JPH06170847A - Production of prepreg - Google Patents

Abstract

PURPOSE:To obtain a method for producing a fiber-reinforced resin prepreg that can be easily handled without an adhesion of an excessive matrix resin to the edges thereof. CONSTITUTION:In a hot melt-type prepreg producing method in which a fibrous sheet material combined with resin-holding release sheets is heated and pressurized by rolls or the like so that a matrix resin is infiltrated into fibers, tape materials having an affinity for the resin are provided on the side parts of the fibrous sheet material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a sheet-like prepreg which is an intermediate for a fiber reinforced composite material.

[0002]

2. Description of the Related Art There are many methods for producing this sheet-like prepreg, and one of the commonly used methods is the hot melt method. What is the hot melt method?
A matrix sheet such as an epoxy resin is applied and supported on a releasable sheet whose surface has been subjected to a release treatment with a silicone resin or the like, and the fibrous sheet-like material is united and heated and pressed by a roll or the like to form a fibrous sheet. This is a method in which a resin is impregnated into a material to form a prepreg. Usually, two releasable sheets are used, and at least one of the releasable sheets carries a matrix resin, and they are incorporated on both sides of the fibrous sheet material.
After impregnation, it is sufficiently cooled by a cooling plate or the like, and then the release sheet on one side is removed to obtain a roll-shaped prepreg as a superposed body of one release sheet and the resin-impregnated fibrous sheet. .

As these methods, for example, JP-A-60-165 is used.
Japanese Patent Laid-Open No. 211-212 discloses a method in which a resin accumulation control plate is installed before the heating roll in the hot melt method to suppress the resin accumulation and reduce the generation of fluff. In addition,
Japanese Patent Laid-Open No. 58-31716 discloses a method of continuously impregnating a curved base material along a curved base material while applying tension thereto. Further, Japanese Patent Application Laid-Open No. 60-157812 discloses a method of manufacturing a prepreg which is laminated with a scrim cloth.

Processing of prepregs into materials for vehicles and civil engineering, fiber reinforced composite material moldings such as fishing rods and golf shafts is carried out by laminating the prepregs according to the molds, and then using an autoclave or core metal. It is performed using a method of winding and tape wrapping.

In such laminating and winding operations, it is important that the prepreg has an appropriate tackiness, and the resin composition, viscosity, content and the like have been conventionally adjusted. In addition, as shown in FIG. 1, the prepreg normally uses a release sheet having a width wider than that of the fibrous sheet-like material, and has only the release sheet on both sides (hereinafter referred to as the release sheet ear portion). Is provided to indicate the type of product and facilitate handling such as portability.

Further, as described in JP-A-60-157812, the scrim cloth-bonded prepreg is used for the purpose of increasing the strength in the width direction of the unidirectionally aligned prepreg. As shown in FIG. 2, a scrim cloth having a width wider than that of the fibrous sheet-like material is usually used, and only scrim cloth portions (hereinafter referred to as scrim cloth ears) are provided on both sides or one side. This portion is used, for example, when connecting the prepreg sheets to each other, and at the same time gives a reinforcing effect of the connecting portion and facilitates the connecting work.

[0007]

When molding is performed using a prepreg sheet, no resin is required for the ear portion of the releasable sheet. For the scrim cross ears,
When a plurality of prepreg sheets are joined and molded, a resin that gives the adhesiveness required for joining and the strength of the joining portion is sufficient, and the presence of excess resin deteriorates the strength and deteriorates the handleability. However, in the prepreg manufacturing method of the hot melt method, as shown in JP-A-58-31716, when impregnating the resin into the fibrous sheet-like material, a heating roll is used to clamp the resin. A cylindrical resin ball is generated in front of the roll, and as a result, the resin protrudes wider than the width of the fibrous sheet, and the protruding resin adheres to the ears of the release sheet or scrim cloth ears. Excess resin will be present. Therefore, a method for producing a prepreg in which the matrix resin does not exist in the ears of the releasable sheet and the excess resin does not exist in the ears of the scrim cloth is provided.

[0008]

DISCLOSURE OF THE INVENTION The present invention relates to a prepreg of a hot melt method in which a fibrous sheet-like material and a resin-supporting release sheet are united and heated and pressed by a roll or the like to impregnate a fiber with a matrix resin. In the method for producing a prepreg, a tape material having affinity for the resin is arranged on a side portion of the fibrous sheet-like material.

The method for producing the prepreg of the present invention is a method using a so-called hot melt method.

In the present invention, the fibrous sheet is a sheet or woven fabric in which reinforced fibers such as carbon fiber, glass fiber, alumina fiber, aramid fiber, tyranno fiber, silicon carbide fiber are aligned in one direction. To use.

The matrix resin is a thermosetting resin such as an epoxy resin, a phenol resin, an epoxy acrylate resin, or an unsaturated polyester resin, which is an uncured or semi-cured resin in which a curing agent and a curing accelerator are premixed. To use.

The releasable sheet of the present invention may be a known commercially available sheet for producing prepreg. That is, as long as it has heat resistance strength and dimensional stability to withstand the temperature and tension at the time of prepreg production, and has releasability capable of peeling after impregnating the prepreg, the thickness is about 0.05 to 0.2 mm. The kraft paper roll paper, glassine paper or the like as a base material is coated with a release agent such as silicone on the surface.

The tape material has a greater adhesiveness with a matrix resin than a release sheet or a scrim cloth, or has a property of impregnating the resin, and withstands a heating temperature at the time of producing a prepreg. It is a thing. For example, a fiber material such as a nylon tape, a polyester tape or the like film material or a fiber sheet, a glass fiber, a fiber sheet such as a nylon fiber or a woven sheet may be used. The width is
It is about 1/50 to 1/10 of the width of the fibrous sheet,
The thickness is about 1/3 to 2 times that of the fibrous sheet material.

In order to dispose the tape material on the side surface of the fibrous sheet-like material, as shown in FIG. 3, when the release sheet carrying the matrix resin is combined with the fibrous sheet-like material.
The tape material is arranged adjacent to the outside of the fibrous sheet material. Thereafter, the resin is impregnated by heating and pressurizing with a pair or a plurality of pairs of rolls. Then, after cooling, it is taken up by a nip roll. Further, before the prepreg is wound into a roll, the release sheet is stripped off, and then the tape material is stripped off. By doing so, most of the matrix resin protruding to the outside of the fibrous sheet-like material is removed along with the tape material.

In the case of producing a prepreg with a scrim cloth, as shown in FIG. 4, after arranging a tape material so as to be adjacent to the outer side of the fibrous sheet-like portion and to be overlapped with the scrim cloth ear portion, To process.

[0016]

When the prepreg is produced by the method of the present invention, the matrix resin is hardly attached to the releasable sheet ears of the wound prepreg and the matrix resin is not excessively attached to the scrim cloth ears. A prepreg having good handleability can be obtained.

[0017]

EXAMPLES The present invention will be specifically described below with reference to the examples using FIG. 5, but the present invention is not limited thereto.

Example 1 Carbon fiber (Magnamite AS4, manufactured by Hercules, 1200)
0 The filament bundle group 1 consisting of 177 filaments and a fineness of 0.88 g / m) is passed through the comb-tooth positioning device 5 and unwound and aligned in parallel at a pitch of 5.80 mm, and the sheet is spread by the spreading bar 6. I made it. The carbon fiber sheet had a fiber areal weight of 151 g / mm ² and a width of 1025 mm. Furthermore, scrim cloth (glass cloth WP 03-104BZ, Nitto Boseki Co., Ltd., plain weave cloth, width 1040 mm, fiber weight 25 g /
mm ² ) and tape material (nylon taffeta, manufactured by Toray Industries, Inc., width 35 mm, thickness 94 μm) 4, 4 ′ were supplied to both ends of the carbon fiber sheet portion.

Then, as a matrix resin, a bisphenol liquid epoxy resin (Sumiepoxy ELA 128,
Sumitomo Chemical Co., Ltd. 4 parts by weight, bisphenol liquid epoxy resin (Sumiepoxy ELA 134, Sumitomo Chemical Co., Ltd.) 52 parts by weight, bisphenol solid epoxy resin (Sumiepoxy ESA 011, Sumitomo Chemical Co., Ltd.) Made)
14 parts by weight, cresol novolac-based solid epoxy resin (Sumiepoxy ESCN 220, manufactured by Sumitomo Chemical Co., Ltd.) 30
4.4 parts by weight of dicyandiamide (Dicyandiamide 2000, manufactured by Nippon Carbide Industry Co., Ltd.) as a curing catalyst and 1,1-dimethyl-3- (3,4-dichlorophenyl) as a curing accelerator were added to an epoxy resin mixture consisting of parts by weight. )
Urea (Deep Hardener 95, DuPont) 4.
A resin composition was prepared by mixing 4 parts by weight.

Width 1080 mm with silicon treatment on both sides
The matrix resin is applied to each of the release papers, and the resin-supported release papers 2 and 2 having a resin areal weight of 57 g / mm ² are passed through a heating roll 7 at 165 ° C to be nipped and united.
It was again nipped by the heating roll 8. At this time, some resin pool was observed in front of the heating roll 7, and the width thereof was about 20 mm larger than the width of the fiber sheet portion at both ends. Then, it is cooled to room temperature by the cooling plate 9, and is taken up by the nip roll 10, the release paper 11 on one side and the tape materials 12, 12 are peeled off, and then the prepreg sheet 13 is wound up by the winding device 14 into a roll shape. . The matrix resin content of the obtained prepreg was 37% by weight, the resin adhering to the scrim cloth ears was about 15 g / mm ² , and it had an appropriate adhesiveness, and the ears of the release paper had a resin. Was hardly attached.

Comparative Example 1 The procedure of Example 1 was repeated except that the tape material was not used.
The matrix resin content of the obtained prepreg was 37% by weight, and the resin adhering to the scrim cloth ears was 30 g /
There was an excess of mm ² . 40 g / mm ² of resin was adhered to the ears of the release paper.

[Brief description of drawings]

FIG. 1 is a schematic view of a combination of a fibrous sheet material and a releasable sheet carrying a matrix resin in a method for producing a prepreg in a normal hot melt method.

FIG. 2 is a schematic view in which a fibrous sheet-like material, a releasable sheet carrying a matrix resin, and a scrim cloth are united in the production of a prepreg with a scrim cloth by an ordinary hot melt method.

FIG. 3 is a schematic view in which a fibrous sheet-like material, a releasable sheet carrying a matrix resin, and a tape material are combined in the method for producing a prepreg of the present invention.

FIG. 4 is a schematic view in which respective materials are united when a prepreg with a scrim cloth is manufactured in the method for manufacturing a prepreg of the present invention.

FIG. 5 is a flow chart of an apparatus used in an example of the present invention.

[Explanation of symbols]

 a Fiber sheet-like material b Resin-carrying release sheet c Scrim cloth d Tape material 1 Fiber bundle 2 Matrix resin-carrying release paper 3 Scrim cloth 4 Nylon taffeta tape 5 Comb-shaped positioning device 6 Expansion bar 7, 8 Heating roll 9 Cooling Plate 10 Nip Roll 11 Peeling Release Paper 12 Peeling Nylon Taffeta Tape 13 Single-Sided Release Paper Prepreg Sheet 14 Winding Device

Claims (1)

[Claims] 1. A method for producing a prepreg by a hot melt method, in which a fiber sheet material and a resin-supporting releasable sheet are united and heated and pressed by a roll or the like to impregnate fibers with a matrix resin. A method of manufacturing a prepreg, which comprises arranging a tape material having an affinity for a matrix resin on a side portion of the shaped article.