JP6119837B2 - Method for producing unidirectional discontinuous fiber band - Google Patents

Method for producing unidirectional discontinuous fiber band Download PDF

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JP6119837B2
JP6119837B2 JP2015252569A JP2015252569A JP6119837B2 JP 6119837 B2 JP6119837 B2 JP 6119837B2 JP 2015252569 A JP2015252569 A JP 2015252569A JP 2015252569 A JP2015252569 A JP 2015252569A JP 6119837 B2 JP6119837 B2 JP 6119837B2
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fiber
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fiber bundle
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JP2016065356A (en
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康 渡邊
康 渡邊
鮫島　禎雄
禎雄 鮫島
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Mitsubishi Chemical Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping

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Description

本発明は、多数本の短繊維が長手方向に沿って配向した一方向不連続繊維帯の製造方法に関する。   The present invention relates to a method for producing a unidirectional discontinuous fiber band in which a number of short fibers are oriented along the longitudinal direction.

繊維強化樹脂成形品を得る際に使用する成形材として、一方向に配向した連続繊維材料に熱硬化性樹脂または熱可塑性樹脂を含浸させた一方向プリプレグが知られている。このような一方向連続繊維プリプレグでは、プリプレグ自体の変形が十分でないため曲面形状に賦形する場合には形状に沿わせることが難しく、所望の形状となるよう裁断してプリフォームを製作する必要がある。また、プリプレグでは保管期間や保管状態の管理も配慮する必要があるなど煩雑である。
これに対して、繊維材料として一方向に配向した短繊維を含むドライプリフォームも検討されている。一方向に配向した短繊維では擬似的に伸びるため、優れた曲面賦形性を発揮するものと期待される。すなわち、一方向連続繊維（長繊維）で立体形状のプリフォームを得る場合には、しわが発生するが、一方向不連続繊維は繊維が短いために、プリフォームとした際には擬似的に伸びる。よって、所望する任意の形状に成形した時に型へのなじみもよく、しわの発生も低減されると考えられ、低コストで高品位の成形が可能なドライプリフォームが得られる。 A unidirectional prepreg in which a continuous fiber material oriented in one direction is impregnated with a thermosetting resin or a thermoplastic resin is known as a molding material used when obtaining a fiber-reinforced resin molded product. In such a unidirectional continuous fiber prepreg, since the deformation of the prepreg itself is not sufficient, it is difficult to conform to the shape when shaping into a curved shape, and it is necessary to produce a preform by cutting to a desired shape There is. In addition, the prepreg is complicated because it is necessary to consider the storage period and storage state.
On the other hand, a dry preform containing short fibers oriented in one direction as a fiber material has been studied. Short fibers oriented in one direction are expected to exhibit excellent curved surface shapeability because they extend in a pseudo manner. In other words, when a three-dimensional preform is obtained with a unidirectional continuous fiber (long fiber), wrinkles are generated. extend. Therefore, it is considered that the mold fits well when it is molded into any desired shape, and the generation of wrinkles is reduced, and a dry preform capable of high-quality molding at a low cost is obtained.

一方向に配向した短繊維は、例えば、一方向に配向した長繊維束（繊維トウ）を巻き出して開繊した後、この長繊維束の長手方向の複数箇所において、長繊維束を幅方向に沿って断続的に切断する方法などにより得られる。このような方法によれば、長繊維束のような連続的な取り扱い（例えば、連続的な巻取りなど。）が可能でありながら、個々の各フィラメントは複数箇所で適宜切断されて短繊維となっている、一方向不連続繊維帯を得ることができる。   The short fibers oriented in one direction are, for example, unwound and opened a long fiber bundle (fiber tow) oriented in one direction, and then the long fiber bundle is spread in the width direction at a plurality of locations in the longitudinal direction of the long fiber bundle. It is obtained by a method of cutting intermittently along the line. According to such a method, continuous handling such as a long fiber bundle (for example, continuous winding, etc.) is possible, but each individual filament is appropriately cut at a plurality of locations to form short fibers. Thus, a unidirectional discontinuous fiber band can be obtained.

ところが、繊維材料として例えば炭素繊維やアラミド繊維を用いた場合には、これらの繊維は一般的な有機繊維よりも引張り強さが大きく、高弾性であるため、ステンレスやセラミックからなる切断具では磨耗による劣化によって安定的に切断できない問題点があった。
このような問題に対して、特許文献１には、繊維材料に冷凍処理を施した後、レーザ光を照射することにより、繊維材料を切断する技術が記載されている。そして、特許文献１には、単にレーザ光を照射するだけでは、フィラメントがばらけてしまい、配向が乱れる場合があったのに対して、繊維材料にあらかじめ冷凍処理を施すことによって、フィラメントがばらけることなく、長繊維束を切断できることが記載されている。 However, when carbon fiber or aramid fiber, for example, is used as the fiber material, these fibers have higher tensile strength and higher elasticity than general organic fibers, so that they are worn by cutting tools made of stainless steel or ceramic. There was a problem that could not be cut stably due to deterioration due to.
For such a problem, Patent Document 1 describes a technique of cutting a fiber material by irradiating the fiber material with a laser beam after freezing treatment. In Patent Document 1, when the laser beam is simply irradiated, the filaments may be scattered and the orientation may be disturbed. On the other hand, the filaments are separated by subjecting the fiber material to freezing. It is described that a long fiber bundle can be cut without breaking.

特開平６−１５８５２８号公報JP-A-6-158528

しかしながら、特許文献１に記載の方法では、繊維材料を冷凍するための冷凍装置や、切断後に繊維材料を乾燥するための乾燥装置、さらには、冷凍のための液体窒素などの液化ガスが必要となり、製造コストが高くなるという問題があった。   However, the method described in Patent Document 1 requires a refrigeration apparatus for freezing the fiber material, a drying apparatus for drying the fiber material after cutting, and a liquefied gas such as liquid nitrogen for freezing. There is a problem that the manufacturing cost becomes high.

本発明は上記事情に鑑みてなされたもので、本発明の目的は、繊維材料を冷凍することなく、また、フィラメントの配向を乱すことなく繊維材料を切断して、低コストで一方向不連続繊維帯を製造することである。   The present invention has been made in view of the above circumstances, and the object of the present invention is to cut the fiber material without refrigeration of the fiber material or disturb the orientation of the filament, and to discontinue the unidirectional at low cost. It is to produce a fiber band.

本発明の一方向不連続繊維帯の製造方法は、一方向連続繊維からなる帯状の繊維材料にレーザ光を照射して、前記繊維材料の長手方向の複数箇所において、繊維方向に対する角度が２〜１７８°となる範囲内で一方向不連続繊維帯とする切断線を形成する切断工程を有し、該切断工程では、前記繊維材料の下面に、レーザ照射が透過することにより切断されない耐レーザ性を備えた支持体を配置して、前記繊維材料を支持し、前記繊維材料の下面側もしくは両面側よりレーザ光を照射して、前記繊維材料を切断する。
前記切断工程の後に、前記繊維材料と前記支持体とを前記繊維材料が内側になるように巻き取る巻取工程をさらに有することが好ましい。 In the method for producing a unidirectional discontinuous fiber band of the present invention, a belt-shaped fiber material composed of unidirectional continuous fibers is irradiated with laser light, and the angle with respect to the fiber direction is 2 to 2 at a plurality of positions in the longitudinal direction of the fiber material. has a cutting step of forming a cut line for unidirectional discontinuous fibers band within which the 178 °, in the cutting step, the lower surface of the fibrous material, resistant laser uncut by excessive laser irradiation GaToru A support having a property is arranged to support the fiber material, and the fiber material is cut by irradiating laser light from the lower surface side or both surface sides of the fiber material .
After the cutting step, it is preferable to further include a winding step of winding the fiber material and the support so that the fiber material is inside.

本発明によれば、繊維材料を冷凍することなく、また、フィラメントの配向を乱すことなく、繊維材料を切断して、低コストで一方向不連続繊維帯を製造することができる。   According to the present invention, it is possible to produce a unidirectional discontinuous fiber band at low cost by cutting the fiber material without freezing the fiber material and without disturbing the orientation of the filament.

本発明の製造方法で製造される一方向不連続繊維帯の一例を示す平面図である。It is a top view which shows an example of the unidirectional discontinuous fiber belt manufactured with the manufacturing method of this invention. 図１の一方向不連続繊維帯を製造する製造装置の一例を示す概略構成図である。It is a schematic block diagram which shows an example of the manufacturing apparatus which manufactures the unidirectional discontinuous fiber band of FIG.

以下、本発明の一方向不連続繊維帯の製造方法について、詳細に説明する。
なお、本発明において、一方向不連続繊維帯とは、長手方向（一方向）に沿って、多数本の短繊維が配向した帯状の材料のことを言う。また、短繊維とは、長さが１５ｍｍ以上、２００ｍｍ未満の繊維のことを意味し、長繊維とは、長さが２００ｍｍ以上の繊維のことを意味する。 Hereinafter, the manufacturing method of the unidirectional discontinuous fiber band of this invention is demonstrated in detail.
In the present invention, the unidirectional discontinuous fiber band refers to a band-shaped material in which a large number of short fibers are oriented along the longitudinal direction (one direction). The short fiber means a fiber having a length of 15 mm or more and less than 200 mm, and the long fiber means a fiber having a length of 200 mm or more.

図１は、本発明の製造方法で製造される一方向不連続繊維帯の一例を示す平面図である。
この一方向不連続繊維帯１０は、長手方向に沿う一方向（矢印Ａ方向）に配向した多数本の短繊維の炭素繊維フィラメントからなる幅Ｗの帯状の材料であり、詳しくは後述するが、３０００〜１８００００本程度のフィラメントからなり、開繊された幅Ｗの１本の長繊維束（一方向連続繊維）を材料として製造されたものである。また、この一方向不連続繊維帯１０の厚みは０．０４〜０．２５ｍｍである。 FIG. 1 is a plan view showing an example of a unidirectional discontinuous fiber band manufactured by the manufacturing method of the present invention.
This unidirectional discontinuous fiber band 10 is a band-shaped material having a width W composed of carbon fiber filaments of a plurality of short fibers oriented in one direction (arrow A direction) along the longitudinal direction, and will be described in detail later. It consists of about 3,000 to 180,000 filaments, and is produced using a single long fiber bundle (unidirectional continuous fiber) having a width W opened. The unidirectional discontinuous fiber band 10 has a thickness of 0.04 to 0.25 mm.

この一方向不連続繊維帯１０は、長手方向の複数箇所Ｐｎ（ただし、ｎ＝１，２，３・・・）、すなわち、この例ではＰ１，Ｐ２，Ｐ３，Ｐ４，Ｐ５の５箇所それぞれにおいて、炭素繊維フィラメントと交差する方向（繊維方向と交差する方向。）に部分的に形成された複数の切断線（切れ目）１１を有している。 This unidirectional discontinuous fiber band 10 has a plurality of longitudinal locations P n (where n = 1, 2, 3...), That is, P 1 , P 2 , P 3 , P 4 , P in this example. 5 has a plurality of cutting lines (cuts) 11 partially formed in the direction intersecting the carbon fiber filament (direction intersecting the fiber direction).

具体的には、各切断線１１は、一方向不連続繊維帯１０の幅方向に沿う長さがＬ、一方向不連続繊維帯１０の幅方向に沿う間隔がＱ１、一方向不連続繊維帯１０の長手方向に沿う間隔がＱ２で配置され、長手方向の各箇所それぞれにおいて一方向不連続繊維帯１０の幅方向に沿って断続的に形成されている。また、各切断線１１は、一方向不連続繊維帯１０の厚み方向に貫通している。
図１の一方向不連続繊維帯１０は、このように形成された切断線１１により、元々は長繊維であった各炭素繊維フィラメントそれぞれが長手方向に分断され、長さＲの短繊維とされたものである。そのため、この一方向不連続繊維帯１０をプリプレグに使用した際には、一方向に配向した長繊維を含むプリプレグと同等の物性や取扱性を有しながら、優れた曲面賦形性を発揮し、特に立体的な成形物の成形に適したものとなる。 Specifically, each cutting line 11 has a length along the width direction of the one-way discontinuous fiber band 10 as L, an interval along the width direction of the one-way discontinuous fiber band 10 as Q 1 , and a one-way discontinuous fiber. interval along the longitudinal direction of the band 10 are arranged in Q 2, in each of positions in the longitudinal direction along the width direction of the unidirectional discontinuous fibers band 10 are intermittently formed. Each cutting line 11 penetrates in the thickness direction of the unidirectional discontinuous fiber band 10.
In the unidirectional discontinuous fiber band 10 of FIG. 1, the carbon fiber filaments, which were originally long fibers, are divided in the longitudinal direction by the cutting lines 11 formed in this way, thereby forming short fibers having a length R. It is a thing. Therefore, when this unidirectional discontinuous fiber band 10 is used for a prepreg, it exhibits excellent curved surface formability while having the same physical properties and handleability as a prepreg containing long fibers oriented in one direction. In particular, it is suitable for forming a three-dimensional molded product.

また、この例では、長手方向に隣り合う箇所、すなわちＰｎとＰｎ＋１とでは、切断線１１の幅方向における配置位置が一致せず、互い違いにずれるようなパターンで、切断線１１が配置されている。 Further, in this example, the cutting lines 11 are arranged in a pattern in which the arrangement positions in the width direction of the cutting lines 11 do not coincide with each other in places adjacent to each other in the longitudinal direction, that is, Pn and Pn + 1. ing.

このような一方向不連続繊維帯１０は、例えば図２に示す一方向不連続繊維帯の製造装置２０により連続的に製造できる。
図２の製造装置２０は、一方向連続繊維からなる繊維束の巻回物を巻き出す巻出装置２１と、巻き出された繊維束２２を開繊して、例えば厚みが０．０４〜０．２５ｍｍ程度の均一な厚みの帯状とする開繊装置２３と、開繊された帯状の繊維束２２ａの下面側に支持体２４を供給、配置する供給装置２５と、支持体２４が配置された繊維束２２ａに対して、支持体２４が配置されていない上面側にレーザ光を照射して繊維束２２ａの所望の部分を切断し、複数の切断線１１を形成する切断装置２６と、切断装置２６を経た繊維束２２ｂを支持体２４と共に巻き取る巻取装置２７とを備えている。 Such a unidirectional discontinuous fiber band 10 can be continuously manufactured by, for example, the unidirectional discontinuous fiber band manufacturing apparatus 20 shown in FIG.
The manufacturing apparatus 20 of FIG. 2 opens the unwinding apparatus 21 which unwinds the wound product of the fiber bundle which consists of a unidirectional continuous fiber, and the unwinded fiber bundle 22, for example, thickness is 0.04-0. A fiber opening device 23 having a uniform thickness of about 25 mm, a supply device 25 for supplying and arranging the support 24 on the lower surface side of the opened fiber bundle 22a, and the support 24 are arranged. A cutting device 26 that cuts a desired portion of the fiber bundle 22a by irradiating the upper surface side where the support 24 is not disposed with respect to the fiber bundle 22a to form a plurality of cutting lines 11, and a cutting device 26 and a winding device 27 that winds the fiber bundle 22b having passed through 26 together with the support 24.

この例の切断装置２６は、水平方向に搬送される繊維束２２ａの上面側において、レーザ光を自在に走査して、繊維束２２ａの上面における任意の位置を切断可能なものである。
また、開繊装置２３の後段には、開繊された繊維束２２ａと、供給された支持体２４とを両面側から挟む一対のニップローラ２８が配置され、このニップローラ２８により、巻出装置２１から巻き出され、支持体２４で支持される前までの繊維束に対して、所定の張力が付与されるようになっている。また、ニップロール２８から巻き取り装置２７までの間は、支持体２４に対し、張力が付与され、繊維束２２ｂのフィラメントの配向を乱すことなく巻き取ることができるようになっている。 The cutting device 26 of this example is capable of cutting an arbitrary position on the upper surface of the fiber bundle 22a by freely scanning laser light on the upper surface side of the fiber bundle 22a conveyed in the horizontal direction.
In addition, a pair of nip rollers 28 that sandwich the opened fiber bundle 22a and the supplied support 24 from both sides are disposed at the subsequent stage of the fiber opening device 23. A predetermined tension is applied to the fiber bundle before being unwound and supported by the support 24. Further, tension is applied to the support 24 from the nip roll 28 to the winding device 27 so that the support 24 can be wound without disturbing the orientation of the filaments of the fiber bundle 22b.

この製造装置２０により、図１の一方向不連続繊維帯１０を製造する場合には、まず、巻出装置２１により繊維束２２を連続的もしくは間欠的に巻き出し、この繊維束２２を開繊装置２３の具備する複数本のバーで擦過もしくは揺動によって開繊して、帯状の繊維束２２ａとする。
ついで、開繊された帯状の繊維束２２ａの下面側に、供給装置２５から支持体２４を供給し、この支持体２４により繊維束２２ａを下方から支持して、繊維束２２ａを支持体２４とともに切断装置２６へと送る。
そして、支持体２４が配置された繊維束２２ａの上面側から、切断装置２６によりレーザ光を照射して、繊維束２２ａの所定の位置を走査して切断し、図１のようなパターンで複数の切断線１１を形成する（切断工程）。
この例では、被切断物である帯状の繊維束２２ａは、所定の供給速度で連続的に切断装置２６に送られているため、切断装置２６は、繊維束２２ａの供給速度を考慮した方向および速度でレーザ光を走査し、複数の切断線１１を連続的に形成していく。 When the unidirectional discontinuous fiber band 10 of FIG. 1 is manufactured by the manufacturing apparatus 20, first, the fiber bundle 22 is unwound continuously or intermittently by the unwinding apparatus 21, and the fiber bundle 22 is opened. The fibers are opened by rubbing or swinging with a plurality of bars included in the device 23 to form a belt-like fiber bundle 22a.
Next, a support 24 is supplied from the supply device 25 to the lower surface side of the opened belt-like fiber bundle 22 a, and the fiber bundle 22 a is supported from below by the support 24, and the fiber bundle 22 a together with the support 24. Send to cutting device 26.
Then, the cutting device 26 irradiates laser light from the upper surface side of the fiber bundle 22a on which the support 24 is disposed, and scans and cuts a predetermined position of the fiber bundle 22a. The cutting line 11 is formed (cutting step).
In this example, since the strip-shaped fiber bundle 22a that is the object to be cut is continuously sent to the cutting device 26 at a predetermined supply speed, the cutting device 26 has a direction in consideration of the supply speed of the fiber bundle 22a and The laser beam is scanned at a speed to continuously form a plurality of cutting lines 11.

ついで、切断工程後の繊維束２２ｂと、その下面側に配置された支持体２４とを共に、繊維束２２ｂが内側となるように巻取装置２７で巻き取る（巻取工程）。繊維束２２ｂが内側に位置するように巻き取ると、すでに切断線１１が形成されている状態の繊維束２２ｂが、巻回物の外側に向けてばらけてフィラメントの配向が乱れてしまうことがない。
このような方法により、支持体２４に支持された巻回物の形態で、一方向不連続繊維帯１０を得ることができる。 Next, the fiber bundle 22b after the cutting step and the support 24 arranged on the lower surface side thereof are both wound by the winding device 27 so that the fiber bundle 22b is on the inner side (winding step). If winding is performed so that the fiber bundle 22b is positioned on the inner side, the fiber bundle 22b in which the cutting line 11 has already been formed is scattered toward the outside of the wound product, and the orientation of the filament may be disturbed. Absent.
By such a method, the one-way discontinuous fiber band 10 can be obtained in the form of a wound product supported by the support 24.

こうして得られた一方向不連続繊維帯１０がプリプレグの製造に使用される場合には、図示略のプリプレグ化工程において、一方向不連続繊維帯１０に対して熱硬化性樹脂または熱可塑性樹脂を含浸させて、プリプレグを製造する。
得られたプリプレグは、製造する成形物の形状、強度などに応じて、複数枚重ねられて成形に供される。 When the unidirectional discontinuous fiber band 10 obtained in this way is used for the production of a prepreg, a thermosetting resin or a thermoplastic resin is applied to the unidirectional discontinuous fiber band 10 in a prepreg forming process (not shown). Impregnation to produce a prepreg.
A plurality of the obtained prepregs are stacked for use in molding according to the shape and strength of the molded product to be produced.

支持体２４としては、レーザ照射が反射もしくは透過することにより切断されない耐レーザ性を備え、少なくとも切断工程中に、繊維束２２ａを支持できるものであればよく、帯状（シート状、テープ状、フィルム状、ベルト状、バンド状など。）のものがよい。例えば、ＹＡＧレーザであればＰＥＴフィルムや、シリコーン樹脂やテフロン（登録商標）でコーティングされた紙であればよい。また、炭酸ガスレーザであればシリコーンフィルムやシリコーン又はテフロン（登録商標）でコーティングされた紙であればよい。   The support 24 may be any support as long as it has laser resistance not to be cut by reflection or transmission of laser irradiation and can support the fiber bundle 22a at least during the cutting process. Shape, belt shape, band shape, etc.). For example, a YAG laser may be a PET film, or a paper coated with silicone resin or Teflon (registered trademark). In addition, if it is a carbon dioxide laser, it may be a paper coated with a silicone film, silicone, or Teflon (registered trademark).

切断工程で照射するレーザ光の種類としては、例えば、炭酸ガスレーザやエキシマレーザなどの気体レーザ、ＹＡＧレーザやＹＶＯ４レーザなどの固体レーザ及びファイバーレーザなどが使用できるが、短時間の照射で繊維束を良好に切断できる点では、ＹＡＧレーザ及びＹＶＯ４レーザなどの固体レーザ及びファイバーレーザが好ましい。
切断工程で使用される切断装置２６としては、キーエンス製の型式ＭＤ−Ｆ３０００や型式ＭＤ−Ｖ９９００、ＳＵＮＸ製の型式ＬＰ−Ｚ２５０、ＬＰ−Ｇ０５０、ＬＰ−４３１Ｕ、Ａｄｖａｎｃｅｄ Ｏｐｔｏｗａｖｅｓ Ｃｏｒｐ製の型式ＡＷＡＶＥ−３５５−１５−１００Ｋなどが挙げられる。
また、レーザ出力、発振モード、走査する速度、パルス幅、パルス周波数などを繊維束２２aの材質、厚み、供給される速度、厚み方向の切断の度合いに応じて設定することが好ましい。 As the type of laser light irradiated in the cutting process, for example, a gas laser such as a carbon dioxide laser or an excimer laser, a solid-state laser such as a YAG laser or a YVO 4 laser, and a fiber laser can be used. Are preferable, solid lasers such as YAG laser and YVO 4 laser and fiber lasers are preferable.
As the cutting device 26 used in the cutting process, model MD-F3000, model MD-V9900 manufactured by Keyence, model LP-Z250 manufactured by SUNX, LP-G050, LP-431U, model AWAVE-355 manufactured by Advanced Optowaves Corp. -15-100K etc. are mentioned.
In addition, it is preferable to set the laser output, the oscillation mode, the scanning speed, the pulse width, the pulse frequency, and the like according to the material, the thickness, the supplied speed, and the degree of cutting in the thickness direction of the fiber bundle 22a.

このような製造方法では、以上説明したように、一方向連続繊維からなる繊維束２２ａの下面に、繊維束２２ａを支持する支持体２４を配置して切断工程を行う。
そのため、切断工程を行うにあたって繊維束２２ａを冷凍しなくても、繊維束２２ａを構成している炭素繊維フィラメントの配向を乱すことなく、レーザ光により繊維束２２ａの所望の箇所を切断することができる。よって、繊維束を冷凍するための冷凍装置や、切断後に繊維束を乾燥するための乾燥装置、さらには、冷凍のための液体窒素などの液化ガスは一切必要なく、低コストで図１の例のような一方向不連続繊維帯１０を連続的に製造することができる。 In such a manufacturing method, as described above, the cutting step is performed by arranging the support 24 that supports the fiber bundle 22a on the lower surface of the fiber bundle 22a made of unidirectional continuous fibers.
Therefore, even when the fiber bundle 22a is not frozen when performing the cutting step, a desired portion of the fiber bundle 22a can be cut by laser light without disturbing the orientation of the carbon fiber filaments constituting the fiber bundle 22a. it can. Therefore, there is no need for a refrigeration apparatus for freezing the fiber bundle, a drying apparatus for drying the fiber bundle after cutting, or liquefied gas such as liquid nitrogen for freezing. The one-way discontinuous fiber band 10 can be continuously manufactured.

また、この例の製造方法では、切断工程の後に、繊維束２２ｂと支持体２４とを繊維束２２ｂが内側になるように巻き取る巻取工程をさらに有している。そのため、すでに切断線１１が形成されている状態の繊維束２２ｂが、巻回物の外側に向けてばらけてフィラメントの配向が乱れてしまうことがない。   Further, the manufacturing method of this example further includes a winding step of winding the fiber bundle 22b and the support 24 so that the fiber bundle 22b is inside after the cutting step. Therefore, the fiber bundle 22b in the state where the cutting line 11 is already formed is not scattered toward the outside of the wound product, and the filament orientation is not disturbed.

なお、この例では、繊維束２２ａの上面側に切断装置２６を配置し、レーザ光を繊維束２２ａの上面側より照射して切断線１１を形成しているが、繊維束２２ａの下面側にある支持体２４がレーザ光を透過する支持体の場合には、支持体２２はレーザ光により切断されずに繊維束２２ａを支持することができるため、切断装置２６を繊維束２２ａの下面側もしくは両側に配置して、繊維束２２ａの下面側もしくは両面側よりレーザ光を照射して切断線１１を形成してもよい。繊維束２２ａの両面側からレーザ光を照射する場合には、一方からのレーザ光と他方からのレーザ光により、繊維束２２ａを両面側から切断することにより、厚み方向に貫通した切断線１１を形成してもよい。   In this example, the cutting device 26 is arranged on the upper surface side of the fiber bundle 22a, and the cutting line 11 is formed by irradiating the laser beam from the upper surface side of the fiber bundle 22a, but on the lower surface side of the fiber bundle 22a. In the case where a certain support 24 is a support that transmits laser light, the support 22 can support the fiber bundle 22a without being cut by the laser light, so the cutting device 26 is connected to the lower surface side of the fiber bundle 22a or The cutting line 11 may be formed by irradiating the laser beam from the lower surface side or the both surface side of the fiber bundle 22a. When irradiating the laser beam from both sides of the fiber bundle 22a, the cutting line 11 penetrating in the thickness direction is cut by cutting the fiber bundle 22a from both sides with the laser beam from one side and the laser beam from the other side. It may be formed.

なお、この例では、繊維材料として炭素繊維を例示したが、炭素繊維以外の繊維、例えばアラミド繊維などであってもよい。しかしながら、上述の切断工程によれば、配向を乱さずに切断することがより難しい炭素繊維であっても、良好に切断することができる。   In this example, carbon fibers are exemplified as the fiber material, but fibers other than carbon fibers, such as aramid fibers, may be used. However, according to the above-described cutting step, even a carbon fiber that is more difficult to cut without disturbing the orientation can be cut well.

また、この例では、一方向不連続繊維帯１０として、長手方向の複数箇所Ｐｎそれぞれにおいて、複数の切断線１１が断続的に形成されているものを例示した。しかしながら、一方向不連続繊維帯１０を構成する各フィラメントが、切断工程により短繊維になっている限り、各箇所Ｐｎそれぞれにおける切断線の本数は１本であってもよい。
また、この例では、一方向不連続繊維帯１０として、長手方向に隣り合う箇所では、切断線１１の幅方向における配置位置が互い違いにずれるパターンで切断線１１が形成されたものを例示した。しかしながら、一方向不連続繊維帯１０を構成する各フィラメントが、切断工程により短繊維になっている限り、切断線１１の形成パターンには特に制限はない。例えば図１の例のように一定の規則性をもったパターンでもよいし、規則性のないランダムなパターンであってもよい。また、各切断線１１の長さ、切断線１１の本数、間隔Ｑ１、Ｑ２などにも制限はない。
また、この例では、一方向不連続繊維帯１０として、各切断線１１が厚み方向に貫通して形成されているものを例示した。しかしながら、一方向不連続繊維帯１０を構成する各フィラメントが、切断工程により短繊維になっている限り、すべての切断線が厚み方向に貫通している必要はない。 Further, in this example, the one-way discontinuous fiber band 10 is exemplified in which a plurality of cutting lines 11 are intermittently formed at each of a plurality of locations Pn in the longitudinal direction. However, as long as each filament constituting the unidirectional discontinuous fiber band 10 is a short fiber by the cutting process, the number of cutting lines at each location Pn may be one.
Further, in this example, the one-way discontinuous fiber band 10 is illustrated in which the cutting lines 11 are formed in a pattern in which the arrangement positions in the width direction of the cutting lines 11 are staggered in places adjacent to each other in the longitudinal direction. However, as long as each filament constituting the unidirectional discontinuous fiber band 10 is a short fiber by the cutting process, the formation pattern of the cutting line 11 is not particularly limited. For example, a pattern having a certain regularity as in the example of FIG. 1 or a random pattern having no regularity may be used. The length of each cut line 11, the number of cutting lines 11, there is no limitation to such interval Q 1, Q 2.
Further, in this example, the one-way discontinuous fiber band 10 is illustrated in which each cutting line 11 is formed penetrating in the thickness direction. However, as long as each filament constituting the unidirectional discontinuous fiber band 10 is a short fiber by the cutting process, it is not necessary that all cutting lines penetrate in the thickness direction.

さらに、この例では、各切断線１１の方向が一方向不連続繊維プリプレグ１０の幅方向と一致しているものを例示した。しかしながら、各切断線１１の方向は、繊維方向と交差する方向であればよい。ただし、レーザ光の照射されるスポット径による切断幅の点からは、各切断線１１の方向は、繊維方向に対する角度が２〜１７８°となる範囲内であることが好ましい。更に好ましくは３０〜１５０°の範囲がよい。なお、各切断線の方向は、一致していなくてもよい。   Furthermore, in this example, the case where the direction of each cutting line 11 coincides with the width direction of the unidirectional discontinuous fiber prepreg 10 is illustrated. However, the direction of each cutting line 11 may be a direction that intersects the fiber direction. However, from the viewpoint of the cutting width depending on the spot diameter irradiated with the laser beam, the direction of each cutting line 11 is preferably within a range where the angle with respect to the fiber direction is 2 to 178 °. The range of 30 to 150 ° is more preferable. In addition, the direction of each cutting line does not need to correspond.

また、この例では、一方向不連続繊維帯１０として、１束の一方向連続繊維からなる繊維束（長繊維束（繊維材料））から形成されたものを例示したが、複数本の一方向連続繊維束が幅方向に並べられた繊維材料から形成されたものであってもよい。その場合、巻出装置から複数の繊維束を幅方向に並べた状態で巻き出せばよい。このような方法によれば、幅の大きな一方向不連続繊維帯を得ることができる。
以上説明したように、切断線１１の形成パターン、本数、間隔、方向や、切断工程に供給される長繊維束の本数などは、得られた一方向不連続繊維帯を用いたプリプレグの用途や、成形品に求められる物性などに応じて適宜設計でき、特に制限はない。 In this example, the unidirectional discontinuous fiber band 10 is illustrated as being formed from a fiber bundle (long fiber bundle (fiber material)) made of one bundle of unidirectional continuous fibers. The continuous fiber bundle may be formed from a fiber material arranged in the width direction. In that case, what is necessary is just to unwind in the state which arranged the several fiber bundle from the unwinding apparatus in the width direction. According to such a method, a wide unidirectional discontinuous fiber band can be obtained.
As explained above, the formation pattern of the cutting line 11, the number, the interval, the direction, the number of long fiber bundles supplied to the cutting process, and the like are used for the prepreg using the obtained unidirectional discontinuous fiber band. Further, it can be appropriately designed according to the physical properties required for the molded product, and there is no particular limitation.

１０ 一方向不連続繊維帯
１１ 切断線
２２ａ 帯状の繊維束（繊維材料）
２４ 支持体
２６ 切断装置 10 Unidirectional discontinuous fiber band 11 Cutting line 22a Band-shaped fiber bundle (fiber material)
24 support body 26 cutting device

Claims (2)

一方向連続繊維からなる帯状の繊維材料にレーザ光を照射して、前記繊維材料の長手方向の複数箇所において、繊維方向に対する角度が２〜１７８°となる範囲内で一方向不連続繊維帯とする切断線を形成する切断工程を有し、
該切断工程では、前記繊維材料の下面に、レーザ照射が透過することにより切断されない耐レーザ性を備えた支持体を配置して、前記繊維材料を支持し、前記繊維材料の下面側もしくは両面側よりレーザ光を照射して、前記繊維材料を切断する、一方向不連続繊維帯の製造方法。 By irradiating a belt-shaped fiber material composed of unidirectional continuous fibers with laser light, and at a plurality of positions in the longitudinal direction of the fiber material, the unidirectional discontinuous fiber band is within a range where the angle with respect to the fiber direction is 2 to 178 ° Having a cutting step to form a cutting line to
In the cutting step, the lower surface of the fibrous material, by arranging a support having a resistance to laser of not cleaved by excessive laser irradiation GaToru, supporting the fibrous material, the lower surface or both surfaces of said fibrous material A method for producing a unidirectional discontinuous fiber band , wherein the fiber material is cut by irradiating a laser beam from the side . 前記切断工程の後に、前記繊維材料と前記支持体とを前記繊維材料が内側になるように巻き取る巻取工程をさらに有する、請求項１に記載の一方向不連続繊維帯の製造方法。   The manufacturing method of the unidirectional discontinuous fiber belt of Claim 1 which further has a winding-up process which winds up the said fiber material and the said support body after the said cutting process so that the said fiber material becomes an inner side.
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