JPH1142638A - Method and apparatus for producing prepreg - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable response to a small lot without generation of a kind of resin powder by a method in which a fiber backing to be unwound continuously is cut by a cutter into sheets, which are coated with a kind of resin varnish, impregnated, and dried. SOLUTION: A supplied fiber backing 1 is sent to a cutter 3 to be cut in a constant size. A shearing cutter and others are used as the cutter. The backing 1 which was cut by the shearing cutter into sheets is transported by a conveyer 4. A curtain coater, which is a coating device 6, is mounted on the upper part of the conveyer 4, and the transported backing 1 is coated with a kind of resin varnish 5. Additionally, the backing 1 is transported to the conveyer 4 of a heat resistant mesh belt to be transported to a heater 7. In the heater 7, the backing 1 is heated and impregnated with the varnish 5 and further heated to obtain a prepreg.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a prepreg manufacturing method and a prepreg manufacturing apparatus suitably used for manufacturing a printed wiring board.

[0002]

2. Description of the Related Art A prepreg generally used is formed using a roll-shaped fiber base material such as pulp paper, glass woven fabric, or glass nonwoven fabric. As a production method, the roll-shaped fiber base material is continuously impregnated with a thermosetting resin varnish comprising a thermosetting resin such as an epoxy resin, an imide resin, a phenol resin, and a cyanate resin and an organic solvent, and then heated. The prepreg is manufactured by heating and drying the curable resin and curing it to the semi-cured B stage. Thus, in the conventional prepreg manufacturing method, continuous impregnation, heating,
Since a step of drying is required, if the resin varnish is switched, the fiber base material in the steps from impregnation to drying is wasted, and it is difficult to cope with a small lot.

[0003] In addition, since the prepreg manufactured by impregnating a resin varnish as described above is continuously manufactured in a B-stage state in which the resin is in a semi-cured state, the prepreg is used for a laminated board or a printed wiring board. Must be cut into single sheets, and a large number of cutting powders and resin powders containing resin were generated at the time of cutting. This resin powder adheres to the prepreg and is conveyed. When the prepreg is used to manufacture a copper-clad laminate, the resin powder scatters on the surface of the copper foil, resulting in poor dust control.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to produce a prepreg which does not generate resin powder and can be used in a small lot. An object of the present invention is to provide a method and an apparatus for producing a prepreg.

[0005]

According to a first aspect of the present invention, there is provided a method for producing a prepreg, comprising the steps of: cutting a continuously wound fiber base material into a single sheet by a cutting device; Is coated with a resin varnish, then impregnated and dried to produce a prepreg.

According to a second aspect of the present invention, there is provided a method for producing a prepreg according to the first aspect, wherein a resin varnish is coated according to the dimensions of the fiber base material.

According to a third aspect of the present invention, there is provided an apparatus for manufacturing a prepreg, comprising: an unwinding roll for unwinding a fibrous base material; a cutting device for cutting the unwound fibrous base material; It is characterized by comprising a transport device for transporting the substrate, a coating device for coating the fiber substrate with a resin varnish, and a heater for heating and drying the fiber substrate coated with the resin varnish.

The present invention relates to a method for producing a prepreg by coating a resin varnish, and a method and an apparatus for producing a prepreg using a solvent-free resin composition having high impregnation.

[0009]

Embodiments of the present invention will be described below.

An epoxy resin composition for a laminate according to the present invention comprises: an epoxy resin having a plurality of epoxy groups in a molecule;
A solvent-free epoxy resin composition for a laminated board, comprising at least the curing agent and a compound that reduces the surface tension of the epoxy resin composition by blending the curing agent.

The epoxy resin used in the present invention is an epoxy resin having a plurality of epoxy groups in one molecule, for example, bisphenol A epoxy resin, bisphenol F epoxy resin, phenol novolak epoxy resin, bisphenol A novolak epoxy resin. Resin, cresol novolak type epoxy resin, alicyclic epoxy resin, aromatic amine epoxy resin, diaminodiphenylmethane type epoxy resin, flame retarded by halogenating some hydrogen atoms in these epoxy resin structures A single, modified, or mixture of epoxy resins and the like can be mentioned.

The curing agent is not particularly limited as long as it reacts with the epoxy resin and cures. Examples thereof include amide-based curing agents such as dicyandiamide and aliphatic polyamides, and amines such as aromatic amines. Examples thereof include a system curing agent, a phenolic compound such as bisphenol A, bisphenol F, phenol novolak, cresol novolak, and pyrogallol, diaminomaleonitrile, a hydrazide compound, and an acid anhydride. These can also be used in combination.

Further, the compound for lowering the tension is a compound generally called a surfactant, for example, a polysiloxane such as a polyether-modified dimethylpolysiloxane copolymer, an aralkyl-modified polysiloxane, and an aralkyl-modified methylalkylpolysiloxane. Or a fluorinated alkyl ester, a perfluoroalkyl alkoxylate, a perfluoroalkylpolyoxyethylene ethanol, a fluoroalkylcarboxylic acid, a fluorosurfactant having a fluorine atom in the structure such as a perfluoroalkylcarboxylic acid, And polyethylene glycol fatty acid esters, sorbitan fatty acid esters, and the like, and may be used in combination.

The melting point of the epoxy resin composition is 80
If the epoxy resin and the curing agent are selected so that the temperature is not more than 0 ° C., more preferably not more than room temperature, it is possible to obtain a prepreg excellent in impregnating the fiber base material.

When the epoxy resin, the curing agent, the compound for lowering the tension, and the like are mixed, the mixture may be heated and melted if necessary, and then filled in a closed container and mixed. There is a method of storing and mixing. Specific examples include a stirrer such as a static mixer, a pipeline mixer, and a kneader.

As a device for coating the fiber base material with the epoxy resin varnish obtained by stirring the epoxy resin or the like, a roll coater, a die coater, and a curtain coater can be used.

FIG. 1 shows a prepreg manufacturing apparatus showing an embodiment of a prepreg manufacturing method according to the present invention.
Unwinding roll 2 for unwinding, a cutting device 3 for cutting the unwound fibrous base material 1, a conveying device 4 for conveying the cut and sheet-shaped fibrous base material 1, It comprises a coating device 6 for coating the resin varnish 5, and a heater 7 for heating and drying the fiber base material 1 coated with the resin varnish 5.

On the unwinding roll 2, the rolled fiber base material 1 is disposed, and is continuously unwound according to the cut size. The wound fiber substrate 1 is cut into a cutting device 3
And cut to a certain size. This cutting device
Shearing cutters can be used, others include
A rotary cutter or a laser cutter can be used. The fiber base material 1 cut into a sheet shape by the shearing cutter is transported by the transport device 4. Here, in order to further control the width dimension, while being conveyed by the conveyance device 4, the sheet can be further cut by a slitter.

Further, a curtain coater, which is a coating device 6, is installed on the upper portion of the transport device 4, and coats the conveyed fiber base material 1 with a resin varnish 5.

A shutter is attached to a portion of the curtain coater to which the resin is applied, and can be opened and closed according to the dimensions of the sheet-shaped fiber base material 1.

Further, the fiber base material 1 is conveyed to a heat-resistant mesh belt conveying device 4 and conveyed to a heater 7 to impregnate and impregnate the coated resin varnish 5. In the heater 7, first, the fiber base material 1 is heated at 100 to 170 ° C. to impregnate the resin varnish 5,
It was heated at 00 ° C. to obtain a prepreg.

In the illustration of FIG. 1, the heater 7 is
Although the embodiment arranged at the upper part of the fiber base material is shown, the heating can be performed from below the fiber base material 1. [Embodiment] A long glass cloth of MIL spec. # 7628 manufactured by Asahi Schebel Co., Ltd. in a wound shape is cut into a predetermined size by a cutting device (shearing cutter).

Further, an epoxy resin varnish from which air bubbles were removed by vacuum degassing (cresol novolac type epoxy resin having an epoxy equivalent of 220 and a melting point of 90 ° C .; EPICLON manufactured by Dainippon Ink and Chemicals, Inc .: 30 parts by weight, epoxy equivalent of 190, Bisphenol A epoxy resin liquid at room temperature; Yuko Shell Epoxy Co., Ltd. Epicoat 82
8: 70 parts by weight, disindiamide: 3 parts by weight, bisphenol A type: 45 parts by weight, curing accelerator 2-methyl-4
-Methyl imidazole (0.1 part by weight) is coated on the sheet-shaped fiber substrate 1 by a curtain coater.

Further, in this heater 7, first, 150
The fiber base material 1 was impregnated with the resin varnish 5 by heating at 150 ° C., and further heated at 180 ° C. for 150 seconds to obtain a prepreg.

The obtained prepreg had a smooth surface without scattering of resin powder.

[0026]

According to the prepreg manufacturing method and the prepreg manufacturing apparatus according to the present invention, the fiber base material wound from the unwinding roll is cut by a cutting device to form a single sheet. Is coated with a resin varnish using a coating device, and the fiber base is heated with a heater.
By drying, it is possible to obtain a smooth prepreg without resin powder generated at the time of cutting, and a laminated board or a printed wiring board using the present prepreg reduces a damp defect. Further, since the sheet-like fiber base is coated with a resin varnish, a prepreg can be manufactured with a minimum amount of resin.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing one embodiment of a prepreg manufacturing apparatus used in a prepreg manufacturing method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber base material 2 Unwinding roll 3 Cutting device 4 Transport device 5 Resin varnish 6 Coating device 7 Heater

Claims (3)

[Claims] 1. A method of manufacturing a prepreg by cutting a continuously wound fiber base material into a single sheet by a cutting device, coating the single sheet fiber base with a resin varnish, impregnating and drying. A method for producing a prepreg. 2. The method for producing a prepreg according to claim 1, wherein a resin varnish is coated according to the dimensions of the fiber base material. 3. An unwinding roll for unwinding a fiber base material,
A cutting device for cutting the unwound fiber base material, a conveying device for conveying the cut and sheet-shaped fiber base material, a coating device for coating the fiber base material with a resin varnish, and a resin varnish being coated Heated fiber substrate,
An apparatus for manufacturing a prepreg, comprising a heater for drying.