JP7085098B2 - 複合シートの成形方法及び成形装置 - Google Patents
複合シートの成形方法及び成形装置 Download PDFInfo
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Description
わせて含浸処理することで、繊維シート内へ熱硬化性樹脂材料が短時間で満遍なく含浸するようになり、熱硬化性樹脂プリプレグシートを繊維の真直性及び樹脂含浸性に優れた高品質な状態で高速に製造することができる。 さらに、複合シートを重ね合わせて処理するので、加圧力を低減しても樹脂の含浸性良くプリプレグシートを製造でき、かつ加圧力を低減するため副資材である離型紙又は離型シートへのダメージを少なくでき繰り返し使用可能となるため、トータル的に副資材である離型紙又は離型シートの使用量を少なくすることが可能となる。
する。よって、前記樹脂転移シートRSに塗布されている前記熱硬化性樹脂材料Rは前記繊維シートCSの片面に加圧され、各繊維と接着又は各繊維間に浸透し易くなる。なお、図1では、加熱ロール31は1本であるが、2本以上配列させ、重ね合っている前記繊維シートCSと前記樹脂転移シートRSの加熱ロールへの接触長さを長くして走行させても良い。このことで、成形速度を高速化させても熱硬化性樹脂材料Rは十分に加熱させることができる。
洞管513の上方開口部がガイドロール511の間に所定幅で形成されている。風洞管513の下側には流量調整バルブ514及び吸気ポンプ515が取り付けられている。吸気ポンプ515を作動させて風洞管513内の空気を吸引することで、ガイドロール511の間の上方開口部において吸引による下降気流が発生する。そして、流量調整バルブ514により下降気流の流量を調整することができる。
シートTSに熱硬化性樹脂材料Rを坦持させながら、繊維シートCSの片面に熱硬化性樹脂材料を転移させ付着させる方法は、転移シートに熱硬化性樹脂材料を坦持させる工程と、繊維シートに熱硬化性樹脂材料を転移させ複合シートを製造する工程を同時に行うため、工程の短縮となり、成形コストの低減につながる効果がある。
シートFSを構成する繊維シートCSの片面に熱硬化性樹脂材料Rが固形状態で付着する、好ましくは繊維シートCSの片面全面に付着することで、複合シートFSに張力が負荷されても、しわや幅収縮などが防止できる。繊維シートCSと熱硬化性樹脂材料Rが部分的に付着つまり繊維シートCSに熱硬化性樹脂材料Rが付着していない部分があったり、付着度合いが弱い場合つまり複合シートFSに張力が負荷したときに繊維シートCSが固形状の熱硬化性樹脂材料Rから離れる部分があったりすると、複合シートFSに張力が負荷されるとしわや幅収縮などを生じ、含浸処理部7への安定した供給ができなくなってしまう。
製 Physica MCR301)を用いて行った。
Claims (19)
- 繊維シートに熱硬化性樹脂材料を含浸させた熱硬化性樹脂プリプレグシートを製造するために用いられる複合シートの成形方法であって、転移シートの片面に密度ρRg/cm3の熱硬化性樹脂材料を目付量WRg/m2で所定の厚さに担持させた樹脂転移シートを、密度ρCg/cm3の繊維を目付量WCg/m2で構成した前記繊維シートの片面に重なり合うよう接触させ、重なり合った状態の前記樹脂転移シートと前記繊維シートを加熱又は加熱加圧処理し、加熱された重なり合った状態の前記樹脂転移シートと前記繊維シートを前記熱硬化性樹脂材料の粘度が10000Pa・s以上となる温度まで冷却又は冷却加圧処理することで、前記熱硬化性樹脂材料を前記繊維シートに転移させて、厚さが[{(WC/ρC)/1000}+{(WR/ρR)/1000}]mmより厚く、かつ前記繊維シートの片面側に前記熱硬化性樹脂材料の一部が層状に形成されて一体化するように付着させる複合シートの成形方法。
- 重なり合った状態の前記樹脂転移シートと前記繊維シートを加熱又は加熱加圧処理するとき、加熱温度が30℃~80℃の範囲であり、前記加熱温度における前記熱硬化性樹脂材料の粘度が100000Pa・s以下である請求項1に記載の複合シートの成形方法。
- 前記転移シートの片面に前記熱硬化性樹脂材料を坦持させながら連続して前記繊維シートの片面に接触させる請求項1から2のいずれかに記載の複合シートの成形方法。
- 前記繊維シートは、目付量が10g/m2~80g/m2である請求項1から3のいずれかに記載の複合シートの成形方法。
- 前記転移シートに担持される熱硬化性樹脂材料は、目付量が10g/m2~55g/m2である請求項1から4のいずれかに記載の複合シートの成形方法。
- 前記転移シートに坦持される前記熱硬化性樹脂材料は、前記転移シートに塗布されて坦持される請求項1から5のいずれかに記載の複合シートの成形方法。
- 前記転移シートは、無端状に形成されている請求項1から6のいずれかに記載の複合シートの成形方法。
- 前記繊維シートは、開繊処理により形成される請求項1から7のいずれかに記載の複合シートの成形方法。
- 前記樹脂転移シートを前記繊維シートの片面に重なり合うよう接触させた後、前記繊維シートの前記樹脂転移シートと接触していないもう一方の片面に離型シートを重なり合うよう接触させる請求項1から8のいずれかに記載の複合シートの成形方法。
- 請求項1から9のいずれかに記載された複合シートの成形方法により成形された複合シートを加熱加圧処理により前記繊維束中に熱硬化性樹脂材料を含浸させて成形する熱硬化性樹脂プリプレグシートの製造方法。
- 前記複合シートに対して熱硬化性樹脂材料が転移された面側に別の繊維シートを付着させて両方の繊維シートに熱硬化性樹脂材料を含浸させる請求項10に記載の熱硬化性樹脂プリプレグシートの製造方法。
- 前記複合シートを複数枚重ね合せて加熱加圧成形する請求項10又は11に記載の熱硬化性樹脂プリプレグシートの製造方法。
- 無端状に形成されている離型シートを前記複合シートに重ね合わせて加熱加圧成形する請求項10から12のいずれかに記載の熱硬化性樹脂プリプレグシートの製造方法。
- 繊維シートに熱硬化性樹脂材料を含浸させた熱硬化性樹脂プリプレグシートを製造するために用いられる複合シートの成形装置であって、転移シートの片面に密度ρRg/cm3の熱硬化性樹脂材料を目付量WRg/m2で所定の厚さに坦持した樹脂転移シートを供給する樹脂転移シート供給部と、密度ρCg/cm3の繊維を目付量WCg/m2で構成した前記繊維シートを供給する繊維シート供給部と、前記転移シートに担持された熱硬化性樹脂材料を前記繊維シートの片面に接触させた状態で加熱又は加熱加圧処理する転移加熱処理部と、前記転移加熱処理部で処理された重なり合った状態の前記樹脂転移シートと前記繊維シートを前記熱硬化性樹脂材料の粘度が10000Pa・s以上となる温度まで冷却又は冷却加圧処理する転移冷却処理部を備え、厚さが[{(WC/ρC)/1000}+{(WR/ρR)/1000}]mmより厚く、かつ前記繊維シートの片面側に前記熱硬化性樹脂材料の一部が層状に形成されて一体化するように付着した複合シートを得る複合シートの成形装置。
- 前記樹脂転移シート供給部は、転移シートの片面に熱硬化性樹脂材料を所定の厚さでシート状に担持させる担持部を備えている請求項14に記載の複合シートの成形装置。
- 前記繊維シート供給部は、前記繊維シートを開繊処理により形成する開繊処理部を備えている請求項14又は15に記載の複合シートの成形装置。
- 請求項14から16のいずれかに記載の複合シートの成形装置と、前記複合シートに対して加熱加圧処理により前記繊維束中に熱硬化性樹脂材料を含浸させて成形する含浸処理部を備えている熱硬化性樹脂プリプレグシートの製造装置。
- 前記含浸処理部は、前記複合シートに対して熱硬化性樹脂材料が転移された面側に別の繊維シートを付着させる請求項17記載の熱硬化性樹脂プリプレグシートの製造装置。
- 前記含浸処理部は、前記複合シートを複数枚重ね合せて加熱加圧成形する請求項17又は18に記載の熱硬化性樹脂プリプレグシートの製造装置。
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