JP3702535B2 - Prepreg manufacturing method and apparatus - Google Patents

Prepreg manufacturing method and apparatus Download PDF

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JP3702535B2
JP3702535B2 JP15130496A JP15130496A JP3702535B2 JP 3702535 B2 JP3702535 B2 JP 3702535B2 JP 15130496 A JP15130496 A JP 15130496A JP 15130496 A JP15130496 A JP 15130496A JP 3702535 B2 JP3702535 B2 JP 3702535B2
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fiber bundle
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prepreg
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JPH10404A (en
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秀誉 松前
俊英 関戸
徹 花野
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Toray Industries Inc
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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/18—Separating or spreading

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  • Application Of Or Painting With Fluid Materials (AREA)
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Description

【０００１】
【発明の属する技術分野】
本発明は、走行する１本もしくは互いに並列して同時に走行する複数本の繊維束を開繊してプリプレグを製造するための方法および装置に関する。詳しくは、例えば炭素繊維やガラス繊維などの強化繊維からプリプレグシートやヤーンプリプレグを成形する前処理として、予め繊維束を十分開繊してからプリプレグを製造する方法およびその装置に関する。
【０００２】
【従来の技術】
近年、炭素繊維やガラス繊維といった複数本の繊維からなる強化繊維束を互いに平行に引き揃えた後、エポキシ樹脂や不飽和ポリエステル等のマトリクス樹脂を含浸させてシート化したプリプレグが、航空機材料や一般用工業材料の他、例えばゴルフクラブシャフトや釣竿を始めとするスポーツレジャー用途の成形材料として広く利用されつつあることは周知のとおりである。
【０００３】
このようなプリプレグの使用用途の多様化にともない、プリプレグ自体としても、極薄プリプレグや熱可塑性樹脂によるプリプレグの需要が急速に拡大し、またプリプレグの品位向上、すなわち厚み斑減少の声が高まってきている。こういった需要を満たすためには、プリプレグを成形する際のマトリクス樹脂含浸前に予め繊維束を開繊して繊維束の厚みを薄くし、繊維束の単糸間にまでマトリクス樹脂が十分浸透しやすくしてやることが必須条件である。
【０００４】
かかる従来の開繊方法としては、例えば、図３に示すような特開昭５６−４３４３５号公報に記載の方法や、その他にも特開平２−３６２３６号公報や特開平３−２５１４０８号公報に記載の方法が提案されている。この従来方法では、パッケージから巻き出され、互いに平行して走行する強化繊維束２を、コーム３を通過させて繊維間ピッチを整えた後、加振源４によって軸方向に振動させるローラ５に押し付け、繊維束２の幅方向に擦ることで開繊を行っている。
【０００５】
【発明が解決しようとする課題】
しかしながら、本発明者等の知見によれば、上記従来技術では、開繊されるべき強化繊維束２の単糸同士が交絡していたり、繊維束自身に撚りが残っている場合には、振動させるローラ５上では繊維束は一旦は開繊するものの、ローラから離れてしばらくすると張力によって再び単糸同士が集束し、繊維束の幅は開繊前とほぼ同じ幅にまで戻ってしまうという結果に至っている。このような繊維束に対して、その後に樹脂含浸工程を加えても、得られるプリプレグはマトリクス樹脂が未含浸となり、実用上使用に耐えられるものではないという問題がある。
【０００６】
また、個々の強化繊維２には、弾性率が高くて単糸径が細いため折れ易く毛羽が多発するという理由から、取扱い性を向上させるために、一般的に例えばエポキシ系樹脂のようなサイジング剤が付与されている。このサイジング剤は、いわゆる「糊」の働きをするもので、単糸同士を接着しているため、繊維束を開繊するには妨げとなる。したがって、サイジング剤の接着力に抗して開繊できる何らかの手段を講じなければ、開繊性の向上は期待できない。
【０００７】
本発明は、上述した従来技術の問題点に鑑み、単糸同士が交絡していたり、撚りが残存している強化繊維束であっても、さらにはサイジング剤が付与されている繊維束であっても、十分に開繊し、かつその幅を維持できるプリプレグの製造方法およびその装置を提供することを目的とする。
【０００８】
【課題を解決するための手段】
上記目的を達成するため、本発明のプリプレグの製造方法は、複数本の単糸が引き揃えられてなる繊維束を複数個のローラ上に所定角度に屈曲させるとともに、前記複数個のローラのうちの少なくとも１本を前記繊維束の走行方向に対して交差する方向に振動させつつ通過させることにより、前記繊維束を開繊させ、しかる後に合成樹脂を含浸させてプリプレグを製造する方法において、
（Ａ）前記振動させるローラの直後に位置するローラを振動させずにその周面に前記繊維束を押し当て、
（Ｂ）次に該振動させないローラの周面に、前記繊維束を前記振動させるローラの周面に接触している繊維束の接触長の２倍以上の接触長さで接触させることにより前記繊維束の開繊状態を維持させることを特徴とする。
【０００９】
この場合、前記「振動させるローラの直後に位置するローラ」とは、振動させるローラから振動させないローラまでの繊維束の自由長さ（ローラと接触していない距離）が１００ｍｍ未満までの範囲内の距離に位置するローラをいうものとする。１００ｍｍ以上になるとローラの振動による繊維束への開繊効果が弱くなるからである。
【００１０】
また、前記振動させないローラに接触している繊維束の接触長は、前記振動ローラと繊維束の接触長の２〜１０倍の範囲であるのが好ましい。また、前記振動ローラと前記無振動ローラのうちの少なくとも１本の接糸面を加熱することにより、前記繊維束に付与されているサイジング剤を軟化させつつ開繊するのが好ましい。さらに、前記振動ローラの振動周波数は、１〜１００Ｈｚの範囲、振幅は、１〜５０ｍｍの範囲で開繊するのが好ましい。そして、前記振動ローラと前記無振動ローラが２組以上設けられているとともに、各組の振動ローラの振動周波数と振幅はそれぞれ異ならせることができるのが好ましい。
【００１１】
一方、上記目的を達成するため、本発明のプリプレグの製造装置は、複数本の単糸が引き揃えられてなる繊維束を所定角度に屈曲・支持する複数本のローラと、前記複数本のローラのうちの少なくとも１本を前記繊維束の走行方向に対して交差する方向に振動させる加振手段と、前記繊維束を前記ローラ間を通過させつつ引取る引取手段とを備えたプリプレグの製造装置において、
（Ａ）前記加振手段によって振動させるローラの直後に位置するローラは振動させず、かつ、
（Ｂ）前記振動させないローラは、該ローラの周面に接触している繊維束の接触長さが、前記振動させるローラの周面に接触している繊維束の接触長さの２倍以上となる周面長さを有することを特徴とする。
【００１２】
ここで、前記振動させないローラに接触している繊維束の接触長は、前記加振手段と接続されている振動ローラと繊維束の接触長の２〜１０倍の範囲であるのが好ましい。また、前記振動ローラと前記無振動ローラのうちの少なくとも１本には、その接糸面を加熱する加熱手段が設けられているのが好ましい。また、前記振動ローラと前記無振動ローラは、２組以上有するとともに、各組の振動ローラの振動周波数と振幅を異ならせる振動周波数・振幅調整手段が設けられているのが好ましい。
【００１３】
なお、本発明でいう繊維束とは、複数本の単糸が引き揃えられた１本の繊維束でもよいし、この繊維束が複数本互いに平行に引き揃えられてシート状になっている繊維束でもよい。
【００１４】
【発明の実施の形態】
以下、本発明に係るプリプレグの製造装置の一実施形態例を図面に基づいて説明する。
【００１５】
図１は、本発明に係るプリプレグ製造装置の繊維束開繊部分の概略側面図、図２は該部分の概略斜視図である。
【００１６】
図１において、１は、例えば炭素繊維やガラス繊維等の強化繊維束２が巻き取られている巻取パッケージ、３は複数の繊維束の繊維間ピッチを整えるためのコームである。
【００１７】
４ａおよび４ｂは、後述する振動ローラ５ａ、５ｂを繊維束２の走行方向と交差する方向である軸方向に振動させるための加振源であり、公知の電磁式加振機を始め、カム等を用いたメカニカル式などを用いることができる。なお、この加振源４ａ、４ｂには、その振動周波数と振幅を個々に調整するための図示しない調整手段が設けられている。
【００１８】
振動ローラ５ａ、５ｂは、強化繊維束２を支持するとともに、上述したようにその走行方向と交差する方向に振動して強化繊維束に開繊作用を与えるもので、その軸を中心にフリーで回転するもの、固定されているものいずれであってもよい。この振動ローラの外径は、開繊効果からいえば小さいほど望ましく、具体的にはφ５０ｍｍ以下である。
【００１９】
次に６ａ、６ｂは、振動ローラ５ａ、５ｂで開繊された繊維束２の開繊幅を維持するための無振動ローラである。この無振動ローラは開繊後の糸幅を維持するためのものであって、振動ローラ５ａ、５ｂのように振動させると糸幅が不安定になったり、毛羽発生を促進する等の悪い結果がでるので、振動せずに固定されていることが重要である。このローラは軸を中心にフリーで回転するもの、駆動されているもの、固定されているものいずれであってもよく、要は繊維束が静止または回転する曲面に適度の押圧力で押し当てられた状態で周回するものであればよい。したがってこのような曲面は、図ようなローラに限らず、半円筒面やその他の形状の曲面であってもよい。この曲面は、開繊後の繊維束の幅を維持するためには繊維束との接触長が大きいほど好ましい。よって、前記振動ローラと繊維束の接触長と比較して、該無振動ローラと繊維束の接触長は２から１０倍であるのが好ましい。具体的長さとしては、無振動ローラーと繊維束の接触長を１００ｍｍ以上にできることが好ましい。
【００２０】
また、振動ローラ５ａ、５ｂと無振動ローラ６ａ、６ｂの間での繊維束の幅の狭まりを最小限に抑えるには、繊維束がどちらのローラにも接触していない長さが短いほど好ましい。具体的には２０ｍｍ以下となるように、無振動ローラ６ａ，６ｂを設置すべきである。
【００２１】
これら振動ローラ５ａ、５ｂと、無振動の無振動ローラ６ａ、６ｂは、それぞれ少なくとも１本づつを１組として備えているものであれば開繊の効果を生じるものであって、２組以上備えていればより一層の開繊効果がある。
【００２２】
７は、上記振動ローラおよび無振動ローラの接糸面を加熱することによって、繊維束に付与されているサイジング剤を軟化させるための加熱手段であって、繊維束をサイジング剤の軟化点である３４３〜３７３Ｋ（７０〜１００℃）まで加熱できる能力を備えていれば、近赤外線ヒータや中赤外線ヒータ、遠赤外線ヒータ等いずれの加熱手段を用いてもよい。また、上記振動ローラおよび無振動ローラ内部にヒータを埋め込むなど振動ローラおよび無振動ローラ自身を直接加熱してもよく、このような形態も本発明の加熱手段に含まれる。
【００２３】
最後に９は、強化繊維束２を振動ローラ５ａ、５ｂおよび無振動ローラ６ａ、６ｂ上を通過させながら図の右方向に引取るための図示しない引取り手段であり、モータ等の適当な駆動手段によって強制回転される回転ドラム、ドライブステーション等を用いることができる。
【００２４】
次に、本発明の繊維束の開繊方法の好ましい実施の形態を、上記図１および図２を用いて説明する。
【００２５】
まず、強化繊維束２は、巻き出し時の張力が０．１〜５Ｎ（約１０〜５００ｇｆ）の範囲になるように巻き出すのが好ましい。張力が高すぎると開繊に不利であり、逆に低すぎると繊維束は蛇行してしまう。また、強化繊維束２の走行速度は小さいほど振動ローラ５ａ、５ｂや無振動ローラ６ａ、６ｂとの接触時間を長くできるため有利であるが、走行速度が大きくなった場合であっても振動ローラと無振動ローラの組数を増やすことで、適宜対応は可能である。
【００２６】
次に、振動ローラ５ａ、５ｂの振動周波数は１〜１００Ｈｚの範囲の中で大きいほど好ましいが、機構的な制約から５〜２０Ｈｚでも十分である。また、振動ローラの振幅は、１〜５０ｍｍの範囲でやはり大きいほど好ましいが、振動によって発生する擦過毛羽抑制の点から５〜２０ｍｍがより好ましい。
【００２７】
【実施例】
本発明の実施例を、上記図面を参照して以下に説明する。
【００２８】
実施例１
図１の装置において、強化繊維束２には、開繊前の繊維幅約１ｍｍ、単糸数３，０００本の高弾性タイプ炭素繊維５０本を用い、パッケージ１からの巻き出し張力は１Ｎ（約１００ｇｆ）、走行速度は０．０４ｍ／ｓ（約２．５ｍ／分）に設定した。
【００２９】
一方、加振源４ａ、４ｂには、市販の電磁式加振機（ボクスイ・ブラウン（株）、ＶＧ１００型）を用いた。
【００３０】
次に、振動ローラ５ａ、５ｂは各々フリー回転とし、その径は５ａ、５ｂともφ３０ｍｍとした。そして、各ローラの繊維束との接触長はそれぞれ２５ｍｍ，４０ｍｍとし、いずれもその振動周波数を８Ｈｚに、振幅を１０ｍｍに設定した（条件▲１▼）。
【００３１】
また、無振動の無振動ローラ６ａ、６ｂは、各々フリー回転のローラとした。その無振動ローラの径および繊維との接触長は、それぞれ、６ａをφ７０ｍｍ，１００ｍｍ、６ｂをφ１００ｍｍ，１５０ｍｍとした（条件▲２▼）。
【００３２】
加熱手段７には遠赤外線ヒータを使用し、強化繊維束２の温度がサイジング剤の軟化点である約３５０Ｋ（７７℃）になるように設定した。この時ヒータ表面温度は約５３０Ｋ（２５７℃）であった（条件▲３▼）。
【００３３】
このような実施例の開繊の実測結果を示したのが次の表１である。
【００３４】
【表１】

Figure 0003702535
この表１によれば、本発明の開繊方法および装置を用いることで、強化繊維束は１ｍｍから６ｍｍまで開繊幅が向上したことがわかる。
【００３５】
実施例２
振動ローラ５ａの振動周波数を８Ｈｚ、振幅を１０ｍｍとし、また振動ローラ５ｂの振動周波数を１６Ｈｚ、振幅を２０ｍｍとした（条件▲１▼）。
【００３６】
その他の条件は実施例１と全く同様に設定した。
【００３７】
このような実施例の開繊の実測結果を示したのが上記の表１である。この表によれば、開繊後の繊維束幅は７ｍｍで、振動ローラ５ｂの振動周波数および振幅を増加させたことにより、開繊効果が実施例１よりもさらに１ｍｍアップしたことが分かる。
【００３８】
比較例１
図３の従来技術の装置において、振動ローラ５は外径φ３０ｍｍのフリー回転とし、繊維束との接触長は１０ｍｍとした。そして、その振動周波数を８Ｈｚに、振幅を１０ｍｍに設定した（条件▲１▼）。また、フリー回転ローラ８の径はφ２０ｍｍとした（条件▲２▼）。なお、加熱手段は使用していない（条件▲３▼）。その他の条件は実施例１と全く同様に設定した。
【００３９】
このような比較例の開繊の実測結果を示したのが上記の表１の比較例である。この表によれば、開繊後の繊維束幅は３ｍｍである。すなわち従来技術の方法および装置を用いた場合、実施例１に比べると３ｍｍ、実施例２に比べると４ｍｍ、それぞれ開繊性が劣っていることがわかる。
【００４０】
【発明の効果】
本発明によれば、以下のような効果を奏することができる。
【００４１】
請求項１および２記載のプリプレグの製造方法によれば、互いに平行に引き揃えられた複数本の繊維束が、複数本のローラ上を所定角度に屈曲しながら通過する際に、ローラの少なくとも１本が前記繊維束の走行方向に対して交差する方向に振動しているため、繊維束と振動ローラ間に発生する擦過力によって十分に開繊される。また、開繊された繊維束は、振動ローラ直後に位置させた振動させないローラの周面上にその接触長さが振動ローラでの接触長の２倍以上で押し当てられるため、繊維束と無振動ローラの間に発生する摩擦力によって、その開繊幅を維持することができる。
【００４２】
請求項３および４記載のプリプレグの製造方法によれば、少なくとも１本のローラを加熱することにより、繊維束は、該繊維束に付与されているサイジング剤が軟化する温度まで加熱されるため、単繊維間相互の開繊性が向上する。
【００４３】
請求項５および６記載のプリプレグの製造方法によれば、振動ローラと無振動ローラは２組以上存在し、各組の振動ローラの振動周波数および振幅がそれぞれ異なるため、例えば１組目の振動ローラを小振幅、低振動周波数に、２組目の振動ローラを大振幅、高振動周波数といった具合にそれぞれ設定すれば、繊維束は徐々に開繊するため、振動ローラとの擦過で繊維束を痛めずに、無理なく開繊させることができる。また、繊維束の走行速度が大きくなっても、振動ローラと無振動ローラの組数を増やすことで容易に対応できる。
【００４４】
請求項７および８記載のプリプレグの製造装置によれば、互いに平行に引き揃えられた複数本の繊維束を、複数本のローラ上に所定角度で屈曲させながら通過させる際に、ローラの少なくとも１本を繊維束の走行方向に対して交差する方向に振動させるため、繊維束と振動ローラ間に発生する擦過力によって繊維束を十分に開繊することができる。また、この開繊された繊維束を振動ローラ直後に設けた、前記繊維束の接触長さが振動させるローラでの接触長さの２倍以上の周面長さを有する振動させないローラ表面に押し当てて引取るため、繊維束と無振動ローラの間に発生する摩擦力によって、開繊された繊維束の開繊幅を維持したまま引取ることができる。
【００４５】
請求項９記載のプリプレグの製造装置によれば、少なくとも１本のローラを加熱することが可能となるため、繊維束に付与されているサイジング剤が軟化する温度まで加熱することができ、繊維束の開繊性が向上する。
【００４６】
請求項１０記載のプリプレグの製造装置によれば、振動ローラと無振動ローラを２組以上備えており、さらに各組の振動ローラの振動周波数および振幅をそれぞれ別々に変化させることが可能なため、例えば１組目の振動ローラを小振幅、低振動周波数に、２組目の振動ローラを大振幅、高振動周波数といった具合にそれぞれ設定すれば、繊維束を徐々に開繊させることが可能となり、振動ローラとの擦過で繊維束を痛めずに無理なく開繊させることが可能となる。また、繊維束の走行速度を大きくしても振動ローラと無振動ローラの組数を増設することで容易に対応できる。
【図面の簡単な説明】
【図１】本発明に係るプリプレグ製造装置の繊維束開繊部の概略側面図である。
【図２】本発明に係るプリプレグ製造装置の繊維束開繊部の概略斜視図である。
【図３】従来装置の繊維束開繊部の概略側面図である。
【符号の説明】
１ ：巻取パッケージ
２ ：強化繊維束
３ ：コーム
４ ：加振源
４ａ：加振源
４ｂ：加振源
５ ：振動ローラ
５ａ：振動ローラ
５ｂ：振動ローラ
６ａ：無振動ローラ
６ｂ：無振動ローラ
７ ：加熱手段
８ ：フリー回転ローラ
９ ：引取り手段[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for producing a prepreg by opening one traveling fiber bundle or a plurality of fiber bundles traveling simultaneously in parallel with each other. Specifically, the present invention relates to a method and an apparatus for manufacturing a prepreg after sufficiently opening a fiber bundle in advance as a pretreatment for forming a prepreg sheet or a yarn prepreg from reinforcing fibers such as carbon fibers and glass fibers.
[0002]
[Prior art]
In recent years, prepregs that have been made into sheets by impregnating matrix fibers such as epoxy resins and unsaturated polyesters after aligning reinforcing fiber bundles made of a plurality of fibers such as carbon fibers and glass fibers in parallel with each other have been used as aircraft materials and general As well known industrial materials, it is well known that it is being widely used as a molding material for sports and leisure applications such as golf club shafts and fishing rods.
[0003]
With such diversification of usage of prepregs, the demand for prepregs using ultra-thin prepregs and thermoplastic resins is rapidly expanding as prepregs themselves. ing. In order to meet these demands, the fiber bundle is opened in advance to reduce the thickness of the fiber bundle before impregnation with the matrix resin when molding the prepreg, and the matrix resin penetrates sufficiently between the single yarns of the fiber bundle. It is essential to make it easy to do.
[0004]
As such a conventional fiber opening method, for example, the method described in Japanese Patent Application Laid-Open No. 56-43435 as shown in FIG. 3, or other methods disclosed in Japanese Patent Application Laid-Open No. 2-36236 and Japanese Patent Application Laid-Open No. 3-251408. The described method is proposed. In this conventional method, the reinforcing fiber bundles 2 that are unwound from the package and run parallel to each other are passed through the comb 3 and the interfiber pitch is adjusted, and then the roller 5 is vibrated in the axial direction by the vibration source 4. Opening is performed by pressing and rubbing in the width direction of the fiber bundle 2.
[0005]
[Problems to be solved by the invention]
However, according to the knowledge of the present inventors, in the above-described prior art, when the single yarns of the reinforcing fiber bundle 2 to be opened are entangled with each other, or when the twist remains in the fiber bundle itself, vibration occurs. As a result, the fiber bundle once opens on the roller 5 to be opened, but after separating from the roller for a while, the single yarns are converged again by tension, and the width of the fiber bundle returns to almost the same width as before the fiber opening. Has reached. Even if a resin impregnation step is subsequently added to such a fiber bundle, the resulting prepreg is not impregnated with the matrix resin and has a problem that it cannot be practically used.
[0006]
In addition, the individual reinforcing fibers 2 are generally sized such as an epoxy resin in order to improve the handling property because they have a high elastic modulus and the single yarn diameter is thin, so that they easily break and fluff frequently occurs. An agent is given. This sizing agent functions as a so-called “glue” and bonds single yarns to each other, which hinders fiber bundles from being opened. Therefore, the improvement of the spreadability cannot be expected unless some measure is taken against the adhesive strength of the sizing agent.
[0007]
The present invention is a fiber bundle to which a sizing agent is further applied, even in the case of a reinforcing fiber bundle in which single yarns are entangled or a twist remains, in view of the above-described problems of the prior art. However, an object of the present invention is to provide a prepreg manufacturing method and apparatus capable of sufficiently opening and maintaining the width.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, a method of manufacturing a prepreg according to the present invention includes bending a fiber bundle formed by aligning a plurality of single yarns at a predetermined angle onto a plurality of rollers, and among the plurality of rollers. In a method for producing a prepreg by allowing at least one of the fibers to pass while vibrating in a direction intersecting the traveling direction of the fiber bundle, thereby opening the fiber bundle and then impregnating with a synthetic resin,
(A) The fiber bundle is pressed against the peripheral surface without vibrating a roller located immediately after the roller to be vibrated,
(B) Next, the fiber bundle is brought into contact with the peripheral surface of the non-vibrating roller with a contact length of at least twice the contact length of the fiber bundle in contact with the peripheral surface of the vibrating roller. It is characterized by maintaining the open state of the bundle.
[0009]
In this case, the “roller located immediately after the vibrating roller” means that the free length of the fiber bundle from the vibrating roller to the non-vibrating roller (distance not in contact with the roller) is less than 100 mm. Let's say a roller located at a distance. This is because the fiber opening effect on the fiber bundle due to the vibration of the roller is weakened when the thickness is 100 mm or more.
[0010]
Moreover, it is preferable that the contact length of the fiber bundle in contact with the non-vibrating roller is in the range of 2 to 10 times the contact length of the vibration roller and the fiber bundle. Further, it is preferable to open the fiber while softening the sizing agent applied to the fiber bundle by heating at least one contact surface of the vibration roller and the non-vibration roller. Further, it is preferable that the vibration frequency of the vibrating roller is opened in the range of 1 to 100 Hz and the amplitude is in the range of 1 to 50 mm. In addition, it is preferable that two or more sets of the vibration roller and the non-vibration roller are provided, and the vibration frequency and amplitude of the vibration roller of each group can be made different from each other.
[0011]
On the other hand, in order to achieve the above object, the prepreg manufacturing apparatus of the present invention includes a plurality of rollers that bend and support a fiber bundle formed by aligning a plurality of single yarns at a predetermined angle, and the plurality of rollers. An apparatus for manufacturing a prepreg, comprising: a vibrating means that vibrates at least one of the fiber bundles in a direction intersecting the traveling direction of the fiber bundle; and a take-up means that pulls the fiber bundle while passing between the rollers. In
(A) The roller located immediately after the roller vibrated by the vibration means does not vibrate; and
(B) The non-vibrating roller has a contact length of the fiber bundle in contact with the peripheral surface of the roller being at least twice the contact length of the fiber bundle in contact with the peripheral surface of the roller to be vibrated. It has the surrounding surface length which becomes.
[0012]
Here, the contact length of the fiber bundle in contact with the non-vibrating roller is preferably in the range of 2 to 10 times the contact length of the vibration roller connected to the vibrating means and the fiber bundle. Moreover, it is preferable that at least one of the vibrating roller and the non-vibrating roller is provided with a heating unit that heats the yarn contact surface. Preferably, the vibration roller and the non-vibration roller have two or more sets, and vibration frequency / amplitude adjusting means for making the vibration frequency and amplitude of each vibration roller different from each other is provided.
[0013]
The fiber bundle referred to in the present invention may be a single fiber bundle in which a plurality of single yarns are aligned, or a fiber in which a plurality of fiber bundles are aligned in parallel with each other to form a sheet. A bunch may be used.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of a prepreg manufacturing apparatus according to the present invention will be described with reference to the drawings.
[0015]
FIG. 1 is a schematic side view of a fiber bundle opening portion of a prepreg manufacturing apparatus according to the present invention, and FIG. 2 is a schematic perspective view of the portion.
[0016]
In FIG. 1, 1 is a winding package in which a reinforcing fiber bundle 2 such as carbon fiber or glass fiber is wound, and 3 is a comb for adjusting the inter-fiber pitch of a plurality of fiber bundles.
[0017]
4a and 4b are vibration sources for vibrating vibration rollers 5a and 5b, which will be described later, in an axial direction that is a direction intersecting the traveling direction of the fiber bundle 2, including known electromagnetic vibrators, cams, etc. A mechanical type using the can be used. The excitation sources 4a and 4b are provided with adjustment means (not shown) for individually adjusting the vibration frequency and amplitude.
[0018]
The vibration rollers 5a and 5b support the reinforcing fiber bundle 2 and vibrate in a direction crossing the traveling direction as described above to give the reinforcing fiber bundle an opening action. It may be either rotating or fixed. The outer diameter of the vibration roller is preferably as small as possible in view of the opening effect, and is specifically φ50 mm or less.
[0019]
Next, 6a and 6b are non-vibrating rollers for maintaining the spread width of the fiber bundle 2 opened by the vibrating rollers 5a and 5b. This non-vibrating roller is intended to maintain the yarn width after opening, and when it is vibrated like the vibrating rollers 5a and 5b, the yarn width becomes unstable, and bad results such as promoting the generation of fluff are promoted. Therefore, it is important that it is fixed without vibration. This roller may be free to rotate about the shaft, driven or fixed, and in short, it is pressed against the curved surface on which the fiber bundle is stationary or rotating with an appropriate pressing force. Anything that circulates in a closed state is acceptable. Therefore, such a curved surface is not limited to a roller as shown in the figure, and may be a semi-cylindrical surface or a curved surface having another shape. In order to maintain the width of the fiber bundle after opening, the curved surface is preferably as long as the contact length with the fiber bundle is large. Therefore, the contact length between the vibrationless roller and the fiber bundle is preferably 2 to 10 times as long as the contact length between the vibration roller and the fiber bundle. As a specific length, it is preferable that the contact length between the vibration-free roller and the fiber bundle can be 100 mm or more.
[0020]
Further, in order to minimize the narrowing of the width of the fiber bundle between the vibration rollers 5a and 5b and the non-vibration rollers 6a and 6b, it is preferable that the length that the fiber bundle is not in contact with either roller is short. . Specifically, the non-vibrating rollers 6a and 6b should be installed so as to be 20 mm or less.
[0021]
If these vibration rollers 5a and 5b and non-vibration non-vibration rollers 6a and 6b are provided with at least one each as a set, the effect of opening is produced, and two or more sets are provided. If so, there is a further opening effect.
[0022]
7 is a heating means for softening the sizing agent applied to the fiber bundle by heating the yarn contact surfaces of the vibration roller and the non-vibration roller, and the fiber bundle is a softening point of the sizing agent. Any heating means such as a near-infrared heater, a mid-infrared heater, or a far-infrared heater may be used as long as it has the ability to heat up to 343-373 K (70-100 ° C.). Further, the vibrating roller and the non-vibrating roller itself may be directly heated, for example, by embedding a heater inside the vibrating roller and the non-vibrating roller, and such a form is also included in the heating means of the present invention.
[0023]
Finally, 9 is a take-out means (not shown) for taking the reinforcing fiber bundle 2 in the right direction in the figure while passing it over the vibrating rollers 5a and 5b and the non-vibrating rollers 6a and 6b. A rotating drum, a drive station, or the like that is forcibly rotated by the means can be used.
[0024]
Next, a preferred embodiment of the fiber bundle opening method of the present invention will be described with reference to FIG. 1 and FIG.
[0025]
First, the reinforcing fiber bundle 2 is preferably unwound so that the tension during unwinding is in the range of 0.1 to 5 N (about 10 to 500 gf). If the tension is too high, it is disadvantageous for fiber opening. Conversely, if the tension is too low, the fiber bundle will meander. Further, the smaller the traveling speed of the reinforcing fiber bundle 2, the longer the contact time with the vibrating rollers 5a and 5b and the non-vibrating rollers 6a and 6b, which is advantageous. However, even when the traveling speed increases, the vibrating roller By increasing the number of sets of non-vibrating rollers, it is possible to take appropriate measures.
[0026]
Next, the vibration frequency of the vibration rollers 5a and 5b is preferably as large as possible within the range of 1 to 100 Hz, but 5 to 20 Hz is sufficient due to mechanical limitations. Further, the amplitude of the vibration roller is preferably as large as possible in the range of 1 to 50 mm, but more preferably 5 to 20 mm from the viewpoint of suppressing fuzz generated by vibration.
[0027]
【Example】
Embodiments of the present invention will be described below with reference to the above drawings.
[0028]
Example 1
In the apparatus of FIG. 1, the reinforcing fiber bundle 2 uses 50 high-elasticity carbon fibers having a fiber width of about 1 mm before opening and 3,000 single yarns, and the unwinding tension from the package 1 is 1 N (about 1 100 gf), and the running speed was set to 0.04 m / s (about 2.5 m / min).
[0029]
On the other hand, a commercially available electromagnetic exciter (Bokusui Brown Co., Ltd., model VG100) was used as the excitation sources 4a and 4b.
[0030]
Next, the vibrating rollers 5a and 5b are each free-rotating, and the diameters of both the rollers 5a and 5b are 30 mm. The contact length of each roller with the fiber bundle was set to 25 mm and 40 mm, respectively, and the vibration frequency was set to 8 Hz and the amplitude was set to 10 mm (condition (1)).
[0031]
The non-vibrating non-vibrating rollers 6a and 6b are free-rotating rollers. The diameter of the non-vibrating roller and the contact length with the fiber were 6 mm for φ70 mm and 100 mm, and 6 b for φ100 mm and 150 mm (Condition (2)).
[0032]
A far-infrared heater was used as the heating means 7 and was set so that the temperature of the reinforcing fiber bundle 2 was about 350 K (77 ° C.), which is the softening point of the sizing agent. At this time, the heater surface temperature was about 530 K (257 ° C.) (condition (3)).
[0033]
Table 1 below shows the actual measurement results of the opening of such an example.
[0034]
[Table 1]
Figure 0003702535
According to Table 1, it can be seen that the opening width of the reinforcing fiber bundle was improved from 1 mm to 6 mm by using the opening method and apparatus of the present invention.
[0035]
Example 2
The vibration frequency of the vibration roller 5a was 8 Hz and the amplitude was 10 mm, and the vibration frequency of the vibration roller 5b was 16 Hz and the amplitude was 20 mm (condition (1)).
[0036]
Other conditions were set in exactly the same manner as in Example 1.
[0037]
Table 1 above shows the actual measurement results of the opening of such an example. According to this table, the fiber bundle width after opening is 7 mm, and it can be seen that the opening effect is further increased by 1 mm compared to Example 1 by increasing the vibration frequency and amplitude of the vibration roller 5b.
[0038]
Comparative Example 1
In the prior art apparatus of FIG. 3, the vibrating roller 5 was free rotating with an outer diameter of 30 mm, and the contact length with the fiber bundle was 10 mm. The vibration frequency was set to 8 Hz, and the amplitude was set to 10 mm (condition (1)). The diameter of the free rotating roller 8 was 20 mm (condition (2)). The heating means is not used (condition (3)). Other conditions were set in exactly the same manner as in Example 1.
[0039]
It is the comparative example of the above-mentioned Table 1 that shows the actual measurement result of the opening of such a comparative example. According to this table, the fiber bundle width after opening is 3 mm. That is, when the method and apparatus of the prior art are used, it can be seen that the opening property is inferior 3 mm compared to Example 1 and 4 mm compared to Example 2.
[0040]
【The invention's effect】
According to the present invention, the following effects can be achieved.
[0041]
According to the method for producing a prepreg according to claim 1 and 2, when the plurality of fiber bundles aligned in parallel with each other pass while bending at a predetermined angle on the plurality of rollers, at least one of the rollers. Since the book vibrates in a direction intersecting the traveling direction of the fiber bundle, the book is sufficiently opened by the rubbing force generated between the fiber bundle and the vibrating roller. Further, the opened fiber bundle is pressed against the peripheral surface of the non-vibrating roller positioned immediately after the vibration roller so that the contact length is more than twice the contact length of the vibration roller. The spread width can be maintained by the frictional force generated between the vibrating rollers.
[0042]
According to the method for producing a prepreg according to claims 3 and 4, since the fiber bundle is heated to a temperature at which the sizing agent applied to the fiber bundle is softened by heating at least one roller, The spreadability between single fibers is improved.
[0043]
According to the prepreg manufacturing method according to claim 5 and 6, since there are two or more sets of vibration rollers and non-vibration rollers, and the vibration frequency and amplitude of each vibration roller are different, for example, the first vibration roller If the second vibration roller is set to a small amplitude and a low vibration frequency, and the second vibration roller is set to a large amplitude and a high vibration frequency, the fiber bundle is gradually opened, and the fiber bundle is damaged by rubbing with the vibration roller. Without unreasonableness. Moreover, even if the traveling speed of the fiber bundle is increased, it can be easily handled by increasing the number of sets of the vibrating roller and the non-vibrating roller.
[0044]
According to the prepreg manufacturing apparatus according to claim 7 and 8, when the plurality of fiber bundles aligned in parallel with each other are passed through the plurality of rollers while being bent at a predetermined angle, at least one of the rollers. Since the book is vibrated in a direction intersecting the traveling direction of the fiber bundle, the fiber bundle can be sufficiently opened by the rubbing force generated between the fiber bundle and the vibration roller. Further, the spread fiber bundle is pushed on the surface of the non-vibrating roller provided immediately after the vibration roller and having a peripheral surface length that is at least twice the contact length of the roller with which the contact length of the fiber bundle vibrates. Since it is applied and pulled, it can be pulled while maintaining the spread width of the opened fiber bundle by the frictional force generated between the fiber bundle and the non-vibrating roller.
[0045]
According to the prepreg manufacturing apparatus of claim 9, since at least one roller can be heated, the sizing agent applied to the fiber bundle can be heated to a temperature at which the fiber bundle is softened. The spreadability is improved.
[0046]
According to the prepreg manufacturing apparatus of claim 10, since two or more sets of vibration rollers and non-vibration rollers are provided, and the vibration frequency and amplitude of each set of vibration rollers can be changed separately, For example, if the first set of vibration rollers is set to a small amplitude and a low vibration frequency, and the second set of vibration rollers is set to a large amplitude and a high vibration frequency, for example, the fiber bundle can be gradually opened. It is possible to open the fiber bundle without difficulty by rubbing with the vibration roller without damaging the fiber bundle. Moreover, even if the traveling speed of the fiber bundle is increased, it can be easily coped with by increasing the number of sets of vibrating rollers and non-vibrating rollers.
[Brief description of the drawings]
FIG. 1 is a schematic side view of a fiber bundle opening portion of a prepreg manufacturing apparatus according to the present invention.
FIG. 2 is a schematic perspective view of a fiber bundle opening portion of the prepreg manufacturing apparatus according to the present invention.
FIG. 3 is a schematic side view of a fiber bundle opening portion of a conventional apparatus.
[Explanation of symbols]
1: winding package 2: reinforcing fiber bundle 3: comb 4: vibration source 4a: vibration source 4b: vibration source 5: vibration roller 5a: vibration roller 5b: vibration roller 6a: vibration-free roller 6b: vibration-free roller 7: heating means 8: free rotating roller 9: take-up means

Claims (10)

複数本の単糸が引き揃えられてなる繊維束を複数個のローラ上に所定角度に屈曲させるとともに、前記複数個のローラのうちの少なくとも１本を前記繊維束の走行方向に対して交差する方向に振動させつつ通過させることにより、前記繊維束を開繊させ、しかる後に合成樹脂を含浸させてプリプレグを製造する方法において、
（Ａ）前記振動させるローラの直後に位置するローラを振動させずにその周面に前記繊維束を押し当て、
（Ｂ）次に該振動させないローラの周面に、前記繊維束を前記振動させるローラの周面に接触している繊維束の接触長の２倍以上の接触長さで接触させることにより前記繊維束の開繊状態を維持させることを特徴とするプリプレグの製造方法。A fiber bundle formed by aligning a plurality of single yarns is bent at a predetermined angle on a plurality of rollers, and at least one of the plurality of rollers intersects the traveling direction of the fiber bundle. In the method of producing a prepreg by opening the fiber bundle by passing it while vibrating in the direction, and then impregnating with a synthetic resin,
(A) The fiber bundle is pressed against the peripheral surface without vibrating a roller located immediately after the roller to be vibrated,
(B) Next, the fiber bundle is brought into contact with the peripheral surface of the non-vibrating roller with a contact length of at least twice the contact length of the fiber bundle in contact with the peripheral surface of the vibrating roller. A method for producing a prepreg, characterized by maintaining an open state of a bundle. 前記振動させないローラの周面に接触している繊維束の接触長さは、前記振動させるローラの周面に接触している繊維束の接触長さの２〜１０倍であることを特徴とする請求項１に記載のプリプレグの製造方法。The contact length of the fiber bundle in contact with the peripheral surface of the roller not to be vibrated is 2 to 10 times the contact length of the fiber bundle in contact with the peripheral surface of the roller to be vibrated. The method for producing a prepreg according to claim 1. 前記振動させるローラと前記振動させないローラのうちの少なくとも１本のローラの接糸面を加熱することにより、前記繊維束に付与されているサイジング剤を軟化させつつ、開繊させることを特徴とする請求項１または２に記載のプリプレグの製造方法。By heating the yarn contact surface of at least one of the vibrating roller and the non-vibrating roller, the sizing agent applied to the fiber bundle is softened and opened. The manufacturing method of the prepreg of Claim 1 or 2. 前記軟化温度は、７０〜１００℃の範囲であることを特徴とする請求項１〜３のいずれかに記載のプリプレグの製造方法。The said softening temperature is the range of 70-100 degreeC, The manufacturing method of the prepreg in any one of Claims 1-3 characterized by the above-mentioned. 前記振動させるローラの振動周波数を１〜１００Ｈｚの範囲、振幅を１〜５０ｍｍの範囲で開繊させることを特徴とする請求項１〜４のいずれかに記載のプリプレグの製造方法。The method for producing a prepreg according to any one of claims 1 to 4, wherein the vibration frequency of the roller to be vibrated is opened in a range of 1 to 100 Hz and an amplitude is in a range of 1 to 50 mm. 前記振動させるローラと前記振動させないローラとをそれぞれ２組以上設け、各組の振動させるローラの振動周波数と振幅とをそれぞれ異ならせて開繊させることを特徴とする請求項１〜５のいずれかに記載のプリプレグの製造方法。Two or more sets of each of the roller to be vibrated and the roller that is not to be vibrated are provided, and the fiber is opened with different vibration frequencies and amplitudes of the rollers to be vibrated. A method for producing a prepreg according to 1. 複数本の単糸が引き揃えられてなる繊維束を所定角度に屈曲・支持する複数本のローラと、前記複数本のローラのうちの少なくとも１本を前記繊維束の走行方向に対して交差する方向に振動させる加振手段と、前記繊維束を前記ローラ間を通過させつつ引取る引取手段とを備えたプリプレグの製造装置において、
（Ａ）前記加振手段によって振動させるローラの直後に位置するローラは振動させず、かつ、
（Ｂ）前記振動させないローラは、該ローラの周面に接触している繊維束の接触長さが、前記振動させるローラの周面に接触している繊維束の接触長さの２倍以上となる周面長さを有することを特徴とするプリプレグの製造装置。A plurality of rollers that bend and support a fiber bundle formed by aligning a plurality of single yarns at a predetermined angle, and at least one of the plurality of rollers intersects the traveling direction of the fiber bundle. In an apparatus for manufacturing a prepreg, comprising: an oscillating means that vibrates in a direction; and a take-up means that pulls the fiber bundle while passing between the rollers.
(A) The roller located immediately after the roller vibrated by the vibration means does not vibrate; and
(B) The non-vibrating roller has a contact length of the fiber bundle in contact with the peripheral surface of the roller being at least twice the contact length of the fiber bundle in contact with the peripheral surface of the roller to be vibrated. An apparatus for producing a prepreg characterized by having a circumferential surface length. 前記振動させないローラに接触している繊維束の接触長さは、前記振動させるローラに接触している繊維束の接触長さの２〜１０倍の周面長さを有することを特徴とする請求項７記載のプリプレグの製造装置。The contact length of the fiber bundle in contact with the non-vibrating roller has a circumferential surface length that is 2 to 10 times the contact length of the fiber bundle in contact with the vibrating roller. Item 8. The prepreg manufacturing apparatus according to Item 7. 前記振動させるローラと前記振動させないローラのうちの少なくとも１本のローラの接糸面を加熱する手段を備えたことを特徴とする請求項７または８に記載のプリプレグの製造装置。The prepreg manufacturing apparatus according to claim 7 or 8, further comprising means for heating a contact surface of at least one of the vibrating roller and the non-vibrating roller. 前記振動させるローラと前記振動させないローラとをそれぞれ２組以上有するとともに、各組の振動させるローラの振動周波数と振幅とをそれぞれ異ならせる振動周波数・振幅調整手段が設けられていることを特徴とする請求項７〜９のいずれかに記載のプリプレグの製造装置。In addition to having two or more sets of the vibrating roller and the non-vibrating roller, there are provided vibration frequency / amplitude adjusting means for differentiating the vibration frequency and amplitude of each group of vibrating rollers. The prepreg manufacturing apparatus according to any one of claims 7 to 9.
JP15130496A 1996-06-12 1996-06-12 Prepreg manufacturing method and apparatus Expired - Fee Related JP3702535B2 (en)

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