JPH03216307A - Manufacture of prepreg - Google Patents

Abstract

PURPOSE:To facilitate the production of prepreg materials for bias layers by laminating release sheets carrying resin thereon on both upper and lower surfaces of a sheet consisting of parallel reinforced fibers, peeling off one of the release sheets from a prepreg produced while allowing resin carried on the release sheets to be transferred to and infiltrated into the fiber-reinforced sheet, and taking up the laminated sheet consisting of the fiber-reinforced sheet and the other release sheet after cutting and removing the edges of the other release sheet that are pressed out. CONSTITUTION:Release sheets 32, 33, at least one of which carries resin on its one face on a fiber-reinforced sheet 31 side, are continuously laminated on both faces of the fiber-reinforced sheet 31 made by uniformly drawing out a reinforcing fiber bundle in one direction in the form of a sheet. After this laminate is preliminarily heated by a heating plate 39, it is heated and pressed by heating rolls 40a to 40c and press rolls 41a to 41c, whereby the resin carried on the release sheet is transferred to and infiltrated into the fiber-reinforced sheet 31 and a prepreg 42 is thus formed. The release sheet 32 on the upper side is then peeled off, and a laminated sheet 48, from which the edges 46 of the release sheet 33 that have been pressed out on both sides of the prepreg 42 over its width are continuously cut and removed, is taken up by a roll. The laminated sheet 48 thus made is cut into parallelogrammatic sheets 53 along cutting lines 52 inclined by an angle alpha with respect to the array direction 51 of the reinforcing fibers to make prepreg materials for bias layers.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field 1] The present invention relates to a method for manufacturing a prepreg used for molding a fiber-reinforced composite abrasive material such as fiber-reinforced plastic (FRP), and particularly relates to a method for manufacturing a prepreg used for molding a golf shaft made of FRP. The present invention relates to a method for manufacturing a prepreg used for a bias layer.

[Prior Art] As a prepreg used for molding fiber-reinforced composite materials, a sheet made by aligning reinforcing fibers in one direction is known. Such prepreg is manufactured, for example, as shown in FIG. 4.

Release sheets 2 and 3 carrying resin on one side are superimposed on the upper and lower surfaces of the reinforcing fiber sheets 1 to 1 that have been sent, respectively.
This polymerized body 4 is preheated by a heating means 5, heated and pressed from both sides by a heating roll 6 and a press roll 7, and the resin is transferred and impregnated into the reinforcing fiber sheet 1 to produce a prepreg 8. In this method, after peeling off the release sheet 2, the prepreg 8 is wound up together with the other release sheet 3 as a bripreg roll 9. This prepreg roll 9 is used by being rewound into a sheet shape, as shown in FIG. 5, when preparing a prepreg material for molding a fiber-reinforced composite trA resin. When applying pressure to impregnate the reinforcing fiber sheet 1 with resin, the reinforcing fiber sheet 1 and the resin are expanded in the width direction of the sheet.
The release sheets 2 and 3 used have a wider width than the prepreg 8 to be produced. Therefore, prepreg 8
In the laminate of the release sheet 3 and the release sheet 3, the ears 10 of the release sheet 3 are present on both outer sides in the width direction of the prepreg 8.

Using such a laminate of the prepreg 8 and the release sheet 3, the prepreg for the bias layer of the fiber reinforced composite material is
It is usually made as follows.

Bias 1 is a layer in a fiber-reinforced composite material that is laminated with the reinforcing fibers arranged at a certain angle with respect to the main prepreg layer in which reinforcing fibers are arranged mainly in the direction to be reinforced. Therefore, as shown in FIG. 6, the pre-reg 8 unwound from the pre-preg roll 9 and the release sheet. The laminated sheet of + and 3 is cut along the cut line 12 at a predetermined angle α with respect to the reinforcing fiber arrangement direction 11.Next, from the cut parallelogram sheet 13, the 7th As shown in the figure, the ears 10 at both ends are cut and removed.The sheet 14 from which the ears 10 have been removed is
As shown in FIG. 8, a plurality of edge removal sides 15 are arranged on a release sheet 16 so as to butt and connect with each other. At this time, the release sheet 3 is located on the upper side, and the prepreg 8 is located between the release sheet 3 and the release sheet 16. Then, heat the prepreg 8 with an iron or the like from above.
A laminated sheet of the mold release sheet 3 and the mold release sheet 3 is temporarily adhered to the mold release sheet 16. Next, as shown in FIG. 9, cut the temporarily adhered sheet to the specified length of the prepreg material to be used as the bias layer, for example, to the length of the part to be wound as the bias layer of the shaft of a golf club. The sheet 18 cut to a specified length L is passed through a calender device consisting of a heating roll 19 and a pressure roll 20, for example, as shown in FIG. The mold release sheet 1-3 is peeled off from the prepared sheet 18, and the sheet 21 from which the mold release sheet i-3 has been peeled is cut along the cutting line 22 as shown in FIG. By cutting along the lines, each laminated sheet 23 of the prepreg 8 and the release sheet 16 of a predetermined size, which is used for forming the bias layer, is obtained.This laminated sheet 23 is
It is wound on a tapered shaft-shaped mandrel (not shown) or on the main prepreg layer already wound on the mandrel, and the release sheet 16 on the outer side is peeled off and removed, and used for forming a bias layer. In addition, each laminated sheet 23 cut to a predetermined size can be made into a two-layer structure by gluing the eight prepreg faces together, and if necessary, by sequentially laminating them, a bias of a multi-layer structure can be formed. It can also be used as a prepreg material for layers.

[Problems to be Solved by the Invention] In the method for manufacturing the bias layer prepreg material as described above, in order to continuously butt connect the bias layer prepreg material as shown in FIG. As shown in the figure 1
A process of cutting and removing the ears 10 of the release sheet 3 is required.

The present invention eliminates the need for cutting and removing the release sheet edges as shown in FIG. 7 during the production of bias layer prepreg material after prepreg production, by making improvements in the prepreg production stage, and makes it possible to create a bias layer prepreg material by eliminating the need for cutting and removing the release sheet edges as shown in Figure 7. The purpose is to facilitate the production of materials.

[Means for Solving the Problems] A method for producing a prepreg of the present invention in accordance with this objective is to carry a resin on at least one of the upper and lower surfaces of a sheet formed by aligning reinforcing fibers in one direction and parallel to each other. The release sheets are stacked on each other on their resin-supporting surfaces, and the supported resin is transferred to and impregnated into the reinforcing fiber sheet to produce a prepreg.One release sheet is peeled from the prepreg, and the prepreg is removed together with the other release sheet. It consists of the method of winding.

[Function] In such a method, the edges of the release sheet are already cut and removed at the prepreg A manufacturing stage, and the widths of the prepreg and release sheet in the rolled up prepreg roll are substantially equal to each other. They are assumed to have the same width.

Therefore, in the laminated sheet of prepreg and release sheet obtained by unwinding the Bripreglo roll, there is no longer an edge of the release sheet, and the edge of the release sheet is no longer present when producing the prepreg material for the bias layer. The cutting process becomes unnecessary, and the entire manufacturing process is simplified.

[Examples] Examples of the present invention will be described below with reference to the drawings.

FIG. 1 shows a prepreg manufacturing apparatus for carrying out a method according to an embodiment of the present invention, and FIG. 2 shows a laminated sheet i~ of prepreg and a release sheet manufactured by the apparatus of FIG. 1. In FIG. 3, the cross sections are respectively reduced.

In FIG. 1, numeral 31 indicates a reinforcing fiber sheet 1- formed by aligning reinforcing fiber bundles in a sheet shape in one direction.

Reinforcing fibers include carbon fiber, graphite fiber, organic high modulus fiber (
These are high-strength, high-modulus fibers such as aramit fibers, silicon carbide fibers, alumina fibers, holon fibers, tungsten carbide fibers, and glass fibers. Only one type of such reinforcing fibers may be used for the same prepreg, or different types of reinforcing fibers may be used in combination by arranging them regularly or irregularly.

Release sheets 32 and 33, on which at least one side (both sides in this example) support resin on one side (the surface on the reinforcing fiber sheet 31 side), are rewound from release sheet rolls 34 and 35, respectively; After being changed in direction by guide rolls 36 and 37, it is superimposed on both sides (upper and lower surfaces) of the reinforcing fiber sheet 31 that has been continuously fed out.

The release sheets 32 and 33 have a thickness of 0, for example.
．． Clay, starch, polyethylene,
A coating layer of a sealing agent such as polyvinyl alcohol is provided, and a silicone or non-silicone mold release agent, preferably a condensation reaction type of polydimethylsiloxane and polydimethylhydride sealant siloxane or It is like applying a mold release agent made of addition reaction type silicone. It is also possible to use a synthetic resin film that has been given release properties by corona discharge treatment or a synthetic resin film that has been coated with a release agent (for example, polyethylene film, polypropylene film).The width of the release sheets 32 and 33 is as follows: , the width is set to be larger than the width of the prepreg to be produced.

At least one of the upper and lower release sheets 32 and 33 carries a resin that is transferred to and impregnated into the reinforcing fiber sheet 31. This supporting resin may be a thermosetting resin or a mixture of a thermosetting resin and a thermoplastic resin. Examples of thermosetting resins include epoxy resins, maleimide resins, polyimide resins, resins with acetylene ends, resins with vinyl ends, resins with allyl ends, resins with nadic acid ends, and resins with cyanate ester ends. It will be done. These can generally be used in combination with curing agents and curing catalysts. Moreover, it is also possible to use a mixture of these thermosetting resins as appropriate.

Further, as the resin, it is also suitable to use a mixture of the above-mentioned thermosetting resin and a thermoplastic resin. Suitable thermoplastic resins have a main chain selected from carbon-carbon bonds, amide bonds, imide bonds, ester bonds, ether bonds, carbonate bonds, urethane bonds, urea bonds, thioether bonds, sulfone bonds, imidazole bonds, and carbonyl bonds. A thermoplastic resin having a bond, more preferably polyacrylate, polyamide, polyaramid, polyester, polycarbonate, polyphenylene sulfide, polybenzimidazole, polyimide, polyether imite, polysulfone, polyether sulfone, poly It is a group of thermoplastic resins that belong to engineering plastics such as ether ether ketone. In particular, polyimide, polyetherimide, polysulfone, polyether sulfone, and polyether ether ketone have excellent heat resistance properties.

reinforcing fiber sheet 31 and upper and lower resin-supported release sheets 32;
After the polymer 38 with 33 is preheated with a heating plate 39,
In this embodiment, three stages of heating rolls 40a and 40b are used.
, 40c, and three-stage press roll 4.
1a, 4tb, and 41c, and due to the heating and pressurization, the resin supported on the release sheets 32 and 33 is transferred and impregnated into the reinforcing fiber sheet 31, and a prepreg 42 is formed.

From the laminate of the prepreg 42 and the upper and lower release sheets 32 and 33, one (upper)
The release sheet 1-32 is peeled off, and the release sheet 32 is wound up as a release sheet roll 44 as a single sheet. After the mold release sheet 32 is peeled off, a laminated sheet 45 consisting of the prepreg 42 and the lower mold release sheet 33 is obtained. The ears 46 of ~33 are continuously cut by the cutter 47, and the laminated seal l~33 is cut continuously by the cutter 47.
45 and removed.

The cut ears 46 are wound up by a suitable winding device (not shown) or taken up and crushed by a suitable crusher (not shown).

After the ears 46 of the release sheet 33 are cut and removed, a laminated sheet 48 of the prepreg 42 and the release sheet 33, which are arranged to have the same width, is formed.
It is wound up on a winding core 49 as a burry preg roll 50.

This pre-preg roll 50 is rewound into a sheet shape as shown in FIG. 2 when producing the prepreg material for the bias layer. Similarly to the method shown in FIG. 6, the rewound laminated sheet 48 is cut into a parallelogram sheet 5 along a cutting line 52 inclined by a predetermined angle α with respect to the reinforcing fiber arrangement direction 51.
It is cut into 3. As shown in the cross section in FIG. 3, this laminated sheet 48 does not have the ears 46 of the release sheet 33, so the edge cutting process shown in FIG. 7, which was necessary in the conventional method, is unnecessary. become. Note that the above-mentioned angle α is determined depending on the application and the like. For example, in the case of golf shoes 71~, it is ideal for the reinforcing fibers to be arranged in a direction of ±45° with respect to the longitudinal direction H in the bias layer that has the effect of preventing twisting. , ease of wrapping around the mantrell (depends on prepreg thickness, stiffness of reinforcing fibers, etc.), mandrel taper (6,'
Considering the deviation in the winding direction and the deviation in the winding force due to the angle of 30°<α<47°, it is preferable to set the angle in the range of 30°<α<47°.

The method for producing the bias layer prepreg material using a plurality of cut parallelogram-shaped laminated sheets 53 is the same as the method shown in FIGS. 8 to 11.

Although not shown, before winding up the laminated sheet 48 as a buripregrol 50 and after peeling off one of the release sheets 1 to 1 after producing the laminated sheet shown in FIG. 11,
The prepreg side surface, which tends to become sticky, may be covered with a cover film (for example, polyethylene film). This cover film is made in a later process.
You can peel it off if necessary.

[Effects of the Invention] As explained above, when using the prepreg manufacturing method of the present invention, the release sheet ears are cut and removed from the laminate of the prepreg and the release sheet i in the prepreg manufacturing stage. This eliminates the need for cutting and removing the ears at the stage of producing the prepreg material for the piecing layer.
The effect is that the preparation of the prepreg material for the bias layer can be greatly facilitated.

[Brief explanation of drawings]

FIG. 1 is a schematic side view of a prepreg manufacturing apparatus for carrying out a prepreg manufacturing method according to an embodiment of the present invention, and FIG. 2 is a lamination of the prepreg manufactured by the apparatus of FIG. 1 and a release sheet. Perspective view of the seat, Figure 3 is shown in Figure 2.
4 is a schematic side view of a conventional prepreg manufacturing device; FIG. 5 is a perspective view of a laminated sheet of prepreg and a release sheet manufactured by the device shown in FIG. 4; The figure is a plan view of the sheets 1 to 1 in FIG. 5, FIG.
A plan view showing how the sheet 1- obtained by cutting the edges shown in the figure is placed on a release sheet, and Fig. 9 shows how the sheet obtained in Fig. 8 is cut into a specified shape. Fig. 10 is a schematic side view of a calender device that heats and presses the sheet obtained in Fig. 9; Fig. 11 shows one of the release sheets peeled from the sheet obtained in Fig. 10. Top view of the seat. 31・・・・・Reinforcement I! fiber sheets 32, 33...release sheet 38...polymerized body 39...heating plates 40a, 40b, 40c...heating rolls 41a, 41b, 41c...Press roll 42...Prepreg 45, 48...Laminated sheet 46...Ear portion 47...Cut 49... ... Core 50 ... Bripreglo roll 51 ... Arrangement direction of reinforcing fibers 52 ... Cutting line 53 ... Cut sheet 1 Fig. 34 2nd i! I Figure 3 42 Figure 4) 3 ○ 3

Claims (1)

[Claims] 1. On both upper and lower surfaces of a sheet made of reinforcing fibers aligned parallel to each other in one direction, a release sheet with at least one side carrying resin is superimposed on the resin-carrying surface, and the supported resin is formed into a reinforcing fiber sheet. In a method for manufacturing a prepreg, in which a prepreg is produced by transfer and impregnation, one release sheet is peeled from the prepreg, and the prepreg is wound together with the other release sheet, after peeling off the one release sheet, the prepreg is A method for producing a prepreg, which comprises cutting and removing an edge of the other release sheet that protrudes beyond the width of the sheet, and then winding up the prepreg together with the other release sheet.