JP3278097B2 - Tubular body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tubular body formed by winding a prepreg in which a thermosetting resin is impregnated into unidirectionally aligned carbon fibers and subjecting the prepreg to a heat treatment under pressure. Therefore, it can be used for a rod tube of a fishing rod, a shaft of a golf club, and the like.

[0002]

2. Description of the Related Art Fishing rods are required to be lightened in order to hold them for a long time and to improve their operability, and are also required to have increased strength in order to receive a large bending force due to strong pulling by fish. Also, golf clubs are light and
High strength properties are required. Thus, fishing rods, shafts of golf clubs, and the like are required to have conflicting performances of light weight and high strength. For this reason, conventionally, a high-strength and lightweight fiber such as carbon fiber is used, a prepreg impregnated with a synthetic resin such as an epoxy resin is formed, and the prepreg is wound and subjected to pressure and heat treatment. And a lightweight and high-strength tubular body.

In this case, the weight percentage of the resin in the prepreg is generally 35% to 40%.
-44492. In addition, the invention according to this publication discloses the resin impregnation amount of the first prepreg of the innermost layer of the rod tube and the resin of the second prepreg for the main body layer of the outer layer from the viewpoint of conformability to the core metal and adhesion of each layer. It specifies the relationship with the amount of impregnation, and discloses that the content of the innermost layer is made larger than that of the outer layer to be 50% or less, and that of the outer layer is made 33% or less.

[0004]

However, the amount of resin disclosed in the above-mentioned publication is too large for the fiber and is too heavy, and the amount of resin as a whole is too large. The formation of pools (portions where fibers are absent or extremely low) has been observed by microphotography by the applicant. In addition, resin flow occurs during molding, and the fibers are also likely to move along with the flow, and meandering and deviation of the fibers occur, and strength reduction and bending are likely to occur.

In particular, the resin amount of the prepreg for the main body layer is 25
If it exceeds about wt%, if it is wound and wound tightly with a tape and heated and formed, depending on the tightening conditions, the prepreg material will be displaced in the circumferential direction during molding, and many molding defects will occur. On the other hand, if a prepreg impregnated with a small amount of resin is impregnated on average, the adhesion at the boundary of the wound layer becomes poor, voids are generated at the boundary, and the prepreg winding of the fiber is particularly oriented in the longitudinal direction of the core metal. At the boundary between layers, the voids are likely to be continuous in the longitudinal direction, which causes a decrease in strength due to peeling.

Accordingly, an object of the present invention is to provide a lightweight and high-strength tubular body in which a main body layer is formed by prepreg in which a thermosetting synthetic resin is impregnated into carbon fibers while preventing molding defects.

[0007]

SUMMARY OF THE INVENTION In view of the above-mentioned object, the present invention provides a method for producing a plurality of carbon fibers, comprising a plurality of carbon fibers aligned unidirectionally and impregnated with an epoxy resin.
In a laminated tubular body made of a fiber reinforced resin having a main body layer composed of a plurality of layers and an average impregnation amount of the epoxy resin of the main body layer in a range of about 10 wt% to 20 wt%, the main body layer is ,
At least one layer on the layer boundary faces the resin rich area.
There is provided a tubular body characterized in that a layer in which the ratio of the epoxy resin is unevenly distributed in a thickness direction in the layer so as to face each other is a main component. Here, wt% indicates a weight percentage based on the total weight of the fiber and the resin.

[0008]

According to the first aspect of the present invention , the epoxies extend in the thickness direction in the layer.
When the localizing ratio of a resin, a number of relatively the necessary portion of each layer since it reduced allocations to unnecessary portions by distributing the epoxy resin, compared to the state of being uniformly distributed, as a whole of the epoxy resin The amount can be reduced, and a lightweight and high-strength tubular body can be obtained. Also, at least at the border
Also, because the layer on one side faces the rich area, the adhesion is
Can be secured.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in more detail with reference to the embodiments shown in the accompanying drawings. FIG. 1 is a partial sectional view of a laminated tubular body 10 according to the present invention. The tubular body 10 is formed by arranging a sheet-like prepreg obtained by impregnating a bundle of carbon fibers aligned so as to face one direction with an epoxy resin so that the direction of the carbon fibers is substantially in the longitudinal direction of the tubular body 10. It has a main body layer 12 which is wound and pressed and heated .

On the inside and outside of the main body layer 12, a reinforcing layer 14 and a reinforcing layer 16 which are thinner than the main body layer 12 are formed, respectively. Each of the reinforcing layers 14 and 16 is made of a prepreg obtained by impregnating an epoxy resin into a carbon fiber bundle aligned so as to be oriented in one direction, such that the main direction of the fiber is substantially in the circumferential direction of the tubular body 10. Wound and cured by applying pressure and heat together with the main body layer 12,
A tubular body 10 is formed. The direction of the carbon fibers of the main body layer 12 is the longitudinal direction of the tubular body, but a direction intersecting this direction, for example, a reinforcing layer mainly composed of the circumferential fibers is mixed between the winding layers oriented in the longitudinal direction. May be.

Such a sheet-like prepreg is formed by, for example, handling a thermosetting synthetic resin film along one side of a bundle of aligned carbon fibers TS, or by forming both sides of a carbon fiber bundle. In the former case, a thermosetting synthetic resin film is inserted between a pair of rollers and pressed. In the former case, the cross section of a single prepreg is schematically shown in FIG. Like
In the latter case, it is as shown in FIG. That is, (a) shows a relatively large amount of epoxy resin as a thermosetting synthetic resin, and a resin-amount rich region RA is present on one side, which can prevent generation of voids when heated and cured in a resin-impregnated state. On the other surface side, the amount of resin is small, and if the resin is impregnated with heat and cured by heating, the amount of resin in the resin poor area PA
In the meantime, an intermediate resin amount area MA between the two is obtained. On the other hand, in (b), the resin amount rich area RA is on both sides, the center is a resin amount poor area PA, and the middle is the resin amount intermediate area MA. It indicates that there is.

As shown in the figure, the arrangement of the carbon fibers TS in the resin amount poor area PA is mainly a triangular arrangement, and the arrangement of the carbon fibers in the resin amount rich area RA is mainly a square arrangement. If the cross-sectional shape of the fiber is circular and the same size, the amount of resin is the minimum in the triangular arrangement, and more can be impregnated in the square arrangement. In the present invention, the average impregnation amount of the synthetic resin of the prepreg thus formed is set to a value within a range of approximately 10 wt% to 20 wt%.
The configuration is considerably smaller than in the past. This produces an effect such as prevention of occurrence of resin pool described later.

[0013] The sheet-shaped prepreg is wound an appropriate number of times in such a direction that at least one layer of the adjacent wound layers sandwiching the boundary faces the resin-rich region RA to the boundary, and after heating under pressure, the main body is heated. A layer corresponding to the main body layer to be the layer 12 is formed, and a heat-hardening treatment is performed while applying pressure together with the layers corresponding to the reinforcing layers 14 and 16 inside and outside the layer to form the tubular body 10. Of these reinforcing layers, the resin amount of the inner reinforcing layer 14 is the same as that of the main body layer 1.
In the case where the outer reinforcing layer 16 is pressurized by the tightening tape, an air pocket due to tape polymerization remains between the tightening tape and the reinforcing layer 16. Body layer 12 to discharge
More impregnated with resin than before. In addition, there is a form in which the reinforcing layer is only one of the inside and outside due to the necessity of the reinforcement, and also a form in which the reinforcing layer is disposed between each winding layer in the main body layer 12.

In the corresponding layer of the main body layer formed as described above, the amount of resin is small, and there is a concern that poor adhesion at the boundary of each wound layer may occur. In the present invention, however, the amount of resin in each wound layer is insufficient. Uniformity is provided, and at least one layer at the boundary faces the rich region RA, so that adhesion can be ensured. In addition, in addition to the movement of the resin from the rich region RA to the poor region PA at the time of pressurized heat molding, there is no problem that some small voids remain. Furthermore,
The amount of resin in the corresponding layer of the outer reinforcing layer 16 is large,
Since this layer is thin, the absolute amount of the resin is small, and it is used for eliminating the air pocket by the tightening tape, so that it can hardly move to the inside of the layer corresponding to the main body layer, and penetrates into the adjacent contact area. When the resin amount of the inner reinforcing layer 14 is made large, the resin layer is thin, so that the absolute resin amount is small, and the resin penetrates into the adjacent contact area. The same applies to the case where the reinforcing layer is provided between the winding layers in the main body layer. As described above, in the present invention, the amount of the resin is an appropriate amount, and it is possible to prevent the fiber from shifting, meandering, and deviating, and to further reduce the weight and improve the adhesion at the boundary of the wound layer, thereby causing molding failure. It is difficult to improve the specific strength of the tubular body.

In addition, the present invention is also effective in preventing the resin pool J described below. That is, FIG. 3 is a diagram schematically showing a cross section of a tubular body formed by winding a conventional prepreg having a resin amount after pressure and heat curing, and includes an inner reinforcing layer 14 ′,
The main body layer 12 ′ includes a main body layer 12 ′ and an outer reinforcing layer 16 ′, and the main body layer 12 ′ includes an inner first sheet prepreg layer 12 A and an outer second sheet prepreg layer 12 B. have. In such a case, the winding start end and the winding end end of each sheet-shaped prepreg are superimposed, and in such a superimposed end region, a resin pool J has been liable to occur conventionally, and it has often been peeled off therefrom. FIG. 4 is an enlarged view of the overlapped end region. The resin reservoir J has almost no fibers TS, and the thermosetting synthetic resin occupies most of the resin pool J.

As shown in FIG. 4, the overlapping end region of the main body layer formed by using the sheet-shaped prepreg having the amount of resin according to the present invention has no resin pool as shown in FIG. Disperse in. As described above, according to the present invention, the generation of the resin pool is prevented, and the strength of the tubular body is improved.

If a tubular body is formed by heating using a prepreg in which the synthetic resin ratio is unevenly distributed in the thickness direction as shown in FIG. 2, even if the ratio changes, each winding layer obtained by heating and curing each winding layer is formed. In the thickness direction in the spin forming layer, the uneven distribution state of the synthetic resin ratio remains. For example, FIG.
As shown in FIG. 3, each of the winding forming layers constituting the main body layer 12 has a rich region RA on one side and a poor region PA on the other side. In order to improve the adhesion at the boundary of each layer,
The amount of resin can be reduced as a whole as compared with the case of a uniform resin ratio, and weight reduction can be achieved. Therefore, the specific strength is also improved.
The resin ratio of the inner and outer reinforcing layers 14 and 16 in this embodiment is substantially uniform in each layer, and is set to be equal to or greater than the resin ratio of the rich region RA of the main body layer 12.
The boundary with 2 is also prevented from causing a shortage of resin and has good adhesion moldability, and the reinforcing layer is set thin, the absolute amount of resin is small and does not contradict the weight reduction of the entire tubular body.

FIG. 7 is an enlarged view of a portion A of another embodiment of FIG.
Then, the main body layer 12 is composed of two layers, and the rich region R
A is configured to face each other. In this embodiment, each reinforcing layer 1
The resin ratios 4 and 16 have a substantially uniform resin ratio in each layer, and are set to be equal to or greater than the resin ratio of the rich region RA of the main body layer 12. Therefore, shortage of resin is prevented even at the boundary with the main body layer 12, good adhesion moldability is achieved, and the reinforcing layer is set thin, the absolute amount of resin is small, and it does not contradict the weight reduction of the entire tubular body. .

When the reinforcing layer is not provided on any one of the surfaces, the resin ratio is increased on the surface side of the main body layer. This protects the carbon fibers oriented substantially in the longitudinal direction, prevents damage, and provides a highly durable tubular body. When the main body layer is formed as a single layer, when the resin ratio of the inner and outer reinforcing layers is substantially the same, the side having the higher resin ratio of the main body layer is adjacent to the outer reinforcing layer, and the resin is pressed by the tightening tape. The flow assists in pushing air out of the surface. When the resin ratio of the inner and outer reinforcing layers is different, the side of the main body layer having the higher resin ratio is adjacent to the reinforcing layer having the lower resin ratio, and the resin is supplied to the reinforcing layer having the lower ratio.

The reinforcing fibers of the reinforcing layer intersect with the main reinforcing fibers (carbon fibers) of the main body layer oriented substantially in the longitudinal direction and are usually oriented substantially in the circumferential direction. Since fibers intersect at the interface, voids are likely to occur during molding. For this reason, it is preferable that the side having a higher resin ratio be configured to face the boundary side, and to achieve weight reduction while preventing peeling or breakage from the interface.

In particular, the results of experiments confirming the bending strength of materials required for fishing rod rod tubes and shafts of golf clubs are shown below. Four-point bending of a tubular specimen having an inner diameter of 10 mm and a length of 600 mm (support point interval is 500 mm, load interval is 150 m
m) was measured. As a conventional product, a backing reinforcing prepreg in which a carbon fiber aligned in one direction and an epoxy resin is 25 wt% and a body layer prepreg in which a carbon fiber aligned in a direction orthogonal to the fiber direction and an epoxy resin is 40 wt% is used. (Thickness of about 1/5 of the main body layer prepreg) was stacked and wound four times. As the product of the present invention, the main layer prepreg has a resin amount of 20 wt%, and the backing is as described above.

Although the thickness of each of the four test pieces is slightly different, the thickness (mm), own weight (gw), breaking load (kgw), and specific strength (kgw / gw) are shown in comparison. NO. Thickness Own weight Breaking load Specific strength Conventional product 1 0.63 20.13 73.8 3.67 2 0.64 20.21 75.2 3.72 3 0.64 20.31 70.6 3.48 40 .64 20.22 71.6 3.54 Average 0.64 20.22 72.8 3.60 Invention 1 0.58 19.04 73.5 3.86 2 0.59 19.08 77.0 4.04 3 0.59 19.24 75.8 3.94 4 0.59 19.12 73.5 3.85 Average 0.59 19.12 75.0 3.92

As can be seen from the above experimental results, the invention product has a higher specific strength than the conventional product. That is, it is lightweight, strong, and easy to handle. In the method for producing a tubular body of the present invention,
It should be noted that it is preferable to preheat at the softening temperature of the resin which is equal to or lower than the curing temperature without suddenly raising the temperature to the curing temperature during heating, and to maintain the temperature to allow the entire body to blend in. Furthermore, since the amount of resin is smaller than in the conventional case, it is preferable to increase the pressing force as compared with the conventional molding to improve the adhesion between fibers.

Since the main body layer 12 of the tubular body 10 of the embodiment of FIG. 1 according to the present invention does not always have a sufficient impact strength, it is either outside the outermost reinforcing layer 16 or the main body layer. A layer of a thermoplastic resin having good vibration absorption may be formed directly outside of the layer 12. As an example of this resin layer,
When the polyamide fiber is wound on the layer in which the above-described prepreg is wound, and the above-described heat treatment for curing is performed in this state, the wound polyamide fiber is softened and formed into a layer depending on the temperature. . This softening may be incomplete.
In this way, the durability of a golf club shaft or the like is particularly increased.

[0025]

As is apparent from the above description, according to the present invention, since the amount of resin relative to the amount of fiber is appropriately adjusted, the prepreg material is less likely to be displaced during molding, and molding defects are prevented. In addition, it is possible to provide a lightweight and high-strength tubular body in which a main layer is formed by a prepreg in which carbon fibers are impregnated with an epoxy resin .

[Brief description of the drawings]

FIG. 1 is a partial cross-sectional view of a tubular body according to the present invention.

FIG. 2 is a view showing two types of cross sections of a prepreg forming a tubular body.

FIG. 3 is a schematic cross-sectional view of a conventional tubular body.

FIG. 4 is an enlarged view of an overlapped end portion corresponding to FIG.

FIG. 5 is an enlarged view of a polymerization end portion of a tubular body main layer related to the present invention.

FIG. 6 is an enlarged view of a part A embodiment of FIG. 1;

FIG. 7 is an enlarged view of another embodiment of the part A in FIG. 1;

[Explanation of symbols]

 Reference Signs List 10 tubular body 12 main body layer 14, 16 reinforcing layer

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-49-20274 (JP, A) JP-A-6-7923 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 70/00-70/88 B29D 23/00

Claims (1)

(57) [Claims] [Claim 1] mainly painting carbon fiber aligned pull in one direction
It a plurality of layers by the prepreg impregnated with epoxy resin
In a laminated tubular body made of fiber reinforced resin having an average impregnation amount of epoxy resin of the main body layer in a range of about 10 wt% to 20 wt%, the main body layer is formed at a layer boundary.
Means that at least one layer faces the resin-rich area
Tubular body a layer ratio of the epoxy resin in the thickness direction of the layer is unevenly distributed and wherein the forming a main body so.