JP4842081B2 - Manufacturing method of fiber reinforced resin tubular body - Google Patents

Description

  The present invention relates to a method for manufacturing a fiber reinforced resin tubular body used for, for example, a golf club shaft, a badminton racket, a fishing rod, a ski stock and the like.

For example, a fiber reinforced resin tubular body is widely used for a golf club shaft (hereinafter, also simply referred to as a shaft) because it is lightweight and provides a good feel.
As a manufacturing method of such a shaft, a sheet-like prepreg in which an uncured matrix resin such as an epoxy resin is impregnated with a reinforcing fiber such as carbon fiber is prepared, and the prepreg is wound around a rod-shaped mandrel (mandrel). A so-called sheet wrap method is known in which the mandrel is removed after curing.

In the sea trap method, it is common to prepare a plurality of types of prepregs having different areas and orientations of contained reinforcing fibers, and sequentially winding them one by one on a mandrel to produce a multi-layered shaft. .
Specifically, as shown in FIGS. 4 to 5 of Patent Document 1, for example, first, a prepreg for a plus layer in which the alignment direction of reinforcing fibers with respect to the axial direction (longitudinal direction) of the mandrel is about + 45 °. A bias layer (inner layer) is formed by winding a prepreg for a bias layer composed of two layers, a prepreg for a minus layer and about −45 °. Then, a straight layer (outer layer) is formed by winding a straight layer prepreg in which reinforcing fibers are aligned in a direction substantially along the longitudinal direction of the mandrel. Further, as shown in FIGS. 2 to 5 of Patent Document 2, in addition to these layers, the reinforcing fiber is substantially in the axial direction of the mandrel in order to impart crushing strength and bending strength to the shaft. The hoop layer may be formed by winding a prepreg for a hoop layer that is aligned so as to be vertical.
Japanese Patent Laid-Open No. 06-23076 JP 09-266966 A

However, since the direction of the reinforcing fiber contained in the hoop layer prepreg is substantially perpendicular to the axial direction of the mandrel, when the hoop layer prepreg is wound around the mandrel, the reinforcing fiber repels and the hoop layer prepreg There is a problem that the winding start end portion of the winding springs up without being in close contact with the outer peripheral surface of the mandrel and cannot be wound well.
In addition, in the method of manufacturing a multi-layered shaft by winding a plurality of types of prepregs as described above, manufacturing a shaft with less warping or bending in the length direction is also an important issue.

  The present invention has been made in view of the above circumstances, and is a fiber-reinforced resin tubular body that suppresses jumping of a winding start end portion when winding a prepreg for a hoop layer and is less warped or bent in the length direction. The purpose is to manufacture.

The method for producing a fiber-reinforced resin tubular body of the present invention is a method for producing a tubular body comprising a fiber-reinforced resin including a reinforcing fiber and a matrix resin, and the orientation angle of the reinforcing fiber with respect to the axial direction of the mandrel is + 30 ° to +80. A prepreg for a positive layer of + °, a prepreg for a negative layer of −30 ° to −80 °, and a prepreg for a hoop layer of + 85 ° to + 90 ° or −85 ° to −90 ° are laminated to prepare a prepreg laminate. A pre-lamination step, and a winding step of winding the prepreg laminate around the mandrel, and the prepreg laminate, when the prepreg laminate is wound around the mandrel, One of the minus layer prepregs is laminated to be the outermost layer, and the other prepreg and the hoop layer are laminated. Each winding start end portion of the prepreg, the positioned posterior to the winding start portion of the prepreg of one, and is characterized in that it is arranged so as not to coincide.
The prepreg laminate is preferably arranged so that each prepreg satisfies the following formula (1).
0.25L1 <L2 <0.75L1 (1)
(However, L1 indicates the distance from the one winding start end to the other winding start end, and L2 indicates the distance from the one winding start end to the winding start end of the hoop layer prepreg.)
A golf club shaft is preferably exemplified as the tubular body.

  ADVANTAGE OF THE INVENTION According to this invention, while winding up the prepreg for hoop layers, while curling up of the winding start end part can be suppressed, the fiber reinforced resin tubular body with few curvature and bending can be manufactured.

  Hereinafter, the manufacturing method of the present invention will be described in detail with reference to an embodiment in the case of manufacturing a golf club shaft as a fiber reinforced resin tubular body.

[First Embodiment]
The golf club shaft manufactured in the present embodiment is composed of a fiber-reinforced resin tubular body including reinforcing fibers and a matrix resin, and includes a bias layer that forms the entire length of the shaft, and a hoop layer that also forms the entire length of the shaft. It is comprised at least.
The bias layer is mainly for imparting crushing strength, torsional strength, etc. to the shaft, and the angle of the reinforcing fiber with respect to the axial direction of the shaft (hereinafter referred to as the orientation angle) is set to + 30 ° to + 80 °. The plus layer and the minus layer of −30 ° to −80 ° are combined. The hoop layer is mainly for imparting crushing strength or bending strength to the shaft, and is a layer in which the orientation angle of the reinforcing fibers is + 85 ° to + 90 ° or −85 ° to −90 °. . The orientation angle of the reinforcing fibers is equal to the direction in which the reinforcing fibers are aligned with respect to the axial direction of the mandrel.

When manufacturing a golf club shaft in this embodiment, first, as shown in FIG. 1, the outer diameter gradually increases from one end (small diameter side) 10a to the other end (large diameter side) 10b. As a prepreg wound around the mandrel 10 having a circular cross section, a prepreg 11 for a plus layer for forming a plus layer, a prepreg 12 for a minus layer for forming a minus layer, and a hoop layer are formed. A hoop layer prepreg 13 is prepared. In this case, one bias layer is formed by the plus layer prepreg 11 and the minus layer prepreg 12.
Further, in this example, the plus layer prepreg 11 and the minus layer prepreg 12 are each cut to a size that is wound around the mandrel 10 for about three turns, and the hoop layer prepreg 13 is wound around the mandrel for about one turn. It is cut to size.
In FIG. 1, the hatched direction is the direction in which the reinforcing fibers are aligned in the prepregs 11, 12, and 13.

Subsequently, the plus layer prepreg 11, the minus layer prepreg 12, and the hoop layer prepreg 13 are laminated to prepare a prepreg laminate (preliminary laminating step).
In this preliminary laminating step, when the prepared prepreg laminate is wound around the mandrel 10 in the winding step described later, one of the positive layer prepreg 11 and the negative layer prepreg 12 is the outermost layer. Laminate. The winding start end of the other prepreg of the plus layer prepreg 11 and the minus layer prepreg 12 and the winding start end of the hoop layer prepreg 13 are both from the winding start end of the one prepreg. Are also located behind and do not match.

In this example, as shown in FIG. 2, the positive layer prepreg 11, the negative layer prepreg 12, and the hoop layer prepreg 13 are laminated in this order from the outermost layer side. Further, the winding start end portion 12a of the minus layer prepreg 12 is located behind the winding start end portion 11a of the plus layer prepreg 11 by a distance indicated by L1, and the winding start end portion 13a of the hoop layer prepreg 13 is located. Is positioned behind the winding start end portion 11a of the plus layer prepreg 11 by a distance indicated by L2 (L1> L2), and the winding start end portions 11a, 12a, and 13a are displaced without matching. Yes.
In this example, the distance L1 between the winding start end portion 11a of the plus layer prepreg 11 and the winding start end portion 12a of the minus layer prepreg 12 is ½ the length of the outer circumference of the mandrel 10 (half circumference). Is set to the same. Further, here, “rear” means the downstream side in the winding direction (left side in FIG. 2B), and “does not match” means that they are shifted from each other in the winding direction. To do.

After preparing the prepreg laminate 14A in this way, a temporary fixing agent is then applied to the outer peripheral surface of the mandrel 10, and the winding start end portions 11a, 12a, 13a of each prepreg in the prepreg laminate 14A are the outer peripheral surfaces of the mandrel 10. The prepreg laminate 14A is arranged so as to be in contact with the prepreg. And after pressing a heating plate such as an iron against the winding start end portions 11a, 12a, 13a from the outside, the winding start end portions 11a, 12a, 13a are thermocompression bonded (temporarily fixed) to the outer peripheral surface of the mandrel 10. The prepreg laminate 14A is wound around a mandrel (winding step).
The winding process may be performed manually only by the worker, but it is efficient if the rolling process is performed using a rolling machine equipped with a pair of rolling plates after the first approximately half turn is performed manually. Moreover, it is preferable because the winding operation can be performed uniformly.

According to the method in which the prepreg laminated body 14A is prepared in advance and wound around the mandrel 10 in this manner, the prepregs 11, 12, and 13 are individually wound sequentially, in particular, compared to the method in which the prepregs 11, 12, and 13 are individually wound sequentially. The winding start end 13 a of the hoop layer prepreg 13 can be satisfactorily adhered to the mandrel 10.
That is, in the hoop layer prepreg 13, the reinforcing fibers are aligned so that the orientation angle is + 85 ° to + 90 ° or −85 ° to −90 °. Therefore, the hoop layer prepreg 13 is intended to be wound around the mandrel 10 alone. Then, the repulsion of the reinforcing fiber is large, and the winding start end portion 13 a is likely to jump up without being in close contact with the outer peripheral surface of the mandrel 10. However, in this way, the plus layer prepreg 11 is the outermost layer, and the winding start end portion 13a of the hoop layer prepreg 13 is located behind the winding start end portion 11a of the plus layer 11 prepreg. As described above, when the prepregs 11, 12, and 13 are laminated, the positive layer prepreg 11 disposed outside the prepreg 13 for hoop layer acts to suppress such repulsion at the winding start end 13 a of the hoop layer prepreg 13. Therefore, the winding start end portion 13a of the hoop layer prepreg 13 is prevented from jumping up, and this can be satisfactorily adhered to the mandrel.
Further, since the thicknesses of the prepregs 11, 12, and 13 are thin, it is easier to handle them in the form of the prepreg laminated body 14A in advance than to sequentially roll them one by one. Excellent.

  Further, in this example, the distance L1 from the winding start end portion 11a of the plus layer prepreg 11 to the winding start end portion 12a of the minus layer prepreg 12 and the winding start end portion 11a of the plus layer prepreg 11 to the hoop layer prepreg. 13 and the distance L2 to the winding start end 13a is in a relationship of L1> L2, and the winding start end 13a of the hoop layer prepreg 13 is more forward than the winding start end 12a of the minus layer prepreg 12. positioned. Therefore, when temporarily fixing the prepreg laminate 14A as described above prior to the winding step, the winding start end portion 13a of the hoop layer prepreg 13 can be more securely adhered to the mandrel, and as a result, Bounce of the winding start end 13a of the hoop layer prepreg 13 can be suppressed satisfactorily. Here, if the winding start end portion 13a of the hoop layer prepreg 13 is positioned behind the winding start end portion 12a of the minus layer prepreg 12, the winding of the hoop layer prepreg 13 is temporarily performed. There is a tendency that thermocompression bonding of the start end portion 13a to the mandrel tends to be slightly insufficient.

  Further, in this prepreg laminate 14A, the winding start end portion 12a of the minus layer prepreg 12 and the winding start end portion 13a of the hoop layer prepreg 13 are behind the winding start end portion 11a of the plus layer prepreg 11. In addition to being positioned, they are arranged so as not to coincide with each other (L1 ≠ L2). Therefore, when the prepreg laminate 14A is wound around the mandrel 10, the winding start ends 11a, 12a, 13a of the prepregs are dispersed in the circumferential direction of the mandrel 10, and as a result, bend in the length direction. A shaft without warping can be obtained. Here, in the prepreg laminate, if the winding start ends of at least two prepregs of each prepreg are aligned without shifting, the shaft obtained from the prepreg laminate has the winding start ends A so-called bone is formed over the entire length due to the overlapping of the two. A shaft on which such a bone is formed is likely to bend or warp in the length direction.

More preferably, when the distances L1 and L2 have the relationship of the following formula (1), the winding start end portions 11a, 12a, and 13a of each prepreg are more favorably dispersed in the circumferential direction of the mandrel 10. Therefore, it is possible to further suppress bending and warping in the length direction of the shaft.
0.25L1 <L2 <0.75L1 (1)

  In this way, after winding the prepreg laminate 14A around the mandrel, in view of the performance, mass, etc. required for the golf club, the prepreg for the straight layer, the prepreg for the reinforcing layer, etc. are appropriately wound as necessary. A straight layer or a reinforcing layer may be formed. Then, while winding and fixing so that the wound prepregs are not peeled off, the layers are cured by heating at a predetermined temperature for a predetermined time. Subsequently, the mandrel is extracted (decentered), and the obtained fiber-reinforced resin tubular body is subjected to surface polishing, cutting of both end portions, and the like as necessary, thereby obtaining a golf club shaft.

In addition, as the reinforcing fiber used in the prepreg, inorganic fibers such as glass fiber, carbon fiber, boron fiber, silicon carbide fiber, alumina fiber and steel fiber can be used, but a shaft excellent in bending strength can be easily obtained. Therefore, carbon fibers such as PAN-based carbon fibers are preferable.
As the matrix resin, an epoxy resin, a polyimide resin, a bismaleimide resin, a phenol resin, or the like can be used, but an epoxy resin is preferable from the viewpoint of heat resistance, hardness, curing shrinkage rate, chemical resistance, and the like. As the epoxy resin, general epoxy resins such as glycidyl ether type, glycidyl ester type, glycidyl amine type, and alicyclic type can be used. In addition, an appropriate amount of a known curing agent can be added to the matrix resin as necessary.

  Further, in the present embodiment example, the case where the plus layer prepreg 11 is arranged in the outermost layer and the minus layer prepreg 12 is arranged inside the outermost layer has been described, but these may be arranged in reverse. In this case, the same effect can be obtained.

[Second Embodiment]
In this embodiment, in the preliminary laminating step, a prepreg laminate 14B shown in FIG. 3 is prepared instead of the prepreg laminate 14A shown in FIG.
When the prepreg laminate 14B in FIG. 3 is wound around the mandrel 10 in the winding process, the prepreg 11 for the plus layer, the prepreg 13 for the hoop layer, and the prepreg 12 for the minus layer are arranged in this order from the outermost layer side. Although different from the prepreg laminate 14A shown in FIG. 2 in that each prepreg is laminated, the winding start end 12a of the minus layer prepreg 12 is more than the winding start end 11a of the plus layer prepreg 11. Is positioned rearward by a distance indicated by L1, and the winding start end portion 13a of the hoop layer prepreg 13 is positioned rearward by a distance indicated by L2 from the winding start end portion 11a of the plus layer prepreg 11. (L1> L2) is the same in that the winding start ends 11a, 12a, and 13a do not match. Also in this example, the distance L1 between the winding start end portion 11a of the plus layer prepreg 11 and the winding start end portion 12a of the minus layer prepreg 12 is ½ of the outer circumference of the mandrel 10 (half cycle). Min)).

Even when such a prepreg laminate 14B of FIG. 3 is wound around the mandrel 10, the repulsion of the reinforcing fiber at the winding start end portion 13a of the hoop layer prepreg 13 is caused by the plus layer prepreg 11 arranged on the outside thereof. Since it is pressed down, it is possible to prevent the winding start end portion 13a of the hoop layer prepreg 13 from rising.
Even in this example, since the winding start ends 11a, 12a, and 13a of the prepregs are dispersed in the circumferential direction of the mandrel 10, a shaft without bending or warping can be obtained.
Even in this case, more preferably, when the distances L1 and L2 have the relationship of the above formula (1), the winding start end portions 11a, 12a, and 13a of each prepreg are better in the circumferential direction of the mandrel 10. Since it will disperse | distribute, the bending and curvature of the length direction of a shaft can be suppressed more.

In the present embodiment example, the case where the plus layer prepreg 11 is arranged in the outermost layer and the minus layer prepreg 12 is arranged in the innermost layer has been described, but these may be arranged in reverse. In this case, the same effect can be obtained.
Moreover, what is necessary is just to perform processes other than a preliminary | backup lamination process similarly to 1st Embodiment.

[Third Embodiment]
In this embodiment, in the preliminary laminating step, a prepreg laminate 14C shown in FIG. 4 is prepared instead of the prepreg laminate 14A shown in FIG.
In the prepreg laminate 14C of FIG. 4, the winding start end portion 13a of the hoop layer prepreg 13 is positioned behind the winding start end portion 12a of the minus layer prepreg 12, and the relationship of L2> L1 is established. 2 is different from the prepreg laminate 14A shown in FIG. 2 except that the winding start ends 11a, 12a, and 13a do not coincide with each other. Also in this example, the distance L1 between the winding start end portion 11a of the plus layer prepreg 11 and the winding start end portion 12a of the minus layer prepreg 12 is ½ of the outer circumference of the mandrel 10 (half cycle). Min)).

When such a prepreg laminate 14C of FIG. 4 is wound around the mandrel 10, the repulsion of the reinforcing fibers at the winding start end portion 13a of the hoop layer prepreg 13 is negative with the plus layer prepreg 11 disposed on the outer side. Since it is pressed down by the layer prepreg 12, it is possible to prevent the winding start end portion 13 a of the hoop layer prepreg 13 from jumping up.
Even in this example, since the winding start ends 11a, 12a, and 13a of the prepregs are dispersed in the circumferential direction of the mandrel 10, a shaft without bending or warping can be obtained.
However, when the winding start end portion 13a of the hoop layer prepreg 13 is positioned behind the winding start end portion 12a of the minus layer prepreg 12, as described above, prior to the winding step. When the prepreg laminate 14C is temporarily fixed, thermocompression bonding to the mandrel of the winding start end portion 13a of the hoop layer prepreg 13 tends to be slightly insufficient. In that respect, the prepreg laminates 14A and 14B of the first and second embodiments are superior.

In the present embodiment, the case where the plus layer prepreg 11 is arranged in the outermost layer and the minus layer prepreg 12 is arranged inside the outermost layer has been described. However, these may be arranged in reverse. In this case, the same effect can be obtained.
Moreover, what is necessary is just to perform processes other than a preliminary | backup lamination process similarly to the case of 1st Embodiment.

As described above with reference to the first to third embodiments, by winding the prepreg laminate prepared in each example around a mandrel, the winding start end portion when winding the prepreg for the hoop layer is wound. It is possible to manufacture a shaft that can suppress jumping and has less warping or bending in the length direction.
In each example, a golf club shaft was shown and described as an example of a fiber-reinforced resin tubular body. However, according to the manufacturing method of the present invention, fibers for other sports equipment applications such as badminton rackets, fishing rods, and ski stocks. A reinforced resin tubular body can also be produced. Moreover, there is no restriction | limiting in particular in the cross-sectional shape of the tubular body to manufacture, According to a use other than a circular cross section, an elliptical cross section, an irregular cross section, etc. may be sufficient.

It is a top view which shows an example of the mandrel and prepreg used with the manufacturing method of this invention. (A) The top view which shows the prepreg laminated body prepared in 1st Embodiment, (b) While showing the cross section along the II 'direction of the prepreg laminated body of (a), this prepreg laminated body and this It is a figure which shows the positional relationship with the mandrel to wind. It is sectional drawing of the prepreg laminated body prepared by the example of 2nd Embodiment, and the mandrel which winds this. It is sectional drawing of the prepreg laminated body prepared by the example of 3rd Embodiment, and the mandrel which winds this.

Explanation of symbols

Mandrel plus layer prepreg 11a Plus layer prepreg winding start end minus layer prepreg 12a Minus layer prepreg winding start end hoop layer prepreg 13a Hoop layer prepreg winding start end 14A, 14B, 14C Prepreg lamination body

Claims (3)

A method for producing a tubular body comprising a fiber reinforced resin including a reinforced fiber and a matrix resin,
A positive layer prepreg having an orientation angle of the reinforcing fiber with respect to the axial direction of the mandrel of + 30 ° to + 80 °, a negative layer prepreg of −30 ° to −80 °, and +85 to + 90 ° or −85 ° to −90 °. A pre-lamination step of laminating a prepreg for a hoop layer and preparing a prepreg laminate,
A winding step of winding the prepreg laminate around the mandrel,
When the prepreg laminate is wound around the mandrel, the prepreg laminate is laminated so that one of the plus layer prepreg and the minus layer prepreg is the outermost layer, Each of the winding start end portions of the other prepreg and the prepreg for the hoop layer is located behind the winding start end portion of the one prepreg and is arranged so as not to coincide with each other. A method for producing a resin tubular body. The said prepreg laminated body is laminated | stacked so that following formula (1) may be satisfied, The manufacturing method of the fiber-reinforced resin tubular body of Claim 1 characterized by the above-mentioned. .
0.25L1 <L2 <0.75L1 (1)
(However, L1 indicates the distance from the one winding start end to the other winding start end, and L2 indicates the distance from the one winding start end to the winding start end of the hoop layer prepreg.)   The method for producing a fiber-reinforced resin tubular body according to claim 1 or 2, wherein the tubular body is a golf club shaft.

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