JPH02187432A - Production of prepreg - Google Patents

Abstract

PURPOSE:To produce a prepreg useful for producing laminated boards without causing substrate breakage by impregnating a specific glass substrate with a thermosetting resin and drying the impregnated substrate. CONSTITUTION:The objective prepreg (A) obtained by coating, e.g. both sides of a glass nonwoven fabric 1 with preferably a thermosetting resin similar to that impregnated into a substrate as a binder, continuously feeding, superposing and bonding sheets of glass cloth 2 thereto to provide a long glass substrate 3, feeding the resultant glass substrate 3 to a resin impregnation bath 6, passing the substrate through a thermosetting resin 7 (e.g. epoxy resin), impregnating the substrate therewith, feeding the impregnated substrate to a dryer 8 and drying the substrate while heating.

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a method for manufacturing prepreg used for manufacturing laminates.

[Conventional technology]

Prepreg A has conventionally been manufactured as shown in FIG. That is, a long glass substrate 3 is continuously sent to a resin impregnation tank 6 and passed through a thermosetting resin face 7 such as an epoxy resin to be impregnated with a thermosetting resin, and then this is further continuously carried out. 91 is made by sending it to the dryer 8!8 and heating and drying it. Although woven glass fabric is often used as the glass substrate 3, in the laminate obtained by molding the prepreg A produced as described above, if a woven glass fabric is used as the glass substrate 3, the through hole must be processed by drilling, whereas if a glass nonwoven fabric is used as the gamma lath base material 3, through-holes can be easily formed by punching. The use of non-woven fabrics is increasing.

[Problem to be solved by the invention 1] However, because the plush nonwoven fabric is not woven from plush fibers, its tensile strength is low, and it acts when impregnated with thermosetting resin and dried while being continuously fed. There is a risk that cutting may occur due to the tensile force, resulting in a problem of lower yield and lower productivity. The present invention has been made in view of the above points, and an object of the present invention is to provide a prepreg manufacturing method that can prevent the glass base material from being cut while using a glass nonwoven fabric as the glass base material. That is. [Means for Solving the Problems] The prepreg manufacturing method according to the present invention involves creating a long glass base material 3 by laminating and bonding a glass woven fabric 2 to a long glass nonwoven fabric 1; This method is characterized in that the base material 3 is impregnated with a thermosetting resin and then dried. Further, in the present invention, it is preferable to bond the glass woven fabric 2 to the glass nonwoven fabric 1 using the same type of resin as the thermosetting resin impregnated into the glass substrate 3 as a binder.

[For use]

In the present invention, the glass nonwoven fabric 1 can be reinforced with the glass woven fabric 2 and used as the plus base material 3, and can be continuously fed and heat cured without fear of the base material breaking. It can be impregnated with a synthetic resin and dried. [Example I] The present invention will now be described in detail with reference to Examples. In order to bond the glass nonwoven fabric 1 and the glass woven fabric 2 and use them as the positive base material 3, in addition to bonding the glass woven fabrics 2, 2 to both sides of the glass nonwoven fabric 1, respectively, as shown in FIG. 2(a), Alternatively, as shown in FIG. 2(b), the glass woven fabric 2 may be sandwiched between two glass nonwoven fabrics 1.1 and bonded together. The glass nonwoven fabric 1 and the glass woven fabric 2 can be bonded together using a thermosetting resin as a binder, but this thermosetting resin is the same as the thermosetting resin that is impregnated into the glass base material 3 described later. It is preferable to use different types. In addition, the composition ratio of the glass nonwoven fabric 1 and the glass woven fabric 2 constituting the glass substrate 3 is such that the glass woven fabric 2 is thin enough (as long as the reinforcing effect is exhibited) and the glass nonwoven fabric 1
In order to sufficiently maintain these characteristics, it is preferable that half or more of the thickness of the plus base material 3 be occupied by the plus nonwoven fabric 1. Figure @1 shows an example of the process of manufacturing prepreg A using a glass base material 3 with glass woven fabrics 2f2 bonded to both sides of the glass nonwoven fabric 1, while continuously feeding a long glass nonwoven fabric 1. First, a varnish (of thermosetting resin) or the like is applied as a binder to both sides of the positive nonwoven fabric 1 by passing it between application rolls 9 and 9.Next, the glass nonwoven fabric 1 coated with this binder is fed while being coated with a long glass woven fabric. 2, 2 are continuously fed to both sides of the plus nonwoven fabric 1, and the presser roll 10
．． The glass woven fabrics 2, 2 are superimposed and bonded to the glass nonwoven fabric 1 through a space of 10. In this case, instead of applying the binder to the plus nonwoven fabric 1, the binder may be applied to the glass woven fabric 2, or the binder may be applied to both the glass nonwoven fabric 1 and the glass woven fabric 2. It is sufficient that the amount of the thermosetting resin as the binder applied is small enough to bond the glass nonwoven fabric 1 and the glass woven fabric 2 together. Further, as the binder, thermosetting resin powder or the like may be used instead of the thermosetting resin face. After the glass nonwoven fabric 1 and the glass woven fabric 2 are stacked together with the binder in between, heating is performed as necessary to dry the thermosetting resin of the binder. The thermosetting resin of the binder does not need to be completely cured. Then, the long gamma 6 base material 3 obtained by bonding and integrating the glass nonwoven fabric 1 and the glass woven fabric 2 in this way is continuously sent to a resin impregnation tank 6, and heated with epoxy resin etc. Prepreg A is manufactured by impregnating the glass base material 3 with a thermosetting resin by passing it through a curable resin face 7, and then continuously sending it to a dryer 1f18 such as a vertical type and heating and drying it. I can do something. Here, since the glass substrate 3 is formed by adhering the glass woven fabric 2 to the glass nonwoven fabric 1, the glass woven fabric 2 having a fiber structure and high tensile strength increases the tensile strength of the glass nonwoven fabric 1. Even if a tensile force is applied to the positive base material 3 during the step of impregnating the thermosetting resin or drying it, there is no fear that the base material will break. The prepreg A manufactured as described above is cut into predetermined dimensions, and a plurality of sheets of the prepreg A are stacked together, and a metal foil such as copper foil is further stacked on the outer layer on one side or the outer layer on both sides, and this is heated and heated. By pressing and laminating,
Metal foil laminates can be created. Since this laminate includes the glass nonwoven fabric 1 as the positive base material 3, through holes can be formed by punching. In addition, this laminate is a combo laminate using a combination of glass nonwoven fabric 1 and glass woven fabric 2 as the glass substrate 3, but when manufacturing prepreg A, the plus nonwoven fabric 1 and glass woven fabric 2 are combined in advance. Therefore, there is no need to combine the glass nonwoven fabric 1 and the glass woven fabric 2 during lamination molding. still,
When manufacturing a prepreg using the glass nonwoven fabric 1, since the plus nonwoven fabric 1 is a collection of plus single fibers, the single fibers of the plus nonwoven fabric 1 are likely to be released from the surface of the prepreg and float in the air. Laminate molding may be performed with floating single fibers attached to the surface of the metal foil.
In this case, the monomolecular fibers may dig into the surface of the metal foil, causing a dent in the surface of the metal foil, which may result in defects called "strike marks." On the other hand, when glass woven fabrics 2, 2 are bonded to both sides of a glass nonwoven fabric 1 and used as a glass substrate 3 as shown in FIG. 2(a), the glass nonwoven fabric 1 is not exposed on the surface. This prevents the single fibers of the glass nonwoven fabric 1 from becoming loose, and it is possible to significantly reduce defects such as "striking marks". Next, the present invention will be illustrated with a specific example.
00 parts by weight, 4 parts by weight of dicyanamide, 0.2 parts by weight of benzyldimethylamine, and 100 parts by weight of methyl oxidol to prepare an epoxy resin face. And Honshu Paper Co., Ltd. with a thickness of 0.4 mm as the glass nonwoven fabric 1! l! Using GMC and WE-18K manufactured by Nitto Boseki Co., Ltd. with a thickness of 0.18 mm as the glass woven fabric 2, as shown in Fig. 1, while feeding the plus nonwoven fabric 1, 250 g/g of the above epoxy resin face was applied to both sides as a binder. After applying the coating with a coating amount of "a+", the glass woven fabrics 2 and 2 were stacked and heated at 165°C for 60 minutes.Next, the glass nonwoven fabric 1 and the glass woven fabrics 2 and 2 were bonded together in this manner, and the fabrics shown in Fig. 2 ( , ) was impregnated with the above epoxy resin face so that the resin content after drying was 50% by weight, and this was dried to obtain prepreg A. Next, this prepreg Layer two sheets of A, and layer #IM with a thickness of 18μ on top and bottom of each layer, and add this to 40kg/a.
By heating and pressurizing and laminating under the conditions of m2.170° C. and 120 minutes, a 1.6 mol thick double-sided tI4 foil laminated plate was obtained. Glass woven fabric 2 instead of glass non-woven fabric 1 in Figure 1
Pf in FIG. 2(b) was obtained by using the glass nonwoven fabric 1 instead of the glass woven fabric 2, and in the same manner as in Example 1 except for the glass nonwoven fabric 1.
A glass substrate 3 having the I configuration was created, and the rest was carried out in the same manner as in Example 1 to obtain a prepreg A. 2 was carried out in the same manner as in Example 1 except that this prepreg A was used.
A laminate having a thickness of 0 mm and having both sides covered with copper foil was obtained. A prepreg A was prepared in the same manner as in Example 1 except that the glass nonwoven fabric 1 used in Example 1 was used as the glass substrate 3. Next, by stacking 5 sheets of this prepreg A and stacking 18μ thick copper foil on top and bottom of each, and laminating and molding this in the same manner as in Example 1,
1, 8111℃ thick both sides #! I got a laminate board for the insulation. In the above specific examples 1 and 2, no substrate breakage occurred in the glass substrate 3, but in the comparative example, substrate breakage occurred in the process of feeding the glass substrate 3 vertically into a drying fier. *The defect incidence rate of "stroke marks" was 0.21% in specific example 1, and in specific example 2.
In the example, it was 1.9%, and in the comparative example, it was 2.1%. Effect of the invention 1 As described above, in the present invention, a long plus base material is created by laminating and bonding a glass woven fabric to a long glass non-woven fabric, and a thermosetting resin is applied to this plus base material. Since the resin is impregnated with resin and dried, the woven glass fabric with high tensile strength can be used as a glass base material while being reinforced with a non-woven glass fabric, and there is no fear that the base material will break. The positive base material can be continuously fed and impregnated with thermosetting resin and dried.

[Brief explanation of the drawing]

Figure 1 is a schematic diagram of an embodiment of the present invention, Figures 2 (a) and (b).
) is a partially enlarged sectional view showing the layer structure of the above-mentioned plus base material, and FIG. 3 is a schematic diagram of a conventional example. 1 is a plus nonwoven fabric, 2 is a glass woven fabric, 3 is a glass base material,
A is prepreg.

Claims (2)

[Claims] (1) A prepreg characterized in that a long glass base material is created by laminating and bonding a glass woven fabric to a long glass nonwoven fabric, and this glass base material is impregnated with a thermosetting resin and then dried. manufacturing method. (2) The prepreg manufacturing method according to claim 1, characterized in that the glass woven fabric is bonded to the glass nonwoven fabric using the same type of resin as the thermosetting resin impregnated into the glass substrate as a binder.