JP5002895B2 - Method for producing reinforced fiber fabric - Google Patents

Description

  The present invention relates to a method for producing a reinforced fiber fabric. More specifically, in the present invention, when heat treatment is performed on a reinforced fiber woven fabric containing a thermoplastic resin and / or a thermosetting resin, the deformation of the reinforced fiber woven fabric (texture of the woven yarn) is suppressed, and the form of the woven fabric is controlled. The present invention relates to a method for producing a reinforced fiber fabric that is subjected to heat treatment (crushing treatment) effective for holding.

  Conventionally, reinforced fibers such as carbon fibers have a high specific strength and specific elastic modulus. Therefore, sports / leisure products that have a large weight reduction effect as a fiber reinforced plastic (hereinafter referred to as FRP) material, aircraft use and general It is often used for industrial purposes.

Such FRP molding methods include various methods such as hand lay-up molding, autoclave molding, and RTM molding. The molding method depends on the shape and number of molded products, required characteristics, or allowable product price. It is decided as appropriate.
In these various molding methods, it is common that the reinforcing fiber is once made into an intermediate base material in the process of producing FRP, and the intermediate base material is often used in the form of a woven fabric as the intermediate base material. . However, such a reinforced fiber fabric has a problem that the fabric is deformed when the fabric is handled or the weaving yarn is shifted and misaligned, and that the weaving yarn is easily unraveled when the fabric is cut.

To solve this problem, weaving reinforced fibers and thermoplastic fibers simultaneously and then heat-treating them (heated) to soften or melt the thermoplastic fibers, thereby reinforce the intersection between the warp and weft. Proposals have been made to obtain a reinforced fiber woven fabric that has a function of preventing the warp or weft of fibers and a form stabilizing function and is excellent in handleability.
For example, there has been proposed a method in which a fabric after passing through a guide roller is heated with a heater and further passed through a pair of pressing rollers (see Patent Document 1). In such a proposal, heat treatment can be performed with simple equipment. However, since the woven fabric is heated after it has already passed through a plurality of rollers, the reinforced fiber fabric to be heated may already have a collapsed structure (a twist of the yarn). However, it is not possible to obtain a reinforcing fiber woven fabric having a straight orientation. Such a phenomenon is particularly prominent in a unidirectional woven fabric in which the reinforcing fiber is a warp and the auxiliary fiber is finer than the reinforcing fiber.

  Also, a method of heating the fabric on the outer surface of the cylinder (see Patent Document 2), a method of heating the fabric by inserting a heater inside the front roller (see Patent Document 3), and the heating roller as a pressure roller There have been proposed a method of heating the fabric and a method of heating the fabric by blowing hot air on the front roller (see Patent Document 4). These proposals require more complex equipment than the heating method proposed in Patent Document 1, but since heating is performed on a cylinder or a roller, the heating method proposed in Patent Document 1 is used. Can suppress the structural collapse of the reinforcing fiber fabric and the shrinkage of the fabric. However, since the woven fabric is heated after a few contact with the rollers, the collapse of the structure cannot be completely suppressed.

That is, with the technique proposed above, a woven fabric that is effective in maintaining the shape of the woven structure and that completely suppresses the structural collapse of the reinforcing fiber woven fabric (the bending of the woven yarn) has not been obtained. The reinforcing fiber woven fabric obtained by such a conventional technique does not exhibit the high mechanical properties when molded into FRP because the reinforcing fibers are not straightly oriented, and obtains a molded product with excellent surface smoothness. There was a problem that it was not possible.
Japanese Patent Laid-Open No. 63-152637 (FIG. 11) JP 2004-256930 A (FIG. 1) JP 2002-115145 A (FIGS. 3 and 4) Japanese Patent Laid-Open No. 08-302537 (FIGS. 3 and 4)

  Therefore, the object of the present invention is to solve the above-mentioned problems of the prior art, and to suppress the collapse of the texture of the reinforcing fiber fabric (the bending of the weaving yarn) when heat-treating the reinforcing fiber fabric, and is effective in maintaining the shape of the weave texture Another object of the present invention is to provide a method for producing a reinforced fiber fabric that is subjected to an appropriate heat treatment (crushing treatment).

In order to achieve the above object, the present invention adopts the following configuration. That is, the method for producing a reinforced fiber fabric of the present invention has at least a warp yarn composed of reinforcing fibers and a total fineness of 1/5 or less of the warp yarn , and includes a thermoplastic resin and / or a thermosetting resin. A method for producing a reinforcing fiber fabric, which is a unidirectional fabric using a weft weft , comprising the following steps (A) to (D).
(A) Weaving step of weaving warp yarn and driving the weft yarn into the shed to weave the fabric (B) Before the woven fabric comes into contact with the take-up guide roller, the fabric is radiated from the heating source. The heating step (C) in which the thermoplastic resin and / or the thermosetting resin contained in the weft yarn is softened or thermally melted in a non-contact manner by contact with the take-up roller at a contact angle of 45 to 355 °. The take-out process to be sent out (D) The take-up process of winding the woven fabric into a roll. According to a preferred embodiment of the method for producing a reinforced fiber fabric of the present invention, in the take-up process, the take-up roller and / or the take-up guide are provided. A mode in which at least one of the rollers is heated is included.

According to the preferable aspect of the manufacturing method of the reinforced fiber fabric of this invention, the aspect which passes through following (E) process is included between the said taking-up process and the said winding-up process.
(E) The woven fabric is heat-treated in a non-contact manner by radiation from a heating source and / or heat-treated in direct contact by passing the woven fabric through a heating roller, so that the thermoplastic resin and / or heat contained in the weft yarn Reheating step of softening or thermally melting curable resin again According to a preferred embodiment of the method for producing a reinforced fiber fabric of the present invention, between the heating step and the take-up step, or the reheating step, The aspect which passes through the following (F) process is included between the said winding processes.
(F) Cooling step of cooling the heat-treated woven fabric to a temperature lower than the temperature at which the thermoplastic resin and / or thermosetting resin contained in the weft is softened or thermally melted Preferred embodiment of the method for producing a reinforced fiber woven fabric of the present invention According to the above, the heating source is either a far-infrared heater, a mid-infrared heater or a near-infrared heater.
According to a preferred embodiment of the method for producing a reinforced fiber fabric of the present invention, the thermoplastic resin has a melting point in the range of 80 to 200 ° C, and if it does not have a melting point, the glass transition temperature is in the range of 50 to 170 ° C. The basis weight is in the range of 1 to 10 g / m ² and the form is fibrous.

According to a preferred embodiment of the method for producing a reinforced fiber fabric of the present invention, the thermosetting resin has a melting point in the range of 80 to 200 ° C, and a glass transition temperature of 50 to 170 ° C when it does not have a melting point. The basis weight is in the range of 1 to 10 g / m ² and the form is a dot or film.
According to a preferred aspect of the method for producing a reinforced fiber fabric of the present invention, the softening or heat melting resin is a composition comprising a thermoplastic resin and a thermosetting resin, and the melting point thereof is in the range of 80 to 200 ° C. And when it does not have melting | fusing point, it is a thing whose glass transition temperature is the range of 50-170 degreeC, the fabric weight is the range of 1-10 g / m < ² >, and a form is a fibrous form, a dotted | punctate form, or film | membrane form It is. According to a preferred aspect of the method for producing a reinforced fiber fabric of the present invention, in the unidirectional fabric, the warp yarn is composed of carbon fiber, the weft yarn is composed of at least a fibrous thermoplastic resin, and The fibrous thermoplastic resin is melted and the intersection of the warp yarn and the weft yarn is bonded.

  According to the present invention, since the woven fabric is heat-treated before coming into contact with the take-up guide roller, it is possible to suppress the structural collapse of the reinforcing fiber woven fabric (the bending of the woven yarn) and to perform a heat treatment effective for maintaining the shape of the woven tissue. it can. The reinforcing fiber woven fabric obtained by the production method of the present invention is not only exhibiting mechanical properties such as high strength and elastic modulus when molded into FRP, but also excellent because the reinforcing fibers are straightly oriented. It is possible to provide a reinforcing fiber fabric that can achieve the appearance quality. Such an effect is maximized in a unidirectional fabric.

The method for producing a reinforced fiber fabric according to the present invention includes at least a warp yarn made of reinforcing fibers and a weft yarn having a total fineness of 1/5 or less of the warp yarn and containing a thermoplastic resin and / or a thermosetting resin. It is a manufacturing method of the reinforced fiber woven fabric which is a unidirectional woven fabric using , Comprising: It is the manufacturing method of the reinforced fiber woven fabric characterized by passing through the following (A)-(D) process.
(A) Weaving step of weaving warp yarn and driving the weft yarn into the shed to weave the fabric (B) Before the woven fabric comes into contact with the take-up guide roller, the fabric is radiated from the heating source. The heating step (C) in which the thermoplastic resin and / or the thermosetting resin contained in the weft yarn is softened or thermally melted in a non-contact manner by contact with the take-up roller at a contact angle of 45 to 355 °. The take-out process to be sent out (D) The take-up process of winding the fabric into a roll.

  A method for producing a reinforcing fiber fabric of the present invention will be described with reference to the drawings. FIG. 1 is a schematic side view showing an embodiment of a production apparatus for producing a reinforced fiber fabric according to the present invention.

  In the method for producing a reinforcing fiber fabric of the present invention, a reinforcing fiber fabric in which a low-melting point thermoplastic fiber yarn is inserted together with a weft yarn is heated on a loom, and the low-melting point thermoplastic fiber yarn is melted to obtain a warp yarn and a weft yarn. The crossing points are bonded to obtain a fixed woven fabric.

Hereinafter, each of the following (A) weaving step, (B) heating step, (C) take-up step, and (D) winding step of the present invention will be described in detail with reference to FIG.
(A) Weaving process In the weaving process, first, the warp yarns 2 (2a, 2b) made of a plurality of reinforcing fibers in the form of a sheet drawn from the bobbin 1 are warped through the back rollers 3, 4. Each of these is passed through the cage 5 (5a, 5b) and opened and closed by its vertical movement. When the warps 2a and 2b are opened, the weft 7 unwound from the weft bobbin 6 is driven into the shed by means such as shuttle, rapier, gripper, air jet or water jet. The weft thread 7 is then beaten by the scissors 8, and the scissors 5a and 5b are moved up and down again to close, and the fabric 9 is woven. In the woven fabric 9 woven in this manner, at least the warp yarn 2 is composed of reinforcing fibers, and the weft yarn includes a thermoplastic resin and / or a thermosetting resin.
The present invention is to provide a method for producing a reinforced fiber woven fabric that exhibits excellent mechanical properties, is excellent in handleability during molding, and can suppress the collapse of the structure (the bending of the weaving yarn). At least, reinforcing fibers are used for the warp. For example, carbon fibers, glass fibers, and aramid fibers can be used as the reinforcing fibers. As such a reinforcing fiber, a carbon fiber excellent in specific strength and specific elastic modulus is preferable. Among them, a polyacrylonitrile type having a fiber diameter of 5 to 10 μm, a tensile strength of 3 to 7 GPa, and a tensile elastic modulus of 200 to 500 GPa. By using the multifilament, it is possible to obtain FRP exhibiting higher mechanical properties.

The total fineness of the warp of the carbon fiber used in the present invention is preferably thick thread in the range of 500 to 3,000 tex. When the total fineness is in the above range, in the case of carbon fibers having a high fineness exceeding 500 tex, the number of crossing points of warp and weft yarns is reduced, resulting in a fabric that is easily misaligned and difficult to handle. The effect of the present invention that is manifested by the use of the conductive resin is sufficiently exhibited. In addition, carbon fibers generally have an advantage of providing a low-cost woven substrate since the manufacturing cost can be reduced as the fineness increases.
If the total fineness is less than 500 tex, the number of crossing points of warp and weft is large, so the woven form is stable and it is not necessary to awaken and can be used as it is without the heat treatment of the present invention. Therefore, the significance of the present invention is diminished. On the other hand, when the total fineness exceeds 3,000 tex, there is a problem that a woven fabric with uniform fiber dispersion cannot be obtained unless the yarn width is uniformly expanded, and a reinforced fiber woven fabric that sufficiently exhibits mechanical properties can be obtained. difficult.

The reinforcing fiber fabric produced in the present invention is a reinforcing fiber fabric containing at least a thermoplastic resin and / or a thermosetting resin in the weft . Among these, the thermoplastic resin and the thermosetting resin are fibrous, and the weft is composed of at least a fibrous thermoplastic resin and / or a thermosetting resin, and the fibrous resin melts. When the crossing point of the warp and the weft is bonded, the effect of the present invention is highly exhibited. When the thermoplastic resin or thermosetting resin is in a fibrous form, it can be easily inserted in a state wound around a weft thread or in a state aligned with a weft thread, and has a high degree of freedom when manufacturing a woven fabric. Can be secured. In particular, in order to exhibit a high eye-squeaking effect, it is preferable to insert in a state of being wound around a weft thread. With such an embodiment, it is possible to fuse in the entire circumferential direction of the weft yarn, and it is possible to increase the efficiency of the mesh.
As the most preferred embodiment of the reinforcing fiber fabric produced in the present invention, at least the warp yarn is composed of carbon fiber, the weft yarn is composed of at least fibrous thermoplastic fiber and / or thermosetting resin, and the fibrous shape If the thermoplastic resin and / or thermosetting resin is melted and bonded at the intersection of the warp and weft, the fabric will not be misaligned during the molding process. The characteristics of the carbon fiber having an excellent elastic modulus can be exhibited to the maximum, and a composite material that is lightweight and has excellent mechanical properties can be obtained.
In the case where these thermoplastic resins and / or thermosetting resins are in the form of fibers, the filaments made of fibrous thermoplastic resins and / or thermosetting resins may be used alone as weft yarns, You may use as a thread | yarn including a reinforced fiber. And this invention is a form of the unidirectional fabric using the thread | yarn which is 1/5 or less total fineness of a warp as a weft . When the weft is thinner than the warp, especially the weaving and the bending of the weft are prominently exhibited, so that the effects of the present invention can be exhibited to the maximum.
From another point of view, the thermoplastic resin or thermosetting resin is punctiform or film-shaped, and the weft is composed of at least punctiform or film-shaped thermoplastic resin and / or thermosetting resin. Even if such a point-like or film-like thermoplastic resin is melted and the intersection of the warp yarn and the weft yarn is bonded, the effect of the present invention is exhibited to a high degree. When the thermoplastic resin and / or the thermosetting resin is in the form of dots or films, it is possible to apply a resin that cannot be made fibrous. In the case of such a form, it is possible to easily weave by using a woven yarn in which a resin is preliminarily attached to the warp yarn or the weft yarn in a dot or film form. Further, before weaving, the particles can be applied and subjected to a heat treatment to adhere the particles in the form of dots.
As such a resin, a thermoplastic resin is preferable in terms of being easily formed into a fibrous form. Examples of the thermoplastic resin include polyamide, polyester, polypropylene, polyphenylene sulfide, polyvinyl alcohol, copolymer resins, polymer alloy resins, and polymer blend resins. Among them, a copolymer resin is preferable so as to be softened and melted at a relatively low temperature, and in particular, a copolymer polyamide having good adhesiveness with an epoxy resin frequently used as a matrix resin of a composite material is preferable.
On the other hand, a thermosetting resin is preferable in that it is easily formed into a dot or film. Examples of the thermosetting resin include epoxy, vinyl ester, unsaturated polyester, phenol, and the like, and those containing a curing agent, a curing accelerator, a catalyst, and the like. Among them, an epoxy that is softened and melted at a relatively low temperature and has good adhesiveness with an epoxy resin that is frequently used as a matrix resin of a composite material is preferable.
Furthermore, in the present invention, a thermoplastic resin and a thermosetting resin can be used in combination. In this case, it may be a single resin composition in which both are compatible, or may be a phase-separated resin composition that is incompatible, or may be used in combination as independent resins. . In particular, in order to improve the mechanical properties as FRP (particularly, delamination and interlaminar shear strength when woven fabrics are laminated), a high-toughness thermoplastic resin and a thermosetting resin excellent in heat melting property are combined. It is an especially preferable aspect to use as a dissolved resin composition. In this case, a high-toughness thermoplastic resin alone has a problem of heating temperature, and a thermosetting resin excellent in heat melting property has a problem of handleability alone and is difficult to apply. However, by compatibilizing them, the above problems can be solved and the advantages of both can be maximized.

The thermoplastic resin and the thermosetting resin used as the squeezing agent in order to express the squeezing effect are appropriately selected according to the purpose, but are preferably thermoplastic resins and have a melting point of 80 to 200 ° C. When it does not have a melting point, the glass transition temperature is 50 to 170 ° C., and the form is preferably fibrous.
When the melting point is less than 80 ° C. or the glass transition temperature is less than 50 ° C., the heating temperature required for weaving the fabric is low and the workability is excellent, but not only the heat resistance of the composite material is greatly reduced, but also the raw materials are stored. Or when the fabric is transported, it may be inferior in handleability. On the other hand, if the melting point is 200 ° C. or the glass transition temperature exceeds 170 ° C., the heat resistance in the case of a composite material is improved, but the heating temperature at the time of weaving the fabric is too high, and the workability may be extremely reduced. is there. In the present invention, the melting point or glass transition temperature of the resin refers to a melting point (glass transition temperature) measured by DSC (differential scanning calorimeter) from a completely dry state at a rate of temperature increase of 20 ° C./min.
The fabric structure used in the present invention is not particularly limited, but at least a plain weave, twill weave, satin weave, or non-crimp structure with reinforcing fiber yarns as warps (the reinforcing fiber yarns are oriented straight, and the warp and weft auxiliary yarns cross each other) And the like are preferably used.
(B) Heating process In the heating process, before the woven fabric 9 comes into contact with a take-off guide roller 11 described later, the fabric 9 is heat-treated by radiation from the heating source 10 in a non-contact manner to form a weft . The contained thermoplastic resin and / or thermosetting resin is softened or melted.

In the present invention, after weaving the woven fabric 9 and before contacting the take-up guide roller 11, the thermoplastic resin and / or thermosetting resin contained in the weft yarn is softened or thermally melted to awaken, The woven fabric 9 is fixed in form without physically contacting anywhere. By adopting such a process, the weft 7 does not meander in the woven fabric 9 even if it comes into contact with the take-up guide roller 11 or the take-up roller 12 later. The present invention is greatly characterized in that it has been found that the problems of the present invention can be solved through such steps. The conventional heating method that is outside the scope of the present invention described in the background art, that is, the method of heating for the first time after passing through the guide roller or the method of heating for the first time on the roller or the surface thereof cannot solve the problem of the present invention. It is.

The heating source is preferably radiation by an infrared heater such as far infrared rays, middle infrared rays, and near infrared rays. When such a heat source is used, the fabric 9 can be efficiently heated without contact with the fabric 9. In addition, the equipment can be made small and does not interfere with the weaving, and the heating source for the fabric can be shut off when the loom is stopped to suppress overheating. When a hot air heater (combination of air heating by radiation and blowing of heated air) is used as a heating source, there is a problem that particles are blown off when particles of thermoplastic resin and / or thermosetting resin are used. In particular, when carbon fibers are used as warp yarns as reinforcing fibers, the tension of the warp yarns is adjusted to be low at the opening / closing port of the shed and before weaving to suppress fluff. In such a case, the woven fabric may flutter and the fabric structure may induce disturbance. Furthermore, since heat is blown and heated, there is a problem that energy loss is larger than radiation.
When the hot air heater is used with a slight air flow at a level where the woven fabric does not flutter before weaving, it can be considered that air is not blown in practice, and the problem of the present invention can be solved. That is, as described above, when the air is not substantially blown (2 m 3 / min or less for a 1 m wide fabric, which is proportionally calculated by the fabric width), it is regarded as radiation in the present invention.
In the above-mentioned unidirectional reinforcing fiber woven fabric having a large fineness difference between the warp and the weft, since the rigidity of the fine-definition yarn is small and the binding force at the intersection of the warp and the weft is small, the woven fabric If it is left as it is, it is easy to deform in the form and difficult to handle. Since this step does not generate bending or the like even in such a woven fabric, this woven fabric embodiment can be said to be an example that can maximize the effects of the present invention.
(F) Cooling step In the present invention, between the heating step and the take-up step, the temperature at which the heat-treated fabric is softened or melted by the thermoplastic resin and / or thermosetting resin contained in the weft yarn It is preferable to cool to less than.
By such cooling, the heated resin can be surely cooled to a temperature lower than the temperature at which the resin is softened or melted, and the thermoplastic resin and / or the thermosetting resin applied to the take-off guide rollers 11 and 14 and the take-off roller 12 and the like. Sticking and adhesion can be suppressed. When such sticking / adhesion occurs, the reinforcing fiber may be pulled by the roller to induce bending. In particular, when producing a woven fabric at a high speed of 0.3 m / min or more, it is preferable to go through this cooling step. In particular, when carbon fiber is used as the reinforcing fiber, the carbon fiber is excellent in heat conduction, and therefore heat is transferred to peripheral devices of the loom such as the take-up guide roller 11 and the take-off roller 12. It may not be possible to cool below the temperature at which it melts. Further, the intersection of the warp and the weft can be reliably fixed by such a cooling process, and the bending is reliably suppressed when passing through the take-up guide rollers 11 and 14 and the take-up roller 12 thereafter. be able to.
The cooling means is not particularly limited, and examples thereof include cooling of the take-up guide rollers 11 and 14 and the take-up roller 12, contact with the cooling panel and the cooling roller, and air blowing to the fabric after the heat treatment.
(C) Take-up Step In the take-up step, the woven fabric driven by weft yarn 7 is sent out toward the winding core 13 through the take-up guide roller 14, the take-up roller 12 and the take-up guide roller 15. The take-up roller 12 refers to a roller that is driven by itself, and the take-up guide roller 11 refers to a roller that is not driven by itself but rotates freely as the fabric is fed out. Here, the contact angle between the fabric 9 and the take-up roller 12 is preferably 45 to 355 °. If the contact angle is less than 45 °, since the contact length of the warp yarn to the take-up roller 12 is short, a plurality of warp yarns cannot be taken out simultaneously when sending out the fabric, and there is a difference in yarn length for each warp yarn. Which can cause weft meandering. On the other hand, if the contact angle exceeds 355 °, there is no problem of slippage of the fabric 9 on the take-up roller 12, but the winding length of the take-up roller 12 becomes longer, so the distance between the take-up guide rollers becomes smaller and weaving begins. For example, it may be difficult to pass the fabric through each roller, and workability may deteriorate.

In the present invention, when at least one of the take-up roller and / or the take-up guide roller is heated, it is possible to perform the crushing more efficiently and reliably. In the previous heating step, the fabric that has been fixed in shape (restrained) with the heat-bonded resin is brought into contact with the heated take-up roller and / or take-off guide roller, so that the agitated fabric is brought into its form. You can get used to it. In this case, if the resin is completely softened or melted, weaving of the weft thread may occur due to contact with the take-up guide rollers 11, 14, 15 and take-off roller 12 as described above. It is preferable to heat to such an extent that thermal bonding is not released.
In addition, once the form has been fixed (mesh), even if the resin material is completely melted while being in contact with the heated roller, the frictional resistance when the warp and weft are misaligned is reduced. Since it is larger than the frictional resistance of the fabric before being formed, it is hardly bent. From such a point of view, there is no problem even if the resin is heated to such an extent that it completely softens or melts, and such an embodiment can be said to be a preferable example. Moreover, when performing the below-mentioned reheating process, it can utilize also as heating as preheating for reheating. In particular, the location where the weaving speed is too high to be heated to the melting point of the resin material or higher in the reheating step and the adhesion is insufficient can be minimized.
(E) Reheating step In the present invention, after the fabric 9 has passed through the take-up roller 12 and the take-up guide roller 15 between the drawing step and the take-up step, before being wound on the core 13. Heat treatment without contact by radiation from the heating source 16, and / or heat treatment with direct contact by passing a fabric of a heating roller (not shown), softening the thermoplastic resin contained in the weft yarn again Or it is preferable to heat-melt. Also in this step, by heating the heat-bonded resin in the heating step, there was a place where the weaving speed was too high to be heated above the melting point of the resin material and adhesion was insufficient. Even in the case, it is possible to securely bond the same.
There is no misalignment when heated on the heating roller in this reheating process. The woven fabric once fixed (squeezed) is made to melt the resin material completely while contacting the heated roller. This is because the frictional resistance when the warp yarn and the weft yarn are misaligned is larger than the frictional resistance of the fabric before being agitated. For this reason, in this reheating step, even if the heating process is performed by contacting with a heating roller, there is almost no bending.
(F) Cooling step In the present invention, the heat-treated woven fabric between the reheating step and the winding step is softened or melted by the thermoplastic resin and / or the thermosetting resin contained in the weft yarn. It can be cooled below the temperature. This cooling process is as described above.
(D) Winding process In the winding process, the roll 17 is wound up on the winding core 13 through the take-up roller 12 and the take-up guide roller 15. In FIG. 1, an example using a winding device of a loom is shown. However, a winding device is provided at the rear of the winding device separately from the loom to secure a space, and a heating roller or the like is provided between the winding device and the winding device. Heating can be performed by providing an apparatus used for the reheating step.

Example 1
A polyacrylonitrile (PAN) carbon fiber yarn (total fineness: 800 tex) having a tensile strength of 4,900 MPa, a tensile elastic modulus of 230 GPa and a filament number of 12,000 is used as the warp yarn, and a glass fiber yarn is used as the weft yarn. ECE225 1/0 (total fineness: 22.5 tex), pre-covered composite polyamide fiber yarn having a melting point of 110 ° C. (total fineness: 5.6 tex) (covering number: 200 turns / m) was used. Using the apparatus shown in FIG. 1, a unidirectional fabric A in which only the warp is composed of carbon fibers was manufactured by the following procedure.
(A) In the weaving step, first, a plurality of warp yarns 2 drawn from the bobbin 1 are arranged so that the density is 2.5 yarns / cm, and then each warp yarn 2 is passed through the back rollers 3 and 4. It was divided into two ridges 5a and 5b and passed alternately. When the warp yarns 2a and 2b passed through the two reeds 5a and 5b are opened, the weft yarn 7 is driven into the reed port so that the density becomes 3.0 / cm by rapier, A woven fabric having a carbon fiber basis weight of 200 g / m ² plain structure was woven.
(B) In the heating step, the woven fabric is heated in a non-contact manner using only a far-infrared heater as the heating source 10 from the upper surface of the fabric before contacting the take-up guide roller 11, and the heat contained in the weft yarn The plastic resin fiber was melted by heat. Here, the heater temperature was adjusted to 120 ° C. on the fabric surface. Thereafter, the temperature naturally decreased to 60 ° C. due to atmospheric heat radiation until it contacted the take-up guide roller 11.
(C) In the take-up process, the agitated fabric was sent out toward the winding core 13 through the take-up guide rollers 11 and 14, the take-up roller 12 and the take-up guide roller 15. Here, none of the take-up guide rollers 11, 14, 15 and the take-up roller 12 was heated. Further, the take-up roller 12 was able to take up the fabric without causing the fabric to slide with the take-up roller by making the fabric contact and take up so that the contact angle would be 300 °.
(D) In the winding process, the roll 17 was wound around the core 13. The obtained unidirectional woven fabric A was obtained by melting the thermoplastic resin fibers after inserting the weft yarn of the fabric before contacting the guide roller and bonding the crossing points of the warp yarn and the weft yarn. No weft meandering (texture collapse) was observed. A schematic plan view of the unidirectional fabric A is shown in FIG.
(Example 2)
A unidirectional fabric B was produced in the same manner as in Example 1 except that the take-up guide roller 11 was heated to 120 ° C. The obtained unidirectional woven fabric B is melted by the thermoplastic resin fiber after the weft insertion of the woven fabric and before contacting the take-up guide roller, and the crossing point of the warp yarn and the weft yarn is adhered and contacted with the take-up guide roller. Since reheating was performed, adhesion at the crossing point of the warp yarn and the weft yarn became stronger, and no meandering (texture collapse) of the weft yarn was observed in the woven fabric after winding.
(Example 3)
A unidirectional fabric C was produced in the same manner as in Example 1 except that the take-up roller 12 was wound so that the contact angle of the fabric was 60 °. Although the obtained unidirectional fabric C had a contact angle of 60 ° on the take-up roller, which was smaller than that of Example 1, a plurality of warp yarns could be taken out simultaneously when sending out the fabric. After inserting the weft yarn of the woven fabric and before contacting the take-up guide roller, the thermoplastic resin fiber is melted to bond the crossing point of the warp yarn and the weft yarn, and after the take-up roller is wound up. No weaving of the weft yarn (texture collapse) was observed in the woven fabric.
Example 4
As the weft yarn, a composite yarn in which glass fiber yarn ECE225 1/0 (total fineness: 22.5 tex) is coated with an epoxy resin having a glass transition point of 110 ° C. to a weight of 0.01 g per 1 m of glass fiber is used. A unidirectional fabric D was produced in the same manner as in Example 1. The obtained unidirectional woven fabric D has a structure in which, after inserting the weft yarn of the fabric, the thermosetting resin is softened before contacting the take-up guide roller, and the intersection of the warp yarn and the weft yarn is adhered. In the woven fabric, weaving of the weft yarn (texture collapse) was not observed at all .

( Comparative Example 1)
Using the apparatus shown in FIG. 1, instead of performing the heating step (B), the following (G) heating is performed between the take-up step (C) and the winding step (D). A unidirectional fabric F was produced in the same manner as in Example 1 except that heat treatment was performed in the process.
(G) In the heating step, heat treatment was performed between the take-up guide roller 15 and the core 13 in a non-contact manner using only a far-infrared heater as the heat source 16, and the thermoplastic resin fibers contained in the weft yarn were melted by heat. .

  In the obtained unidirectional fabric F, weft meandering was caused by contact with the guide roller after inserting the weft of the fabric, and the thermoplastic resin fiber was melted in this state, and the intersection of the warp yarn and the weft yarn was adhered. Therefore, weft meandering (texture collapse) occurred in the woven fabric after winding. A schematic plan view of the unidirectional fabric F is shown in FIG.

(Comparative Example 2)
A unidirectional fabric G was produced in the same manner as in Example 1 except that the take-up roller 12 was wound so that the contact angle of the fabric was 30 °. The obtained unidirectional fabric G has a small contact angle of 30 ° with the fabric on the take-up roller, so that when the fabric is fed, a plurality of warp yarns cannot be taken at the same time, and there is a difference in yarn length for each warp yarn. As a result, meandering of the weft yarn (texture collapse) occurred.

  The results of the above examples and comparative examples are shown in Table 1.

  According to the method for producing a reinforced fiber fabric of the present invention, since the fabric is heat-treated before coming into contact with the take-off guide roller, the structural collapse of the reinforcing fiber fabric (weaving of the yarn) is suppressed, and the shape of the woven tissue is maintained. An effective heat treatment can be performed. The reinforcing fiber woven fabric obtained by such a manufacturing method has not only high mechanical properties such as high strength and elastic modulus, but also excellent appearance quality when formed into FRP because the reinforcing fibers are oriented straight. Can be achieved. Such a reinforced fiber fabric is suitably used as a reinforcing material for FRP used in other general industries including repair and reinforcement of structures, transportation equipment (automobiles, ships, aircraft, bicycles, etc.), sporting goods, and FRP types. .

FIG. 1 is a schematic side view showing an example of an apparatus for producing a reinforced fiber fabric according to the present invention. FIG. 2 is a schematic side view showing another example of an apparatus for producing a reinforcing fiber fabric according to the present invention. FIG. 3 is a schematic plan view showing a reinforced fiber fabric manufactured according to Example 1 of the present invention. FIG. 4 is a schematic plan view showing a reinforced fiber fabric manufactured by Comparative Example 1 that is outside the scope of the present invention.

Explanation of symbols

1: Bobbin 2, 2a, 2b: Warp
3, 4: Back rollers 5, 5a, 5b: 綜 絖 6: Weft bobbins 7, 21, 23: Weft 8: 筬 9: Woven fabrics 10, 16: Heat sources 11, 14, 15: Take-up guide roller 12: Take-up roller 13 : Roll core 17: Roll 18: Heating rollers 19 and 20: Cooling rollers 22 and 24: Carbon fiber

Claims (9)

At least, the warp consists of reinforcing fibers, and a total fineness of 1/5 or less of the warp, and the reinforcing fibers is unidirectional woven fabric using the weft that contains the thermoplastic resin and / or thermosetting resin A method for producing a reinforced fiber fabric, comprising the following steps (A) to (D).
(A) Weaving step of weaving warp yarn and driving the weft yarn into the shed to weave the fabric (B) Before the woven fabric comes into contact with the take-up guide roller, the fabric is radiated from the heating source. The heating step (C) in which the thermoplastic resin and / or the thermosetting resin contained in the weft yarn is softened or thermally melted in a non-contact manner by contact with the take-up roller at a contact angle of 45 to 355 °. , Take-out process to be sent out (D) Winding process for winding the fabric into a roll At taking over step, the take-up roller and / or take-up guide at least one roller is heated, the manufacturing method of the reinforcing fiber woven fabric according to claim 1, wherein. Between the take-up step and the winding step, through the following step (E), according to claim 1 or 2 method for producing a reinforcing fiber woven fabric according.
(E) The woven fabric is heat-treated in a non-contact manner by radiation from a heating source and / or heat-treated in direct contact by passing the woven fabric through a heating roller, so that the thermoplastic resin and / or heat contained in the weft yarn Reheating process to soften or heat melt curable resin again Between the heating step and the take-up step, or between the reheating step and the winding step, through the following step (F), the manufacturing method of the reinforcing fiber woven fabric according to claim 1.
(F) A cooling step of cooling the heat-treated fabric to a temperature lower than the temperature at which the thermoplastic resin and / or thermosetting resin contained in the weft yarn is softened or melted. Heating source, a far infrared heater, which is either a mid-infrared heater or near infrared heater, a manufacturing method of the reinforcing fiber woven fabric according to claim 1. When the thermoplastic resin has a melting point in the range of 80 to 200 ° C. and does not have a melting point, the glass transition temperature is in the range of 50 to 170 ° C., and the basis weight is in the range of 1 to 10 g / m ² . And the manufacturing method of the reinforced fiber fabric in any one of Claims 1-5 which is a fibrous form. When the thermosetting resin has a melting point in the range of 80 to 200 ° C. and does not have a melting point, the glass transition temperature is in the range of 50 to 170 ° C., and the basis weight is in the range of 1 to 10 g / m ² . There, and form a point-like or membrane-like, the manufacturing method of the reinforcing fiber woven fabric according to any one of claims 1-5. The softening or heat melting resin is a composition comprising a thermoplastic resin and a thermosetting resin, and its melting point is in the range of 80 to 200 ° C., and when it does not have a melting point, the glass transition temperature is 50 to 170 ° C. range is of, its basis weight in the range of 1 to 10 g / m ^2, and form a fibrous, punctate or membranous, of the reinforcing fiber woven fabric according to any one of claims 1 to 5 Production method. In the unidirectional fabric, the warp is composed of carbon fiber, the weft is composed of at least a fibrous thermoplastic resin, and the intersection between the warp and weft is obtained by melting the fibrous thermoplastic resin. The method for producing a reinforced fiber fabric according to any one of claims 1 to 8 , which is bonded.

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