JP6711411B2 - Prepreg sheet manufacturing equipment - Google Patents

Description

The present disclosure relates to a prepreg sheet manufacturing apparatus.
The present application claims priority based on Japanese Patent Application No. 2016-220300, which was filed in Japan on November 11, 2016, and the content thereof is incorporated herein.

Conventionally, CFRP and GFRP using carbon fiber or glass fiber as a reinforcing fiber are lightweight and have high durability, and thus have been used as various structural members constituting automobiles, aircrafts, and the like. As a method of molding such CFRP or GFRP, first, a plurality of prepreg sheets having a thickness of about several tens to several hundreds μm made of reinforcing fibers and a resin are laminated to produce a prepreg sheet laminate, and then, A method is known in which a plurality of prepreg sheet laminates having slightly different outer shapes are stacked to form a desired three-dimensional shape.

A prepreg sheet laminate is manufactured by laminating a plurality of prepreg sheets. The prepreg sheet has very high tensile strength and toughness in the fiber direction (fiber length direction), that is, the orientation direction, but the fiber direction In the direction orthogonal to, the tensile strength and toughness are low, and therefore the mechanical properties are anisotropic. Therefore, in the prepreg sheet laminated body, in order to relax the anisotropy of the prepreg sheet, the prepreg sheets are laminated with different fiber directions.

In order to stack prepreg sheets having different fiber directions, a prepreg original sheet in which the fiber directions are aligned in the length direction of the sheet, that is, a fiber angle of 0° is used to produce a prepreg cut sheet having an arbitrary fiber direction, It is conceivable to laminate a prepreg cut sheet having an arbitrary fiber direction on a prepreg original fabric having a fiber angle of 0°.

As an apparatus for manufacturing such a prepreg sheet, for example, a prepreg sheet manufacturing apparatus described in Patent Document 1 is known. This prepreg sheet manufacturing apparatus is an apparatus for manufacturing a prepreg sheet by joining a plurality of cut prepreg cut sheets in the front-rear direction on the prepreg material web and stacking them on the prepreg material web. This prepreg sheet manufacturing apparatus, a main conveyance path for traveling the prepreg raw fabric and the prepreg cut sheet placed on the prepreg raw fabric, the preceding prepreg cut sheet and the following prepreg cut sheet on the prepreg raw fabric, A gap detecting device for detecting a gap between the two, and a welding device for welding between the trailing edge of the preceding prepreg cut sheet and the leading edge of the following prepreg cut sheet through the prepreg raw fabric. There is.

International Patent Application Publication No. 2015/152325

In the prepreg sheet manufacturing apparatus described in Patent Document 1, a gap detection device is provided to manage the gap between the preceding prepreg cut sheet and the following prepreg cut sheet on the prepreg original fabric. However, when the prepreg cut sheet is thin, and the edges of the prepreg cut sheet are fluffed minutely, it is difficult to detect the gap from the step between the prepreg original fabric and the prepreg cut sheet with a distance sensor, etc. There is. For this reason, the inventors of the present application studied to insert a perforated plate between the prepreg original fabric and the prepreg cut sheet to increase the step between the prepreg original fabric and the prepreg cut sheet.
However, when the perforated plate is inserted, a space is created between the prepreg raw sheet and the prepreg cut sheet, and there is a concern that the prepreg cut sheet may be welded to the prepreg original sheet in a bulged state. Such a prepreg sheet has so-called ruggedness, and there is a problem that cracks and wrinkles occur when it is put in a roller press and cut in a later step.

The present disclosure has been made in view of the above problems, and an object of the present disclosure is to provide a prepreg sheet manufacturing apparatus capable of suppressing ruggedness that causes cracks and wrinkles.

In order to solve the above problems, the first aspect of the present disclosure is a main transport path that runs a prepreg raw fabric, and a transfer device that places a plurality of cut prepreg cut sheets on the prepreg raw fabric. , A gap detection device that detects a gap between the preceding prepreg cut sheet and the following prepreg cut sheet on the prepreg sheet, and the trailing edge of the preceding prepreg cut sheet and the leading edge of the following prepreg cut sheet. The prepreg sheet manufacturing apparatus is provided with a welding device for welding the space between the prepreg original fabrics and a pressing device for pressing the preceding prepreg cut sheet in a flat shape on the downstream side of the welding device.

According to the present disclosure, a gap detection device that detects a gap between a preceding prepreg cut sheet and a succeeding prepreg cut sheet on a prepreg original fabric, and a trailing edge of the preceding prepreg cut sheet and a succeeding prepreg cut sheet. A welding device for welding the front end edge of the sheet via the prepreg raw fabric, and a pressing device for pressing the preceding prepreg cut sheet in a planar shape on the downstream side of the welding device. Therefore, the space formed between the prepreg original fabric and the prepreg cut sheet becomes small. As a result, the bulging of the prepreg cut sheet after welding is reduced, and a prepreg sheet with less roughness can be manufactured. That is, by pressing the prepreg cut sheet in a plane using a pressing device, the wrinkles of the prepreg cut sheet after welding are stretched, and as a result, in the prepreg sheet laminate cut into the roller press machine, cracks or Wrinkles can be prevented.

It is a top view which shows typically one Embodiment of the prepreg sheet manufacturing apparatus of this indication. It is a side view which shows typically one embodiment of the prepreg sheet manufacturing apparatus of this indication. It is a schematic diagram for demonstrating the prepreg sheet laminated body formed by the prepreg sheet manufacturing apparatus. It is a perspective view showing a schematic structure of a cutting device. It is a front view showing a schematic structure of a gap detection device. It is a perspective view showing a schematic structure of a pressing device. It is a side view which shows schematic structure of a pressing device. FIG. 8 is a side view showing a state of the first prepreg cut sheet after welding when a pressing device is not provided as a comparative example.

Hereinafter, the prepreg sheet manufacturing apparatus of the present disclosure will be described in detail with reference to the drawings. In the following drawings, the scale of each member is appropriately changed in order to make each member recognizable.
FIG. 1 is a plan view schematically showing an embodiment of the prepreg sheet manufacturing apparatus of the present disclosure, and FIG. 2 is a side view schematically showing an embodiment of the prepreg sheet manufacturing apparatus of the present disclosure. In these drawings, reference numeral 1 is a prepreg sheet manufacturing apparatus.

The prepreg sheet manufacturing apparatus 1 travels on the main transport path 3 and a feeding device 2 that feeds a roll-shaped prepreg raw fabric P1, a main transport path 3 that runs the prepreg raw fabric P1 that is fed from the roll feeding device 2. And a feeding device 4 for drawing the prepreg sheet laminate P5 and sending it further downstream. In addition, the prepreg sheet manufacturing apparatus 1 includes a first prepreg cut sheet forming unit 5 that forms the first prepreg cut sheet P2 and a second prepreg cut sheet forming unit 14 that forms the second prepreg cut sheet P4. , Is provided.

Further, the prepreg sheet manufacturing apparatus 1 includes a gap detection device 10 or 19 (see FIG. 1) that detects a gap between the prepreg cut sheets arranged in front and back, and a welding device that welds the prepreg cut sheets arranged in front and rear. 11 and 20 (see FIG. 2). Furthermore, the prepreg sheet manufacturing apparatus 1 is provided with a pressing device 40 that presses the prepreg cut sheet in a planar shape on the downstream side of each of the welding devices 11 and 20.

The prepreg original fabric P1 is formed by impregnating a reinforcing fiber (fiber) such as carbon fiber or glass fiber with a thermoplastic resin or a thermosetting resin to a thickness of about 50 to 300 μm, and the reinforcing fiber (fiber) is constant. It is formed so that it is aligned in the direction and oriented.

FIG. 3 is a schematic diagram for explaining the prepreg sheet laminate P5 formed by the prepreg sheet manufacturing apparatus 1. As shown in FIG. 3, in this embodiment, the prepreg raw fabric P1 is oriented so that the direction (length direction) of the reinforcing fibers F is substantially the same as the reference direction, that is, the length direction of the prepreg raw fabric P1. Has been formed. Therefore, the prepreg raw fabric P1 is a prepreg raw fabric in which the orientation of the reinforcing fibers F is 0°.

As shown in FIGS. 1 and 2, the feeding device 2 has rollers and is configured to feed the prepreg original fabric P1 wound in a roll shape in the length direction thereof and to deliver it to the main transport path 3. There is. Here, the prepreg original fabric P1 is fed onto the main transport path 3 by being pulled by the feeding device 4 described later.

As shown in FIG. 1, the main conveyance path 3 has a linear shape (straight plate shape) having a width wider than the width of the prepreg raw fabric P1, and is formed so that the prepreg raw fabric P1 runs on its upper surface. There is. The upper surface of the main transport path 3 is formed as a smooth surface having a small frictional resistance so that the prepreg original fabric P1 can smoothly travel.

The feeding device 4 includes a pair of rollers 4a arranged vertically as shown in FIG. 2 and a drive source 4b such as a motor connected to either one of the pair of rollers 4a as shown in FIG. Have. The feeding device 4 holds the prepreg sheet laminate P5 traveling on the main transport path 3 between the pair of rollers 4a, and draws the prepreg sheet laminate P5 between the rollers 4a by the rotation of the roller 4a by the drive source 4b. It is configured to send to the downstream side. As shown in FIG. 3, the prepreg sheet laminate P5 is formed by sequentially stacking a first prepreg cut sheet P2, a prepreg original fabric P3, and a second prepreg cut sheet P4 on a prepreg raw fabric P1.

As shown in FIG. 1, the first prepreg cut sheet forming unit 5 is arranged on the upstream side of the main transport path 3. The first prepreg cut sheet forming unit 5 includes a feeding device 6 that feeds a roll-shaped prepreg raw fabric P1, a sub-conveying route 7 that runs the prepreg raw fabric P1 that is fed from the feeding device 6, and a sub-conveying route 7. A cutting device 8 that cuts the prepreg original fabric P1 traveling above in the width direction (direction crossing the sub transport path 7) at a preset angle. The prepreg raw fabric P1 delivered from the delivery device 6 is the same as the prepreg raw fabric P1 delivered to the main transport path 3 by the delivery device 2 described above. That is, it is a prepreg raw fabric in which the orientation of the reinforcing fibers F is 0°.

The feeding device 6 includes a feeding device 6a that feeds the roll-shaped prepreg raw fabric P1 and a feeding device 6b that feeds the roll-shaped prepreg raw fabric P1 fed by the feeding device 6a onto the sub-transport path 7. The feeding device 6a has a configuration similar to that of the feeding device 2 described above, and is configured to feed the prepreg original fabric P1 wound in a roll shape in the lengthwise direction and feed it to the sub-conveyance path 7. There is.

The feeding device 6b is formed similarly to the above-described feeding device 4, and has a pair of rollers 6c arranged vertically and a drive source 6d such as a motor connected to either one of the pair of rollers 6c. The feeding device 6b holds the prepreg raw fabric P1 fed from the feeding device 6a between a pair of rollers 6c, pulls the prepreg raw fabric P1 between the rollers 6c by the rotation of the roller 6c by the drive source 6d, and the sub-conveyance path. 7 is configured to be sent to the downstream side.

The sub transport path 7 is arranged on one side of the main transport path 3 and extends so as to be orthogonal to the main transport path 3. The sub-conveyance path 7 also has a linear shape (straight plate shape) having a width wider than the width of the prepreg original fabric P1 like the main conveyance path 3, and is formed so that the prepreg original fabric P1 runs on its upper surface. ing. The upper surface of the sub-conveyance path 7 is also formed as a smooth surface with low frictional resistance so that the prepreg original fabric P1 can smoothly travel.

The cutting device 8 is a device that cuts (cuts) the prepreg original fabric P1 running on the sub-conveyance path 7 in the width direction thereof at a preset angle. FIG. 4 is a perspective view showing a schematic configuration of the cutting device 8. As shown in FIG. 4, the cutting device 8 includes a cutter 8a, a holding bar 8b that movably holds the cutter 8a, and a pair of support portions 8c that support both ends of the holding bar 8b.

The cutter 8a is configured to reciprocate in the lengthwise direction of the holding bar 8b by a driving means such as a motor, thereby cutting the prepreg original fabric P1 by moving in the forward path and moving in the return path. It returns to the initial position and waits for a new disconnection.

The holding bar 8b has an elongated prismatic shape having a length sufficiently longer than the width of the prepreg original fabric P1, and is arranged above the sub-conveying path 7 so as to cross the sub-conveying path 7. Further, the holding bar 8b is configured to guide the cutter 8a in the length direction thereof.

The pair of support portions 8c movably support both ends of the holding bar 8b so that the angle of the holding bar 8b with respect to the prepreg original fabric P1 becomes a preset angle. In the present embodiment, the support portion 8c is configured such that the holding bar 8b intersects 45° (−45°) with respect to the fiber direction (orientation direction) of the prepreg raw fabric P1, that is, the length direction of the prepreg raw fabric P1. It supports the holding bar 8b.

The cutter 8a moves along the length direction of the holding bar 8b to cut the prepreg original fabric P1 in the width direction at an angle of 45° (−45°) with respect to the length direction. Here, the symbol "-" of -45° indicates that the length direction (orientation direction) of the reinforcing fiber F is shifted in the clockwise direction as shown in FIG. Therefore, when it is shifted in the counterclockwise direction, it is indicated by a sign "+".

Further, as shown in FIG. 4, the pair of support portions 8c are configured so that the angle of the holding bar 8b with respect to the prepreg original fabric P1 can be changed to an arbitrary angle. That is, the holding bar 8b is configured such that both ends of the holding bar 8b move in opposite directions of the length direction of the supporting bar 8d with respect to the individual supporting bar 8d directly supporting the holding bar 8b. Thereby, the angle with respect to the length direction of the prepreg original fabric P1 (the length direction of the reinforcing fiber F) is variable. Therefore, in this cutting device 8, for example, instead of cutting the prepreg original fabric P1 at an angle of “−45°”, it is also possible to cut it at, for example, “−30°” or “−60°”. ing. Furthermore, it is possible to cut at “+45°” or the like.

The cutting device 8 is controlled by a control device (not shown) so that the drive of the cutter 8a is interlocked with the operation of the feeding device 6b of the feeding device 6. That is, while the feeding operation of the prepreg raw fabric P1 by the feeding device 6b is temporarily stopped, the cutter 8a is driven to cut the prepreg raw fabric P1 at a preset angle, and the parallelogram shown in FIG. The first prepreg cut sheet P2 is formed. Further, in the sub-conveyance path 7, on the downstream side of the holding bar 8b, at a position where the first prepreg cut sheet P2 formed by cutting is held, a position generated by floating the first prepreg cut sheet P2. In order to prevent the displacement, a lifting prevention means including a suction hole is provided.

When the driving of the cutter 8a is stopped, the first prepreg cut sheet P2 is picked by the transfer hand 9 (transfer device) described later. Then, the prepreg original fabric P1 is again delivered by the feeder 6b. At this time, in the present embodiment, when the distance to be cut by the cutter 8a is indicated by the side L1 in FIG. 3, the length of the side L1 is √2 times the width of the prepreg original fabric P1. The drive of 6b and the cutter 8a is controlled.

As shown in FIGS. 1 and 2, the prepreg sheet formed by the first prepreg cut sheet forming unit 5, that is, the cutting device 8 is provided on the downstream side of the cutting device 8, that is, on the main conveyance path 3 side of the sub-conveyance path 7. A transfer hand 9 is provided for mounting the first prepreg cut sheet P2 shown in FIG. 3 cut (cut) on the prepreg original fabric P1 running on the main transport path 3.

As shown in FIG. 2, the transfer hand 9 holds the first prepreg cut sheet P2 by suction and holds the first prepreg cut sheet P2 in a horizontal plane, and rotates the holding section 9a on a horizontal plane to reinforce the reinforcing fibers of the first prepreg cut sheet P2. And a moving unit 9b for changing the direction (orientation) of F to a preset direction. The holding portion 9a is configured to detachably hold the first prepreg cut sheet P2 by vacuum suction. The moving unit 9b is formed by a robot arm, has a plurality of rotating shafts, and is configured to move the holding unit 9a in the horizontal direction, rotate the holding unit 9a around the axis, and raise and lower the holding unit 9a. ..

The transfer hand 9 having such a configuration holds the parallelogram-shaped first prepreg cut sheet P2 cut by the cutting device 8 by the holding portion 9a and the first prepreg cut sheet held by the moving portion 9b. The first prepreg cut sheet P2 is placed on the prepreg original fabric P1 by moving P2 onto the main conveyance path 3 and then detaching it from the holding portion 9a.

At that time, as shown in FIG. 3, the moving portion 9b causes the fiber direction (orientation direction) of the reinforcing fiber of the first prepreg cut sheet P2 to be a preset direction, that is, the reinforcing fiber of the prepreg original fabric P1. The first prepreg cut sheet P2 is appropriately rotated so as to be +45°, which is an angle different from the direction (orientation) of F, and is placed on the prepreg original fabric P1. Separately from such rotation, the first prepreg cut sheet P2 is moved along the upper surface of the prepreg original fabric P1 to the downstream side of the main transport path 3 as described later.

In this way, when the first prepreg cut sheet P2 is placed, the cutting side L2 and the cutting side L2 of the first prepreg cut sheet P2 are respectively located on the side end edges of the prepreg original fabric P1. Align. As a result, the first prepreg cut sheet P2 is placed without protruding from the prepreg original fabric P1, as shown in FIG.

The transfer hand 9 continuously transfers the first prepreg cut sheet P2 so that the first prepreg cut sheet P2 is almost free from the prepreg original sheet P1 traveling on the main transport path 3. , And arrange (place) in a continuous state without overlapping. However, the shape and size of the first prepreg cut sheet P2 obtained from the prepreg raw fabric P1 also vary due to variations in the width dimension of the prepreg raw fabric P1.

Therefore, in the present embodiment, as shown in FIG. 1, the gap detection device 10 is arranged in the main transport path 3. The gap detection device 10 includes a gap S between a preceding first prepreg cut sheet P2 and a succeeding first prepreg cut sheet P2 on the prepreg original sheet P1 traveling on the main conveyance path 3 (see a later-described figure). 6) is detected. FIG. 5 is a front view showing a schematic configuration of the gap detection device 10. As shown in FIG. 5, the gap detection device 10 includes a gap detection sensor 31 including a pair of sensors 30, and a spacer 35 that increases a step between the prepreg original fabric P1 and the prepreg cut sheet P2.

The sensor 30 is composed of a two-dimensional laser displacement sensor that detects a step between the prepreg original fabric P1 and the prepreg cut sheet P2. One of the pair of sensors 30 is arranged directly above one side end of the first prepreg cut sheet P2 in the width direction, and the other is the other side end of the first prepreg cut sheet P2 in the width direction. The sensor 30 is arranged immediately above the section, and is configured to detect the gap S at the measurement position immediately below the sensor 30. All of the pair of sensors 30 are held by the slider mechanism 34, whereby the position immediately above the side edge of the first prepreg cut sheet P2 and the side of the first prepreg cut sheet P2 are indicated by the arrow. It is configured to move between the outside of the end.

The spacer 35 is a perforated plate having a through hole 35a formed in the thickness direction. The spacer 35 is sandwiched between the prepreg raw fabric P1 and the prepreg cut sheet P2 to increase the step between the prepreg raw fabric P1 and the prepreg cut sheet P2, and to allow the sensor light passing through the gap S to pass through the through hole 35a. It is structured so that it does not block. The spacers 35 are provided in a pair corresponding to the pair of sensors 30, and are inserted into the lower surfaces of the respective side end portions of the first prepreg cut sheet P2. Each of the pair of spacers 35 is supported by the slider mechanism 36 so that it can be moved between a position directly below the sensor 30 and a position upstream of the sensor 30 (a welding device 11 described later). Is configured.

When the gaps S detected by the pair of sensors 30 are both within the allowable range, the gap S between the front and rear first prepreg cut sheets P2 and the first prepreg cut sheets P2 is set appropriately by the control device (not shown). Therefore, the welding described below is performed. On the other hand, when at least one of the gaps S exceeds the allowable range, the position of the first prepreg cut sheet P2 is readjusted by the transfer hand 9 in order to perform the alignment again. The transfer hand 9 rotates the first prepreg cut sheet P2 when the first prepreg cut sheet P2 is misaligned. Further, when the gaps S on both sides are substantially the same, the transfer hand 9 adjusts the gap S by shifting the preceding first prepreg cut sheet P2 in the traveling direction. In addition, as a content range of the gap S, for example, the upper limit is about several mm, and the lower limit is zero, that is, the first prepreg cut sheets P2 adjacent to each other on the prepreg original fabric P1 are in contact with each other unless they overlap. It is within the allowable range.

As shown in FIG. 5, the gap detection device 10 is provided with a welding device 11. The welding device 11 includes a heating unit 11a that heats the gap S of the first prepreg cut sheet P2 and its vicinity, an elevating mechanism 11b that elevates and lowers the heating unit 11a, and the heating unit 11a and the elevating mechanism 11b that make the gap S longer. The moving mechanism 11c for moving in the vertical direction is provided.

The heating unit 11a includes an ultrasonic welding machine, and the ultrasonic welding machine is provided with a gap S and its vicinity, that is, a trailing edge b of the preceding first prepreg cut sheet P2 (see FIG. 6) and a succeeding first prepreg cut sheet P2. The front edge f (see FIG. 6) of the prepreg cut sheet P2 is brought into contact with or brought close to it to heat them. When the heating unit 11a melts and solidifies the resin of the first prepreg cut sheet P2 and the prepreg raw sheet P1 therebelow, the front and rear first prepreg cut sheets P2 and P2 may be welded to each other. At the same time, the first prepreg cut sheet P2 and the prepreg original fabric P1 are welded. As the heating unit 11a, instead of the ultrasonic welding machine, a device having a structure of rolling a heated roller or a device having a structure of pressing a long heater wire can be used.

Here, the heating unit 11a can be moved up and down by the elevating mechanism 11b to come into contact with the first prepreg cut sheet P2 to heat it or separate from it. In addition, the heating unit 11a is configured to be able to heat all of the vicinity of the gap S by being moved in the length direction of the gap S by the moving mechanism 11c. At that time, if the pair of sensors 30 and the pair of spacers 35 are located directly above or below the gap S, they interfere with the movement of the heating unit 11a, and therefore need to be retracted.

When it is determined that the gap S between the front and rear first prepreg cut sheets P2 and the first prepreg cut sheet P2 is appropriate, the pair of sensors 30 is moved from immediately above the gap S to the outside by the slider mechanism 34. Are retracted (moved) to and do not interfere with the movement of the heating unit 11a. In addition, the pair of spacers 35 is moved from immediately below the gap S to its upstream side by the slider mechanism 36 when a part (a part excluding the side end portion) of the first prepreg cut sheet P2 is welded to the prepreg raw fabric P1. It is retracted (moved) and does not interfere with the movement of the heating unit 11a.

A pressing device 40 is arranged on the downstream side of the welding device 11 (gap detection device 10). FIG. 6 is a perspective view showing a schematic configuration of the pressing device 40. FIG. 7 is a side view showing a schematic configuration of the pressing device 40. As shown in FIGS. 6 and 7, in the pressing device 40, on the downstream side of the welding device 11, the preceding first prepreg cut sheet P2 (only the front edge f is welded, and the rear edge b is not welded). It is a device that presses a prepreg cut sheet) in a flat shape.

As shown in FIG. 6, the pressing device 40 includes a flat pressing plate 41, and a positioning pin 42 that positions the pressing plate 41 on the main transport path 3. The pressing plate 41 is a resin plate having a predetermined weight, and the upper surface 41a and the lower surface 41b thereof are formed as smooth surfaces with low frictional resistance. A through hole 43 is formed in the pressing plate 41. The positioning pin 42 is inserted into the through hole 43. The inner diameter of the through hole 43 is slightly larger than the outer diameter of the positioning pin 42. As shown in FIG. 7, the pressing plate 41 is positioned by a positioning pin 42 inserted into the through hole 43 so as to be vertically movable.

As shown in FIG. 6, the positioning pin 42 is arranged so that it can be inserted into the through hole 43 even when the upper surface 41a and the lower surface 41b of the pressing plate 41 are reversed. Specifically, the positioning pins 42 are provided in a pair on the virtual straight line orthogonal to the traveling direction of the prepreg original fabric P1 in the main transport path 3 with a space therebetween. Further, the through holes 43 of the pressing plate 41 are also provided in a pair with a similar spacing. In this way, the positioning pins 42 are arranged symmetrically with respect to the main transport path 3 so that the through holes 43 are formed even in the state where the upper surface 41a and the lower surface 41b of the pressing plate 41 are reversed. Can be inserted.

That is, among various constituent members that configure an automobile, an aircraft, and the like, there are members that are formed symmetrically because they are arranged on the left and right, for example. In the case of producing such a member having plane symmetry, its strength also needs to have plane symmetry, and therefore the fiber direction (orientation direction) of the reinforcing fibers of the prepreg sheet constituting the prepreg sheet laminate is also right and left. It is necessary to be plane-symmetric with the member. Specifically, a prepreg sheet laminate in which the first prepreg cut sheet P2 and the second prepreg cut sheet P4 are replaced with each other in order to impart plane symmetry to the prepreg sheet laminate P5 shown in FIG. To manufacture. At this time, as shown in FIG. 1, it is necessary to rotate the welding device 11 (gap detection device 10) to make the angle −45°. However, according to the pressing device 40 having the above configuration, the pressing plate 41 Since the upper and lower surfaces can be reversed and used, such an inverted prepreg sheet laminate can be manufactured by the same prepreg sheet manufacturing apparatus 1.

As shown in FIG. 6, the pressing plate 41 has a similar shape to the first prepreg cut sheet P2. That is, the pressing plate 41 is formed in a parallelogram in which the one end edge 41A and the other end edge 41B are inclined at 45° with respect to the traveling direction of the prepreg original fabric P1. The pressing plate 41 is formed to be slightly larger than the first prepreg cut sheet P2, and a through hole 43 is formed in a portion extending outside the prepreg original fabric P1. In addition, as shown in FIG. 7, when the trailing edge b of the preceding first prepreg cut sheet P2 is welded, the pressing plate 41 changes the leading edge f of the preceding prepreg cut sheet P2. The size is such that it can be pressed down including the welded portion 100.

The pressing plate 41 is formed with a taper portion 44 that guides the preceding first prepreg cut sheet P2 to the lower surface 41b side. The tapered portion 44 is formed on one end edge 41A and the other end edge 41B of the pressing plate 41. Further, the tapered portion 44 has a symmetrical shape on the upper surface 41a side and the lower surface 41b side of the pressing plate 41. The reason why the tapered portion 44 has a symmetrical shape is that the pressing plate 41 of the present embodiment can be used by reversing the upper and lower surfaces thereof. The height of the inclined surface of the tapered portion 44 may be about 2 to 5 times the thickness of the first prepreg cut sheet P2.

According to the pressing device 40 having the above-described configuration, as shown in FIG. 7, the preceding first prepreg cut sheet P2 can be pressed in a flat shape on the downstream side of the welding device 11, so that the first after welding is performed. The bulge of the prepreg cut sheet P2 can be reduced. FIG. 8 is a side view showing a state of the first prepreg cut sheet P2 after welding when the pressing device 40 is not provided as a comparative example. As shown in FIG. 8, when the pressing device 40 is not provided, a space 50 is formed between the prepreg original fabric P1 and the first prepreg cut sheet P2.

That is, as described above, since the spacer 35 (see FIG. 6) is sandwiched between the prepreg original fabric P1 and the first prepreg cut sheet P2, the floating of the first prepreg cut sheet P2 increases, When the welding is performed in this state, the first prepreg cut sheet P2 after the welding is swollen. On the other hand, in the present embodiment, as shown in FIG. 7, the pressing device 40 that presses the preceding first prepreg cut sheet P2 in a planar shape is provided on the downstream side of the welding device 11, and thus the prepreg original fabric P1 is provided. The floating of the first prepreg cut sheet P2 with respect to is small. For this reason, the bulging of the first prepreg cut sheet P2 after welding is reduced, and so-called wrinkling is reduced.

In other words, by pressing the preceding first prepreg cut sheet P2 in a flat shape using the pressing device 40, the wrinkles of the prepreg cut sheet after welding are extended, and as a result, the prepreg cut sheet P2 is applied to the roller press machine as described later. It is possible to prevent the occurrence of cracks and wrinkles in the prepreg sheet laminate that has been cut by putting it.

Here, as shown in FIG. 6, the pressing device 40 of the present embodiment includes a flat pressing plate 41 and a positioning pin 42 that positions the pressing plate 41 on the main transport path 3. According to this configuration, since the preceding first prepreg cut sheet P2 can be pressed by the wide plate surface of the pressing plate 41, the flatness of the preceding first prepreg cut sheet P2 is increased. Further, according to this configuration, since the weight of the pressing plate 41 is used, a separate drive source such as an elevating device is not required, and the cost can be reduced.

Further, in the present embodiment, as shown in FIG. 7, a through hole 43 is formed in the pressing plate 41, and the pressing plate 41 is moved in the vertical direction by the positioning pin 42 inserted in the through hole 43. Positioned as possible. According to this configuration, since the pressing plate 41 can escape in the vertical direction, the first prepreg cut sheet P2 that precedes the pressing plate 41 is not subjected to a load greater than the weight of the pressing plate 41. That is, an excessive load is not applied to the first prepreg cut sheet P2, and the first prepreg cut sheet P2 is not twisted due to the pressing by the pressing plate 41.

Further, in the present embodiment, as shown in FIG. 7, the pressing plate 41 is formed with a tapered portion 44 that guides the preceding first prepreg cut sheet P2 to the lower surface 41b side. According to this configuration, even if there is a step on the front edge f of the preceding first prepreg cut sheet P2, the first prepreg cut sheet P2 can be smoothly slipped into the lower surface 41b side of the pressing plate 41. Therefore, it is possible to prevent an excessive load from being applied to the first prepreg cut sheet P2.

Further, in the present embodiment, as shown in FIG. 7, when the trailing edge b of the preceding first prepreg cut sheet P2 is welded, the pressing plate 41 removes the preceding first prepreg cut sheet P2, The front end edge f is pressed down including the welded portion 100. As shown in FIG. 8, the floating of the first prepreg cut sheet P2 occurs from the welded portion 100 of the front edge f thereof, and thus according to this structure, the floating of the first prepreg cut sheet P2 is pressed from the beginning. be able to. Therefore, the floating of the first prepreg cut sheet P2 can be further reduced, and the wrinkles of the prepreg cut sheet P2 can be effectively extended over the entire area of the prepreg cut sheet P2.

Returning to FIG. 1, the delivery device 12 is disposed downstream of the pressing device 40. The feeding device 12 is disposed above the main transport path 3 and feeds another prepreg raw sheet P3 onto the laminate of the prepreg raw sheet P1 and the first prepreg cut sheet P2 traveling on the main transport passage 3. Is configured. As shown in FIG. 3, this prepreg raw fabric P3 is a prepreg raw fabric in which the same orientation of the reinforcing fibers F as in the prepreg raw fabric P1 is 0°.

As shown in FIG. 2, the feeding device 12 feeds a roll-shaped prepreg raw fabric P3 and a feed device that feeds the roll-shaped prepreg raw fabric P3 fed by the feeding device 12a onto the main conveyance path 3. 12b and. The feeding device 12a is configured to feed the prepreg original fabric P3 wound in a roll shape in the lengthwise direction thereof and also to temporarily feed it upward.

The feeding device 12b includes a plurality of rollers 12c and a drive source (not shown) such as a motor that is connected to the roller 12c arranged downstream of the rollers 12c to rotate the roller 12c. The feeding device 12b feeds the prepreg original fabric P3, which is fed from the feeding device 12a and once fed upward, from the upper side to the lower side by a plurality of rollers 12c, and feeds it onto the laminate traveling on the main transport path 3. Is configured.

Further, when the prepreg raw fabric P3 is fed onto the laminate in this way, the feeding device 12 causes the side edges of the prepreg raw fabric P3 to have the first prepreg cut sheet P2 in the laminate as shown in FIG. The cutting edge L2 is aligned with the cutting edge L2. As a result, as shown in FIG. 3, the prepreg raw sheet P3 is placed on the first prepreg cut sheet P2 without protruding from the first prepreg cut sheet P2.

A welding device 13 is disposed downstream of the delivery device 12 as shown in FIGS. The fusing device 13 is formed to have a heating part like the fusing device 11, and is the uppermost layer of the prepreg raw fabric P3 and the above-mentioned laminate as the lower layer, that is, the prepreg raw fabric P1 and the first prepreg. The laminate with the cut sheet P2 is welded and integrated.
In the present embodiment, the heating portion is run in the width direction of the prepreg raw fabric P3 shown in FIG. 3, that is, in the direction orthogonal to the length direction of the reinforcing fibers F, and the prepreg raw fabric P3 and the above-mentioned laminate as a lower layer thereof. The resin is melted and solidified, and the prepreg raw fabric P3 and the laminate are welded.

As shown in FIG. 1, a second prepreg cut sheet forming portion 14 is arranged downstream of the welding device 13. The second prepreg cut sheet forming unit 14 has substantially the same configuration as the first prepreg cut sheet forming unit 5, and has a feeding device 15 that feeds the roll-shaped prepreg original fabric P1 and a prepreg that is fed from the feeding device 15. It is provided with a sub-conveyance path 16 for traveling the original fabric P1, and a cutting device 17 for cutting (cutting) the prepreg original fabric P1 traveling on the sub-conveyance path 16 in a width direction thereof at a preset angle. ..

Here, the prepreg raw fabric P1 delivered from the delivery device 15 is also a prepreg raw fabric in which the orientation of the reinforcing fibers F is 0°, like the prepreg raw fabric P1 used in the first prepreg cut sheet forming unit 5.

The feeding device 15 includes a feeding device 15a that feeds the roll-shaped prepreg raw fabric P1, and a feeding device 15b that feeds the roll-shaped prepreg raw fabric P1 fed by the feeding device 15a onto the sub-transport path 16. The feeding device 15b includes a pair of rollers 15c arranged vertically, and a drive source 15d such as a motor that is connected to one roller 15c of the pair of rollers 15c to rotate the roller 15c.

Like the cutting device 8 of the first prepreg cut sheet forming unit 5, the cutting device 17 is a device that cuts the prepreg original fabric P1 running on the sub-conveyance path 16 in the width direction at a preset angle. Is. However, unlike the cutting device 17, the cutting device 8 cuts the prepreg original fabric P1 in the width direction at an angle of −45° to form the first prepreg cut sheet P2 shown in FIG. , The prepreg original fabric P1 is cut in the width direction at an angle of +45° to form a second prepreg cut sheet P4 shown in FIG.

When the driving of the cutter is stopped, the transfer hand 18 picks the second prepreg cut sheet P4. Then, the prepreg original fabric P1 is sent out by the feeding device 15b. At this time, in the present embodiment, when the distance to be cut by the cutter is indicated by the side L3 in FIG. 3, the length of the side L3 is √2 times the width of the prepreg original fabric P1, so that the feeding device 15b is provided. And the drive of the cutter is controlled.

The transfer hand 18 holds the second parallelogram-shaped second prepreg cut sheet P4 cut by the cutting device 17 by the holding unit 18a, and the second prepreg cut sheet P4 held by the moving unit 18b. The second prepreg cut sheet P4 is placed on the prepreg original fabric P3 (laminate) by moving it upward and then detaching it from the holding portion 18a.

At that time, as shown in FIG. 3, the holding portion 18a causes the reinforcing fibers F of the second prepreg cut sheet P4 to have a predetermined orientation (orientation), that is, the prepreg original fabric P1 and the first prepreg fabric sheet P1. The second prepreg cut sheet P4 is placed on the prepreg raw sheet P3 (laminate) so that the prepreg cut sheet P2 and the prepreg original sheet P3 have an angle of −45° which is different from the direction (orientation) of the reinforcing fibers F. Place it.

As shown in FIG. 1, a gap detection device 19 is arranged slightly downstream of the sub-transport path 16 in the main transport path 3. The gap detection device 19 has substantially the same configuration as the gap detection device 10, and thus the front and rear second prepreg cut sheets P4 and P4 do not overlap and fall within a preset range. It is continuously arranged in the front and rear with the adjusted gap S.

Further, the gap detection device 19 is also provided with a welding device 20 as shown in FIG. The welding device 20 also has substantially the same configuration as the welding device 11, and welds the front and rear second prepreg cut sheets P4 together with the second prepreg cut sheet P4 and the laminated material (prepreg raw sheet) below the second prepreg cut sheet P4. P3) is welded and integrated.

As shown in FIGS. 1 and 2, a pressing device 40 is arranged downstream of the welding device 20. The pressing device 40 also has substantially the same configuration as the pressing device 40 shown in FIG. 6, and the second prepreg cut sheet P4 that precedes the pressing device 40 is pressed flatly on the downstream side of the welding device 20 so that The bulge of the second prepreg cut sheet P4 is reduced.

A welding device 21 is disposed downstream of the pressing device 40 as shown in FIGS. 1 and 2. The fusing device 21 re-fuses the laminated body fused and integrated by the fusing device 20, that is, the uppermost second prepreg cut sheet P4 and the laminated body which is a lower layer thereof. At this time, the welding device 21 causes the heating unit to run in the width direction of the second prepreg cut sheet P4 shown in FIG. 3, that is, in the direction orthogonal to the cutting side L4, and the second prepreg cut sheet P4 and the second prepreg cut sheet P4. The resin of the lower layer of the laminate is melted and solidified, and the second prepreg cut sheet P4 and the layer of the laminate are welded. That is, by welding at a different angle from the welding device 20, the obtained laminate is more firmly integrated. As a result, the prepreg sheet laminate P5 is formed as shown in FIG.

The prepreg sheet laminate P5 formed in this way is drawn into the feeding device 4 as described above, and is made to travel to the downstream side of the main transport path 3.
A cutting device 22 is disposed on the downstream side of the feeding device 4 as shown in FIGS. The cutting device 22 has a cutter similar to the cutting device 8 and the cutting device 17, and the prepreg sheet laminated product P5 in the width direction thereof, that is, the reinforcing fibers F of the prepreg raw fabric P1 and the prepreg raw fabric P3 shown in FIG. By cutting in a direction orthogonal to the length direction, a rectangular prepreg sheet laminated body P6 is formed as shown in FIG.

The prepreg sheet laminated body P6 thus formed is sequentially accommodated in the accommodation box 23 arranged on the downstream side of the main transport path 3 as shown in FIG. In the next step, the prepreg sheet laminated body P6 is put into a roller press and cut into an appropriate shape, and a plurality of the obtained prepreg sheet laminated body P6 are further laminated to form a desired three-dimensional shape. It

As described above, the prepreg sheet manufacturing apparatus 1 of the present embodiment places the main transport path 3 on which the prepreg raw fabric P1 travels and the plurality of cut first prepreg cut sheets P2 on the prepreg raw fabric P1. A gap detecting device 10 for detecting a gap S between the transfer hand 9, the preceding first prepreg cut sheet P2 on the prepreg original fabric P1 and the succeeding first prepreg cut sheet P2, and the preceding gap detecting device 10. A welding device 11 for welding between the rear edge b of the first prepreg cut sheet P2 and the front edge f of the subsequent first prepreg cut sheet P2 via the prepreg raw fabric P1 and the downstream side of the welding device 11. The pressing device 40 that presses the preceding first prepreg cut sheet P2 in a flat shape. Therefore, the space formed between the prepreg original fabric P1 and the first prepreg cut sheet P2 becomes small. As a result, the bulge of the first prepreg cut sheet P2 after welding is reduced, and the prepreg sheet laminate P6 with less ruggedness (extended wrinkles of the prepreg cut sheet) can be manufactured. Such a prepreg sheet laminate P6 can be formed into a good shape because cracks and wrinkles are less likely to occur even when cut in a roller press.

Although the preferred embodiments of the present disclosure have been described above with reference to the drawings, the present disclosure is not limited to the above embodiments. The shapes, combinations, and the like of the constituent members shown in the above-described embodiments are examples, and can be variously changed based on design requirements and the like without departing from the gist of the present disclosure.

For example, in the above-described embodiment, the case of manufacturing a laminated body having a four-layer structure as the prepreg sheet to be manufactured has been described, but for example, the main transport path 3, the first prepreg cut sheet forming unit 5, the transfer hand 9, and the gap detection device. By providing the welding device 10 and the welding device 11, the first prepreg cut sheet P2 can be joined together to produce a single-layer prepreg sheet.

Further, in the above-described embodiment, the orientation angle of the reinforcing fibers F of the first prepreg cut sheet P2 and the second prepreg cut sheet P4 is +45° or −45°, but the cutting device 8 and the cutting device 17 are held. By adjusting the angle of the bar, for example, +30° (−30°) or +60° (−60°) may be set.

The wrinkles of the prepreg cut sheet after welding can be extended, and cracks and wrinkles can be prevented from occurring in the prepreg sheet laminate cut in the roller press machine.

1 Prepreg sheet manufacturing device 3 Main transport path 9 Transfer hand (transfer device)
10 Gap Detection Device 11 Welding Device 18 Transfer Hand (Transfer Device)
19 Gap detection device 20 Welding device 40 Pressing device 41 Pressing plate 41a Upper surface 41b Lower surface 42 Positioning pin 43 Through hole 44 Tapered portion 100 Welding point b Rear edge f Front edge P1 Prepreg original sheet P2 First prepreg cut sheet (prepreg cut) Sheet)
P3 Prepreg original sheet P4 Second prepreg cut sheet (prepreg cut sheet)
P5 prepreg sheet laminate (prepreg sheet)
P6 prepreg sheet laminate (prepreg sheet)
S gap

Claims (6)

Main transport path for running the prepreg material,
On the prepreg original fabric, a transfer device for mounting a plurality of cut prepreg cut sheets,
A gap detection device that detects a gap between the preceding prepreg cut sheet and the following prepreg cut sheet on the prepreg raw sheet,
A welding device for welding between the rear edge of the preceding prepreg cut sheet and the front edge of the subsequent prepreg cut sheet through the prepreg raw fabric,
On the downstream side of the welding device, a pressing device that presses the preceding prepreg cut sheet in a planar shape ,
The pressing device is
A flat pressing plate,
A positioning pin for positioning the pressing plate on the main transport path,
Prepreg sheet manufacturing equipment. A through hole is formed in the pressing plate,
The pressing plate is positioned so as to be vertically movable by the positioning pin inserted into the through hole.
The prepreg sheet manufacturing apparatus according to claim 1. The positioning pin is arranged so that it can be inserted into the through hole even when the upper and lower surfaces of the pressing plate are inverted.
The prepreg sheet manufacturing apparatus according to claim 2. The pressing plate has a shape similar to that of the prepreg cut sheet,
The prepreg sheet manufacturing apparatus according to claim 1 . The pressing plate is formed with a taper portion that guides the preceding prepreg cut sheet to the lower surface side,
The prepreg sheet manufacturing apparatus according to claim 1 . The pressing plate is formed with a taper portion that guides the preceding prepreg cut sheet to the lower surface side,
The prepreg sheet manufacturing apparatus according to claim 4 .

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