the resin powder that is sprayed unevenly from the air nozzle 41 (first slit SL1). The height H ₁₁₀ of the top mixer 110 (see FIG. 5) is roughly equal to the height H ₃₇ of the supply pipe 37 (see FIG. 5). One end surface of the top mixer 110 is fixed to, for example, the plate-shaped portion 37a of the supply pipe 37, and the other end surface is fixed to, for example, the plate-shaped portion 37c of the supply pipe 37.

The resin powder sprayed unevenly from the air nozzle 41 (first slit SL1) and supplied to the second slit SL2 by the supply pipe 37 is made uniform (or roughly uniform) in the width direction of the woven fabric base material m1 (the longitudinal direction of the second slit SL2) by the top mixers 110 (multiple) configured and arranged as described above. This will be explained in detail below with reference to Figure 8. Figure 8 is a diagram (enlarged view) of top mixer rows 1 and 2 extracted from Figure 7.

The arrows ARa to ARf in FIG. 8 represent the air and resin powder that are sprayed from the air nozzle 41 (first slit SL1) and collide with the top mixers 110A to 110F. For example, the arrow ARa represents the air and resin powder that are sprayed from the air nozzle 41 (first slit SL1) and collide with the top mixer 110A. The same is true for the other arrows ARb to ARf. Also, the symbols A to F attached to the arrows ARa to ARf in FIG. 8 represent the mass of the resin powder that collide with the top mixers 110A to 110F. For example, the symbol A represents the mass of the resin powder that collide with the top mixer 110A. The same is true for the other symbols B to F.

On the other hand, the arrows ARa1, ARa2 to ARf1, and ARf2 in FIG. 8 represent the air and resin powder that are split into two equal parts by the top mixers 110A to 110F. For example, the arrows ARa1 and ARa2 represent the air and resin powder indicated by the arrow ARa in FIG. 8 that collide with the top mixer 110A and are split into two equal parts by the top mixer 110A. The same is true for the other arrows ARb1, ARb2 to ARf1, and ARf2. Also, the symbols A/2 to F/2 in FIG. 8 represent the mass of the resin powder that is split into two equal parts by the top mixers 110A to 110F. For example, the symbol A/2 represents the mass of the resin powder that is split into two equal parts by the top mixer 110A. The same is true for the other symbols B/2 to F/2.

In addition, the arrows ARab to ARef in FIG. 8 indicate that the air and resin powder diverted as described above join together. For example, the arrow ARab indicates that the diverted flow (air and resin powder) indicated by the arrow ARa2 in FIG. 8 and the diverted flow (air and resin powder) indicated by the arrow ARb1 in FIG. 8 join together. The same applies to the other arrows ARbc to ARef. In addition, the symbols (A/2) + (B/2) to (E/2) + (F/2) in FIG. 8 indicate the mass of the resin powder diverted as described above. For example, the symbol (A/2) + (B/2) indicates the mass of the resin powder diverted as described above and indicated by the arrow ARab in FIG. 8. The same applies to the other symbols (B/2) + (C/2) to (E/2) + (F/2).

As described above, the resin powder sprayed non-uniformly from the air nozzle 41 (first slit SL1) repeats collision with the top mixer 110, diversion due to the collision, and merging after the diversion multiple times when passing through each stage of the top mixer row 1 to N1. As a result, the resin powder sprayed non-uniformly from the air nozzle 41 (first slit SL1) is finally uniformized (or approximately uniformized) in the width direction of the woven fabric base material m1 (longitudinal direction of the second slit SL2) in the supply pipe 37. As a result, the resin powder is sprayed uniformly (or approximately uniformly) from the second slit SL2. The present inventors confirmed this through simulations and experiments. Below, the simulations and experiments performed by the present inventors will be described.
<Simulation 1>
The conditions for simulation 1 are as follows:

The top mixers used in Simulation 1 were arranged in a staggered pattern. Simulation 1 was performed simply using spreadsheet software. The shape and size of the top mixers, and the flow speed of the air and resin powder (high-pressure air mixed with resin powder) sprayed from the air nozzle 41 (first slit SL1) were not taken into consideration.

The distribution of the resin powder sprayed from the air nozzle 41 (first slit SL1) in simulation 1 is as shown in FIG. 9(a). FIG. 9(a) is a graph showing the distribution of the resin powder sprayed from the air nozzle 41 (first slit SL1) in simulation 1. In FIG. 9(a), the vertical axis represents the amount of resin powder, while the horizontal axis represents the widthwise position, i.e., the longitudinal position of the first slit SL1.

In addition, in Simulation 1, simulations were performed for a two-stage arrangement of a frame mixer row consisting of 12 frame mixers (N1=2), a ten-stage arrangement (N1=10), and a fifty-stage arrangement (N1=50).

Next, we will explain the results of simulation 1 performed under the above conditions.

Figure 9(b) is a graph showing the results of simulation 1 (distribution of resin powder injected from the second slit SL2). In Figure 9(b), the vertical axis represents the amount of resin powder, while the horizontal axis represents the widthwise position, i.e., the longitudinal position of the second slit SL2.

Referring to Figure 9 (b), it can be seen that as the number of stages in the top mixer row increases, the resin powder sprayed from the air nozzle 41 (first slit SL1) is ultimately made uniform (or roughly uniform) in the width direction of the woven fabric base material m1 (longitudinal direction of the second slit SL2) within the supply pipe 37.
<Simulation 2>
The conditions for simulation 2 are as follows.

The top mixers used in Simulation 2 were arranged in a staggered pattern. Simulation 2 was performed simply using spreadsheet software. The shape and size of the top mixers, and the flow speed of the air and resin powder (high-pressure air mixed with resin powder) sprayed from the air nozzle 41 (first slit SL1) were not taken into consideration.

The distribution of the resin powder sprayed from the air nozzle 41 (first slit SL1) in simulation 2 is as shown in FIG. 10(a). FIG. 10(a) is a graph showing the distribution of the resin powder sprayed from the air nozzle 41 (first slit SL1) in simulation 2. In FIG. 10(a), the vertical axis represents the amount of resin powder, while the horizontal axis represents the widthwise position, i.e., the longitudinal position of the first slit SL1.

In addition, in Simulation 2, simulations were performed for a two-stage arrangement of 12 frame mixer rows (N1=2), a ten-stage arrangement (N1=10), and a fifty-stage arrangement (N1=50).

Next, we will explain the results of simulation 2, which was performed under the above conditions.

Figure 10(b) is a graph showing the results of simulation 2 (distribution of resin powder injected from the second slit SL2). In Figure 10(b), the vertical axis represents the amount of resin powder, while the horizontal axis represents the widthwise position, i.e., the longitudinal position of the second slit SL2.

Referring to Figure 10 (b), it can be seen that as the number of stages in the top mixer row increases, the resin powder sprayed from the air nozzle 41 (first slit SL1) is ultimately made uniform (or roughly uniform) in the width direction of the woven fabric base material m1 (longitudinal direction of the second slit SL2) within the supply pipe 37.
<Experiment 1>
The conditions for Experiment 1 were as follows.

Figure 11(a) is an oblique view of the top mixer 110 used in experiment 1.

As shown in FIG. 11(a), the top mixer 110 used in experiment 1 includes an upstream portion 111 where the air and resin powder sprayed from the air nozzle 41 (first slit SL1) collide, and a downstream portion 112 on the opposite side.

The upstream portion 111 is configured in a semi-cylindrical shape that is convex toward the upstream side in order to divide the air and resin powder that is sprayed from the air nozzle 41 (first slit SL1) and collides with the top mixer 110 (upstream portion 111) into two equal parts. On the other hand, the downstream portion 112 is configured in a triangular prism shape that tapers toward the downstream side in order to prevent vortexes from being generated downstream of the top mixer 110 when the air and resin powder sprayed from the air nozzle 41 (first slit SL1) collides with the top mixer 110 (upstream portion 111). As described above, by configuring the upstream portion 111 of the top mixer 110 in a semi-cylindrical shape that is convex toward the upstream side and the downstream portion 112 in a triangular prism shape that tapers toward the downstream side, that is, by configuring the top mixer 110 as a whole in a teardrop shape, the flow of air and resin powder (high-pressure air mixed with resin powder) does not separate from the wall surface of the top mixer 110, so that it is possible to suppress the generation of vortexes on the downstream side of the top mixer 110. This makes it possible to suppress the accumulation of resin powder on the downstream side of the top mixer 110. It is generally known that the generation of vortexes on the downstream side can be suppressed by adopting a teardrop shape (see, for example, https://vis-tech.site/air-resistance/).

Figure 12 is an arrow view of the paint nozzle 100 as seen from the direction of the arrow AR8 in Figure 5.

As shown in FIG. 12, the top mixer rows are arranged in a staggered pattern in the supply pipe 37 (three rows are shown in FIG. 12). The top mixer row is composed of five top mixers 110a arranged in the width direction of the woven fabric base material m1 (longitudinal direction of the second slit SL2). The top mixers 110a at both ends of the top mixer row are configured with one half cut (see FIG. 11(b)) in relation to the plate-shaped parts 37b and 37d constituting the supply pipe 37. FIG. 11(b) is a perspective view of the top mixer 110a with one half cut used in Experiment 1. Similarly, the middle mixer row is composed of four top mixers 110a arranged in the width direction of the woven fabric base material m1 (longitudinal direction of the second slit SL2).

Figure 11(c) is a plan view of the top mixer 110a that constitutes the upper and middle top mixer rows.

As shown in FIG. 11(c), the upstream portion 111 of the top mixer 110a constituting the top and middle top mixer rows is part of a cylinder of radius D1. Radius D1 is, for example, 20 mm. The downstream portion 112 of the top mixer 110a constituting the top and middle top mixer rows is part of a triangular prism tapering toward the downstream side, including two side faces tangent to the cylinder of radius D1, with the distance from the center of the cylinder of radius D1 to the apex of the triangular prism being L1. L1 is, for example, 50 mm.

On the other hand, the lower row of top mixers is composed of five top mixers 110b arranged in the width direction of the woven fabric base material m1 (the longitudinal direction of the second slit SL2) (see FIG. 12). Note that the top mixers 110b at both ends of the lower row of top mixers are configured with one half cut out in relation to the plate-shaped portions 37b and 37d that constitute the supply pipe 37.

Figure 11(d) is a plan view of the top mixer 110b that constitutes the lower top mixer row.

As shown in FIG. 11(d), the upstream portion 111 of the top mixer 110b constituting the lower top mixer row is part of a cylinder of radius D2. Radius D2 is, for example, 20 mm. The downstream portion 112 of the top mixer 110b constituting the lower top mixer row is part of a triangular prism tapering toward the downstream side, including two side surfaces tangent to the cylinder of radius D2, with the distance from the center of the cylinder of radius D2 to the apex of the triangular prism shape being L2. L2 is, for example, 30 mm.

As shown in FIG. 12, the distance between the top frame mixer row and the first slit SL1 is L3, the distance between the top frame mixer row and the middle frame mixer row is L4, and the distance between the middle frame mixer row and the bottom frame mixer row is L5. L3 is, for example, 20 mm, and L4 and L5 are, for example, 50 mm.

In the width direction of the woven fabric base material m1 (left-right direction in FIG. 12), the distance between the top mixers in the upper mixer row and the top mixers in the middle mixer row is L6. L6 is, for example, 50 mm.

In addition, in experiment 1, the flow rate of the air and resin powder (high-pressure air mixed with resin powder) sprayed from the air nozzle 41 (first slit SL1) was 4 m/min.

The top mixer 110 is disposed in the supply pipe 37 for the purpose of dispersing the resin powder passing through the supply pipe 37. On the other hand, when the top mixer 110 is disposed in the supply pipe 37, the flow path cross-sectional area is reduced, and the wind speed in the supply pipe 37 is increased. If the wind speed is high, the impact force of the resin powder against the woven substrate m1 is increased, and the resin powder is less likely to adhere to the woven substrate m1. Therefore, in order to gradually reduce (return) the wind speed before reaching the woven substrate m1 (to reduce the impact force of the resin powder against the woven substrate m1), a large-sized top mixer 110a is disposed near the air nozzle 41 (first slit SL1) (see the top mixer rows in the upper and middle rows in FIG. 12), while a small-sized top mixer 110b is disposed farther from the air nozzle 41 (first slit SL1) (see the bottom top mixer row in FIG. 12). For the same purpose, a space L7 (see FIG. 12) is provided between the small-sized top mixer 110b and the outlet (second slit SL2) of the supply pipe 37. Experiment 1 was carried out under the above conditions using a method similar to the manufacturing method shown in FIG. 4.

Next, we will explain the results of Experiment 1, which was conducted under the above conditions.

Figure 13 is a graph showing the results of experiment 1 (uniformity of resin deposition across the width of the prototype woven fabric substrate m1 (prepreg)). In Figure 13, the vertical axis represents Vf, while the horizontal axis represents the widthwise position, i.e., the longitudinal position of the second slit SL2. Vf represents the deposition content of the woven fabric substrate m1. Small variation in Vf represents small variation in the amount of resin powder deposited on the woven fabric substrate m1. Also, in Figure 13, "No top mixer (1)" represents the results of experiment 1 (first time) conducted in a state where no top mixer 110 was placed in the supply pipe 37. Similarly, in Figure 13, "No top mixer (2)" represents the results of experiment 1 (second time) conducted in a state where no top mixer 110 was placed in the supply pipe 37. Meanwhile, in FIG. 13, "With top mixer (1)" represents the results of experiment 1 (first time) conducted with top mixers 110a and 110b arranged in supply pipe 37 as shown in FIG. 12. Similarly, in FIG. 13, "With top mixer (2)" represents the results of experiment 1 (second time) conducted with top mixers 110a and 110b arranged in supply pipe 37 as shown in FIG. 12.

When the coefficient of variation (standard deviation/average value) was calculated based on the results shown in Figure 13, the coefficient of variation for "without top mixer (2)" was 6.8%, while the coefficient of variation for "with top mixer (2)" was 3.4%. The smaller the coefficient of variation, the more uniformly the resin powder adheres to the woven substrate m1 (prepreg). In other words, according to the results shown in Figure 13, it can be seen that the resin powder adheres more uniformly to the woven substrate m1 (prepreg) when the top mixer is used, which has a smaller coefficient of variation.

The conditions of the top mixer (e.g., the number, shape, size, and arrangement of the top mixers) that uniformize (or roughly uniformize) the resin powder sprayed from the air nozzle 41 (first slit SL1) in the width direction of the woven substrate m1 (longitudinal direction of the second slit SL2) vary depending on, for example, the shape and size of the air nozzle 41 and the supply pipe 37, the flow rate and flow rate of the air and resin powder (high-pressure air mixed with resin powder) supplied to the air nozzle 41 via the input pipe 47, and the type of resin powder (particle size, mass, shape, etc.). Therefore, it is difficult to express the conditions of the top mixer that uniformize (or roughly uniform) the resin powder sprayed from the air nozzle 41 (first slit SL1) in the width direction of the woven substrate m1 (longitudinal direction of the second slit SL2) in specific numerical values, etc.

However, by changing (adjusting) at least one of the top mixer conditions using data accumulated from test results such as Experiment 1, and checking the distribution of the resin powder sprayed from the second slit SL2 each time a change is made, it is possible to find the top mixer conditions that make the resin powder sprayed from the air nozzle 41 (first slit SL1) uniform (or roughly uniform) in the width direction of the woven fabric substrate m1 (the longitudinal direction of the second slit SL2).

As described above, according to this embodiment, it is possible to provide a coating nozzle 100 that can uniformly (or approximately uniformly) apply resin powder to a sheet-like fiber substrate (e.g., a woven substrate, a UD substrate), and a prepreg manufacturing device that uses this coating nozzle 100.

Next, we will explain the modified example.

<First Modification>
Hereinafter, as a first modified example, a top mixer rocking mechanism 160 that is added to the coating nozzle 100 of the above embodiment will be described.

Figure 14(a) is an example of a top mixer rocking mechanism 160. Figures 14(b) and 14(c) are diagrams showing the top mixer 110 rocking. The top mixer row shown in Figures 14(a) to 14(c) corresponds to the top mixer row extracted from Figure 12.

As shown in FIG. 14(a), in the first modified example, the top mixer 110 is supported so as to be able to swing about a swing shaft 113. The swing shaft 113 is fixed to the supply pipe 37 and extends in a direction perpendicular to the plane of the paper in FIG. 14(a).

The top mixer rocking mechanism 160 includes guide pins 161 (multiple) that are inserted into guide holes 114 (or guide grooves) formed in the top mixers 110 that make up the top mixer row, a slide shaft 162 to which the guide pins 161 (multiple) are fixed, and an actuator 180 that moves the slide shaft 162 in the direction of the arrow AR9 or AR10 in FIG. 14(a). When the slide shaft 162 is moved in the direction of the arrow AR9 in FIG. 14(a), the top mixers 110 that make up the top mixer row rock as shown in FIG. 14(b). On the other hand, when the slide shaft 162 is moved in the direction of the arrow AR10 in FIG. 14(a), the top mixers 110 that make up the top mixer row rock as shown in FIG. 14(c).

Next, we will explain the control device 170 of this modified example.

The control device 170 includes a processor, RAM, etc., not shown. As shown in FIG. 14(a), the control device 170 is electrically connected to an actuator 180 and a memory unit 190. The memory unit 190 is, for example, a non-volatile memory unit such as a hard disk device or a ROM. The memory unit 190 stores a program 191. The program 191 is a program executed by the control device 170 (processor).

The processor is, for example, a CPU. There may be one processor or multiple processors. For example, the processor functions as a control means for controlling the actuator 180 by executing a program 191 loaded from a storage unit 190 (for example, a ROM) into a RAM. The actuator 180 includes, for example, a motor (not shown) and a mechanism for converting the rotation of the motor into the movement (reciprocating linear motion) of the slide shaft 162.

Next, we will explain an example of control of the frame mixer 110 configured as above (frame mixer control process).

Figure 15 is a flowchart of an example of control of the frame mixer 110 (frame mixer control process).

First, when the top mixer control timing arrives (step S10: YES), the actuator 180 is controlled so that the slide shaft 162 moves a predetermined amount in the direction of the arrow AR9 or AR10 in FIG. 14(a), thereby simultaneously controlling the rocking direction and rocking amount of the top mixers 110 constituting each top mixer row (step S11). Specifically, the rocking direction and rocking amount of the top mixers 110 constituting each top mixer row are controlled so that the resin powder sprayed from the air nozzle 41 (first slit SL1) is uniform (or approximately uniform) in the width direction of the woven fabric substrate m1 (longitudinal direction of the second slit SL2). This is realized by the control device 170 executing the program 191.

The top mixer control timing is, for example, the timing when the variation (for example, standard deviation) in the thickness distribution in the width direction of the woven substrate m1 exceeds a threshold value. The width direction thickness of the woven substrate m1 can be measured, for example, using a scanning X-ray thickness gauge described in JP 2007-298387 A. Although not shown, the scanning X-ray thickness gauge includes an X-ray source and an X-ray detector provided on a movable part that can move in the width direction of the woven substrate m1, and a moving means for moving the X-ray source and the X-ray detector in the width direction of the woven substrate m1. The scanning X-ray thickness gauge is, for example, disposed between the opening 33 and the resin deposition heater 60 in place of the thickness gauge 80 (see FIG. 4).

The process of step S11 is repeated each time the frame mixer control timing arrives.

As with the above embodiment, this modified example also provides a coating nozzle 100 that can uniformly (or approximately uniformly) apply resin powder to a sheet-like fiber substrate (e.g., a woven substrate, a UD substrate), and a prepreg manufacturing device that uses this coating nozzle 100.

In the above modified example, an example was described in which the rocking direction and rocking amount of the top mixers 110 (multiple) were controlled simultaneously, but this is not limited to the above. For example, the rocking direction and rocking amount of each of the top mixers 110 (multiple) may be controlled individually. Also, the rocking direction and rocking amount of some of the top mixers 110 may be controlled, rather than all of the top mixers 110.

In the above modified example, an example was described in which the rocking direction and amount of rocking of the top mixer 110 is controlled using the top mixer rocking mechanism 160, but this is not limited to the above. For example, the rocking direction and amount of rocking of the top mixer 110 may be controlled by controlling a bulkhead using a magnet.

In addition, instead of the top mixer rocking mechanism 160, a top mixer position adjustment mechanism (not shown) that moves (e.g., moves parallel) the top mixer 110 may be used. As the top mixer position adjustment mechanism, for example, a mechanism including a motor may be used.

In addition, the direction and amount of oscillation of the top mixer 110 may be adjusted by manually moving the slide shaft 162 without using the actuator 180, or the position of the top mixer 110 may be adjusted by manually moving the top mixer 110 (e.g., moving it parallel).

The invention made by the inventors has been specifically described above based on the embodiments, but it goes without saying that this disclosure is not limited to the embodiments already described, and various modifications are possible without departing from the gist of the invention.

REFERENCE SIGNS LIST 11 Inlet 12 Acceleration vessel 13 Brush 14 Compression section 15 Storage box 16 Tube 17 Powder 18 Hole 19 Chamber 20 Carbon fiber fabric 30 Resin powder 31, 32 Chamber 31a, 32a Outer shell 31b, 32b Inner shell 33, 34 Opening (resin powder discharge outlet)
Reference Signs (characters) 35, 36 Discharge port 37, 38 Supply pipe 39, 40 Compressor 41, 42 Flat type air nozzle 41a, 42a Main body 43, 44 Powder resin charging section 45, 46 Flow path 47, 48 Input pipe 47a, 48a Input port 50 Sheet-shaped fiber substrate 51, 52 High voltage plate 53, 54 Dust collector T Air multiplier 60 Resin deposition heater 70 High voltage power source 80 Film thickness gauge 90 Quantitative feeder 100 Coating nozzle 110, 110a, 110b Top mixer 120 Air nozzle main body 130 Closing plate 140 First diffusion plate 150 Second diffusion plate 160 Top mixer rocking mechanism 170 Control device 180 Actuator 190 Memory section SL1 First slit SL2 Second slit

Claims (10)

A coating nozzle used in a prepreg manufacturing apparatus for manufacturing a prepreg by adhering a resin powder to a sheet-like fiber base material,
an air nozzle including a first resin powder discharge port having a slit shape extending in a width direction of the sheet-like fiber base material;
A second resin powder discharge port having a slit shape extending in a width direction of the sheet-like fiber base material;
a supply pipe that supplies the air and the resin powder to be sprayed from the first resin powder discharge port and sprayed from the second resin powder discharge port toward the sheet-like fiber base material to the second resin powder discharge port;
a plurality of top mixers disposed within the supply pipe;
The multiple top mixers are arranged so that the resin powder sprayed from the first resin powder outlet is ultimately made uniform or roughly uniform in the width direction of the sheet-like fiber base material by repeatedly colliding with the top mixers, being diverged due to the collision, and merging after the divergence multiple times within the supply pipe, and is then sprayed uniformly or roughly uniformly from the second resin powder outlet. The coating nozzle according to claim 1, wherein a row of top mixers, each of which is composed of a plurality of top mixers arranged in the width direction of the sheet-like fiber substrate, is arranged in multiple stages within the supply pipe. The coating nozzle according to claim 2, wherein the plurality of top mixers are arranged in a staggered pattern. Each of the top mixers includes an upstream portion where the air and the resin powder ejected from the first resin powder ejection port collide with each other, and a downstream portion on the opposite side of the upstream portion,
2. The coating nozzle according to claim 1, wherein the upstream portion is configured to divide into two equal parts the air and the resin powder that are sprayed from the first resin powder discharge port and collide with the upstream portion. The coating nozzle according to claim 4, wherein the upstream portion is semi-cylindrical. The coating nozzle according to claim 4, wherein the downstream portion is configured in a shape that makes it difficult for a vortex to be generated downstream of the top mixer when the air and resin powder sprayed from the first resin powder outlet collide with the upstream portion. The coating nozzle according to claim 6, wherein the downstream portion is triangular prism-shaped. The coating nozzle according to claim 1, further comprising a top mixer rocking mechanism that rocks at least some of the multiple top mixers. The coating nozzle according to claim 1, further comprising a top mixer position adjustment mechanism that moves at least some of the multiple top mixers. A prepreg manufacturing device equipped with a coating nozzle according to any one of claims 1 to 9.

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