JPS61229536A - Method and apparatus for producing fiber-reinforced resin sheet - Google Patents

Abstract

PURPOSE:To control the degree of crystallization according to characteristics of a resin, by a method wherein a fabric woven from a plurality of continuous fibers is heated to a temperature not lower than the softening point of a thermoplastic resin, and a coated film of a thermoplastic resin is provided on the surface of the fabric to impregnate the fabric with the resin. CONSTITUTION:A thermoplastic resin is melted by an extruder, is extruded through a die 21 provided at the tip of the extruder, and is applied to the surface of a heated resin-coating roll 23. A woven fabric 11 is brought into contact with the roll thus coated with the resin, whereby the resin is infiltrated into gaps between the fibers of the fabric. The impregnation is achieved by passage of the coated film of the resin between the fibers of the fabric 11 to the back side of the fabric. The pressure with which the fabric is brought into contact with the roll is such that the fabric can be brought into contact with the surface of the roll while passing through the coated film of the resin. The fabric thus coated with the resin is pressed against one or more heated rolls 23, 24 to enhance the degree of impregnation, is then cooled, and is taken out. The temperature of the heated rolls is not lower than the softening point of the resin.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing a fiber-reinforced resin sheet and a pinning device. [Prior Art] As a method for producing fiber 1 reinforcing composition by impregnating fibers with thermoplastic resin, there is a method of impregnating fiber mat and thermoplastic resin with heat, as described in JP-A-55-77525. A method of applying pressure to melt the resin and impregnating it into a fiber mat, and then cooling it under pressure, or a method of adding hot, synthetic resin as described in JP-A No. 59-47234. ,
A known method is to lower the viscosity by dissolving the plasticizer, impregnate the fiber, and then volatilize the plasticizer. .

However, each of the above methods has significant drawbacks. That is, the method described in JP-A-55-77525 has the disadvantage that when the pressure is increased to eliminate air bubbles, that is, voids that cause molding defects, a resin flow occurs, which disturbs the fiber arrangement and causes fiber breakage. have.

On the other hand, in the method described in JP-A No. 59-47234, plasticity is the biggest bottleneck, and deterioration of the thermoplastic resin and residual plasticizer during the heat process for removing the plasticizer result in poor performance of the composition. , it has disadvantages such as the ability to change significantly.

[Problems to be Solved by the Invention] The present invention provides a method for producing a fiber-reinforced resin sheet that "sufficiently impregnates the fibers and does not disturb the fibers even when a highly viscous thermoplastic resin is used" in the molten state. The technical challenge is to provide a device. Means for Solving Problems] The present invention is the result of extensive research by parents in order to solve the above problems. , , that is, the fiber m1 related to one woman! A fifth method for producing a strong resin sheet is a method for producing a fiber reinforcing composition by impregnating fibers with a thermoplastic resin, in which a woven fabric made of a plurality of continuous fibers being pulled and conveyed is coated with the non-plastic resin. It is characterized in that it is heated to a softening point or higher and passes through at least one resin coating film-applying roll having the thermoplastic resin coating film on its surface while being brought into contact therewith, and then is cooled. , ・.

Further, a manufacturing apparatus for a fiber-reinforced gold layer sheet according to the present invention 1;
Multiple l! Enemy! In an apparatus for manufacturing a fiber-reinforced resin sheet made by impregnating a woven fabric with a plastic resin, 1.
, it has a mechanism to adjust the tension of the fiber! and at least one resin film-applying roll heated above the softening point of the thermoplastic resin, and an extruder and a guide for applying the thermoplastic resin film to the roll. It includes an impregnation section and a take-off section that cools the weaver that has passed through the impregnation section and takes it back! It is characterized by:
.

The present invention will be explained in detail below.0, 5 In the present invention, a plurality of continuous fibers refers to rovings, yarns, tows, and lyra, which are aggregates of filaments that constitute fibers. For multiple applications, the filament is long enough to melt rapidly under the conditions of use, and comes into contact with plastic resins, resin coatings, etc.

It has enough skewers to pull the stone.・.

Preferred materials include glass, fibers, carbon fibers, and highly elastic synthetic resin fibers, but inorganic fibers such as silicon carbide fibers, alumina fibers, titanium fibers, boron wire rods, and metal fibers such as stainless steel may also be used. can.

The synthetic resin fibers are preferably surface-treated to have adhesive properties with the thermoplastic resin to be impregnated.1. Furthermore, the melting temperature of the thermoplastic resin used determines its strength, etc.
For example, aramid fiber (registered trademark R Kevlar 1-) is a synthetic resin fiber that requires no change in its properties.
etc.).

Depending on the thermoplastic resin used, the glass fibers and carbon fibers are coated with a surface treatment agent such as a silane-based or titanium-based coupling agent on the fiber surface to improve adhesion with the resin. It is preferable to do roving, to
to prevent it from unraveling during handling.

It is preferable to use a focusing agent for handling.

In the present invention, a woven fabric refers to a fabric processed into a cloth shape using the above-mentioned continuous fibers, and the weaving method of the fibers is arbitrary; therefore, the woven fabric used in the present invention , generally called plain weave, satin weave, twill weave, and herring twill weave.

It goes without saying that it includes those obtained by weaving methods such as the above, but also includes matte nonwoven fabrics and matte nonwoven fabrics obtained by needle punching.

Next, in impregnating the woven fabric with a thermoplastic resin, the thermoplastic resin used is polystyrene, polyvinyl chloride,
High density polyethylene, polypropylene, nylon, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, etc. are used, but are not limited thereto.

In addition, when the resin sheet obtained according to the present invention is used for applications requiring structural strength, it is preferable that the resin has a high elastic modulus and a large tensile strength. Specific examples include polyether sulfone, polysulfone, and polysulfone. High grade engineering resins such as etherimides (trademark rULTEM J etc.), polyetheretherketones are preferred.

When using these resins, it is preferable to dry them in advance, and it is more preferable to add a titanium-based coupling agent or the like to the resin for the purpose of improving adhesion to fibers.

The thermoplastic resin is melted in an extruder, extruded through a goo provided at the tip of the extruder, and applied to the surface of a heated resin coating roll. It is sufficient to have one resin coating film-applying roll, but it is also possible to provide a plurality of rolls. The resin temperature is preferably higher in order to lower the resin viscosity, but it is determined individually based on the relationship with the thermal deterioration temperature of each resin.

The surface temperature of the roll to which the resin is applied is preferably the same as or higher than the resin temperature.

The width of the resin coating film may be equal to or greater than the width of the woven fabric, and the thickness of the coating film is adjusted to an appropriate thickness corresponding to the thickness of the woven fabric. This thickness is a value determined experimentally by setting a target value for the resin content in the fiber-reinforced sheet finally obtained. On the other hand, since the thickness accuracy greatly affects the resin content described above in the width direction, it is preferably ±10% with respect to the set thickness.

More preferably, the range is within ±5%. As a coating method to improve the thickness accuracy of the coating film, as shown in (2), normal methods can be used.1 For example, a method using a doctor, a method using a coating roll between a goo and a roll (roll coater one type), etc. There is.

The woven fabric comes into contact with the roll coated with the resin coating, and resin impregnation begins between the fibers of the woven fabric. Because the resin coating is passed through the fibers that make up the woven fabric and reaches the back side of the woven fabric, joining is achieved.
The contact pressure of the woven fabric against the roll is sufficient as long as the woven fabric can push through the resin coating and reach the low tL table.
This contact pressure is regulated by the tension applied to the woven fabric.If the force is too strong, the resin will break between each fiber of the woven fabric. ! ! Since the film will not pass through and will be pushed to both ends of the woven fabric in the width direction, the tension must be determined depending on the viscosity of the resin used.The contact length between the woven fabric and the roll is 174~
3/4 is preferred.

The woven fabric coated with the resin is then pressed against, for example, one or more heated rolls to improve the degree of impregnation, and then cooled and taken off. These heating rows 1 Shinosako 11FJ
÷ 41 peep l 7 赫 z side... 4 ^ Lulu divination 1 L - appears.

In this specification, the softening point refers to the lowest temperature that can be measured using a melt index measuring device under a load of 5 kg.' If the surface of the woven fabric is in contact with the first resin coating roll, then While contacting the rolls with the front and back sides alternately, the back side is placed on the next heating roll, the front side is placed on the next heating roll, and the resin present on the front or back side is heated. It is preferable to bring the woven fabric into contact with the roll so that the sail flows between the fibers of the woven fabric in alternating directions from the front side to the back side and then from the back side to the front side, and by doing so, the degree of impregnation can be improved. can.゛Again. In addition to the effect of improving impregnation, the heating roll C4 provided after the resin coating film application roll also has the effect of removing excess resin on the front or back side of the fabric, but only the 5 resin coating film application roll If the purpose of impregnation is achieved, there is no need to provide the heating roll. It would be good if there were 1 to 5 pieces including
It is an extremely effective means to install five or more rolls and adjust the number of heated rolls to the required number depending on the type of resin used.

The impregnating effect of the present invention is that when the woven fabric comes into contact with the resin coating roll, the opposite side of the woven fabric is open, which may cause voids when impregnating the woven fabric from the roll side with resin, for example. The feature is that it is possible to push air bubbles etc. to the open side.

In the present invention, it is preferable to remove the resin adhering to the roll surface with a doctor plate or the like, since this has the effect of controlling the resin content and smoothing the surface of the woven fabric.
.

To prevent oxidative deterioration of the resin, surround it with a metal plate from the position where the resin is applied from the die to the resin coating roll to the rear end of the final heating roll, and create an atmosphere of inert gas such as nitrogen. It is preferable from the viewpoint of the performance of the resulting product, and is also useful for keeping the roll and resin warm.

Next, let's talk about cooling the resin-impregnated fabric.

For crystalline resins, the crystallinity and grain size are affected by the cooling rate, so by adjusting the cooling rate depending on the resin used, it is possible to control the crystallinity and grain size of the resin in the woven fabric. A preferred method for adjusting the cooling rate is to provide a heating zone at the gate of the roll and the take-up machine and gradually cool the fabric by creating a temperature gradient in the heating zone, or to directly apply a cooling medium such as cooling air to the woven fabric. A method of rapidly cooling the material by spraying on it can be adopted.

Next, details of the present invention will be explained with reference to representative embodiments shown in the drawings.

FIG. 1 is a schematic side view showing one embodiment of the present invention, and FIG. 2 is a side view showing details of a resin-impregnated portion.

As shown in FIG. 1, the manufacturing apparatus for carrying out the method of the present invention comprises a supply section 1, a resin impregnation section 2, and a take-off section 3.

, - The woven fabric 11 is wound around a paper tube to form a roll, and is held by the feeding shaft 12 of the supply section l. It is preferable that the feeding shaft 12 has a braking mechanism to prevent the fabric 11 from meandering when the fabric 11 is fed out.The fabric 11 is a guide roll!
5, brake 13. □ ■ Contact the force adjustment roll 14. The tension adjusting roll 14 applies tension to the woven fabric 11, and the tension is applied to the resin-impregnated portion 2.
First, the resin can be impregnated sufficiently, and the wire cone of the woven fabric 11 can be prevented from being disturbed.

This tension is adjusted depending on the material of the woven fabric li and the type and properties of the thermoplastic resin to be impregnated. The surface of the tension adjustment roll 14 is preferably made of rubber or the like so that the tension can be easily adjusted by frictional resistance.

Note that the tension adjustment roll 14 may be omitted if a uniform tension can be applied to the woven fabric 11 in the width direction of the woven fabric 11 by a brake (not shown) provided on the feed-out shaft 12 of the woven fabric 11.゛Next, the woven fabric 11 enters the resin-impregnated section 2, where the thermoplastic resin plasticized by an extruder (not shown) is passed through a die 21 and brought into contact with an imparting roll (hereinafter referred to as the 10th roll) 22. The resin is impregnated, and then the first heating roll (hereinafter referred to as the 20th roll) 23. The second heating port (hereinafter referred to as the 30th roll)
After being brought into contact with resin 9 (hereinafter referred to as "ru") 24 in order and sufficiently subjected to resin 9 impregnation, it is gradually cooled while passing through an annealing furnace 31 and taken to a taking part 3. The die 21 and the three rolls 22, 23, and 24 are heated to a temperature that corresponds to the melt viscosity of the thermoplastic resin used, and suitable heating methods include a heat transfer heater or induction heating.

The three rolls 22, 23, 24 are driven by a motor 25 and also unwind the woven fabric 1.l.

In the embodiment shown in FIG.
9-Roles 22 only, or three rolls 22
．． 23. Several heating rolls may be added in addition to 24, and each roll is configured to be driven by one motor 25, but in order to apply tension to the woven fabric 11 between each roll. A separate motor is attached to each roll,
The tension can be adjusted by controlling the motor load, or by providing a clutch on the drive shaft of each roll.

Next, details of the resin-impregnated portion 2 will be explained based on FIG. 2. That is, the thermoplastic resin supplied from an extruder (not shown) enters the manifold 2B of the die 21, passes through the flow path in the die 21, and enters the section formed by the tenth rule 22 and the die 21. The 10th rule is in contact with the 22 surface. A doctor 27 is installed at the rear end of the die 21, and this doctor 27 regulates the thickness of the resin coating on the 10th rule 22.Next, the 10th rule 22, which has a resin coating on its surface, is indicated by the arrow. direction and comes into contact with the woven fabric 11. Appropriate tension is applied to the woven fabric 11, and this tension causes it to be pressed against the surface of the 10th loop 22, and the resin coating on the surface of the 10th loop 22 is applied to the woven fabric 1.
The resin flows between the fibers constituting the fabric 11, and the resin oozes out onto the surface of the woven fabric 11. Therefore, the thickness of the resin coating on the 10th rule 22 passes through the woven fabric 11, and the resin oozes out onto the surface of the woven fabric 11. The primary woven fabric 11 is preferably such that it oozes out to form a coating film.
The surface opposite to the 0-rule 22 is brought into contact with the 20th-rule 23, and the resin coating formed on the surface of the woven fabric 11 is pressed onto the surface of the 20th-rule 23, thereby applying the resin to the 10th-rule 23. ? The woven fabric 11 is caused to flow in a direction opposite to that in the above case to improve the degree of impregnation.Furthermore, the woven fabric 11 is also in contact with the 30th rule 24, so that the degree of impregnation is further improved.

Each roll 22, 23, 24 is provided with a scraper 28, 29, 30 for WR&removing the resin coating film attached to the surface, and the scraper 28, 29, 30 is always in contact with the resin and the woven fabric, and is transferred to the woven fabric 11 with a clean surface. This prevents the amount of resin impregnated from changing. 40 is a cover, and this cover 40 covers each roll 2.
In addition to the heat retention effect of 2.23.24, although not shown,
An inert gas such as nitrogen is introduced into the cover 40, which also serves to prevent oxidative deterioration of the impregnated resin.

Next, the woven fabric 11 enters an annealing furnace 31 and is cooled at a cooling rate depending on the resin used. As a method of controlling the cooling rate, heaters, hot air,
A method of creating a temperature gradient using cold air or the like is preferred.

When a crystalline resin is used, it is possible to increase the degree of crystallinity by slow cooling, or to make it amorphous by rapid cooling, and to perform control according to the purpose. The cloth 11 is applied with a force by the pull plate roll ρ2 of the take-up section 3: take-up, take-up, and wind up on the shaft 33.In addition, the 3-take take-up roll 32 is wound up on the shaft 33. There is a motor),゛
□ □ In this way, the woven fabric il has a reinforcing strength λ, 5. According to the present invention, a fiber-reinforced resin sheet can be obtained.
[Effects of the invention] ゛ As described above, the present invention - Nyorobara 2 Resin test for woven fabric 1
□The thermoplastic resin whose molten viscosity was too high to be impregnated between the fibers during soaking was formed into crystals. It also achieves the effect of achieving control over both changes.'□
, [Example] , □ Hereinafter, the present invention will be explained by way of examples.'' □, Example 1 ゛
・.

・Each part of the device shown in Figure 1 = Specifications Push In'a40
Part layer φ, width of 1st to 30th loops: 400 mm, 10 mm body 2
50-Nureichi was used. The woven fabric is plain weave (Besphite 1103) made of carbon fiber cone and has a width of 20 mm.
(Adjusted to 1,1-1 Q', ZaraNani Mature 7 Plastic Resin J to Poly 1,000" Chill W-Te JL/ke) 7 (' IC1 Company, VICTREX piEK>"' was used. This polyether ether Ketone i゛.

-゛ is the shear rate i, (1'(laa
It belonged to C'f and Ni'r6jo Pofis.
::.

・Drawing weave: The fabric is mounted on a feeding shaft and used as a tension adjustment roll.

Multiplying the placement of 20Kg, from 10th to 30th:
I passed it through without touching it.
゛Meanwhile, the polyether ether ketone heated and melted at 380℃ in the extruder □ was heated to 4GQ℃ from the die and applied to the □l roll at a thickness of 1 (10μ).
The s'□ cloth was brought into contact with the surface of the i-th column and dipping was started. Heated 5 second
0-Rule, 30th-Rule.

After being gradually cooled in an annealing furnace kept at 14.0°C, it is rolled into one roll using a sendori machine.
.

The obtained sheet has a resin umbrella of 50% by weight and has a thickness? ,ll
, □It was layered. The fibers were not disordered and the void ratio was less than 1%.

Examples 2 to 6 The specifications and operating conditions of the device used in Example 1 were
As shown in the table, the cocoon weight-impregnated sheet was obtained by i-forming.

As is clear from Table 1, it can be seen that according to the present invention, various woven fabrics with no fiber disorder and no voids can be obtained. ’8″F Nahaku

[Brief explanation of the drawing]

FIG. 1 is a schematic side view showing one embodiment of the present invention, and FIG. 2 is a side view showing details of a resin-impregnated portion. In the figure, 1 is a supply section, 2 is a resin impregnating section, and 3 is a take-off section. Patent applicant Nobuaki Sakaguchi, agent of the High Performance Resin New Manufacturing Technology Research Association and patent attorney (and one other person)

Claims (5)

[Claims] (1) In a method for manufacturing a fiber reinforcing composition by impregnating fibers with a thermoplastic resin, a woven fabric made of a plurality of continuous fibers being pulled and conveyed is heated to a temperature above the softening point of the thermoplastic resin, and the surface of the woven fabric is heated to a temperature higher than the softening point of the thermoplastic resin. 1. A method for producing a fiber-reinforced resin sheet, which comprises passing it through at least one resin coating roll having a thermoplastic resin coating while being in contact with the roll, and then cooling the sheet. (2) After passing the woven fabric in contact with a resin coating roll, before cooling it, pass it in contact with one or more heating rolls heated to the softening point or higher of the thermoplastic resin. A method for producing a fiber-reinforced resin sheet according to claim 1, characterized in that: (3) After bringing the woven fabric into contact with a resin coating roll, the surface opposite to the surface that contacts the resin coating roll is brought into contact with a first heating roll. A method for producing a fiber-reinforced resin sheet according to Scope 2. (4) In an apparatus for manufacturing a fiber-reinforced resin sheet in which a woven fabric made of a plurality of continuous fibers is impregnated with a thermoplastic resin,
A supply unit having a mechanism for adjusting the tension of the fibers, and at least one resin coating film-applying roll heated above the softening point of the thermoplastic resin, for applying a thermoplastic resin coating to the roll. 1. An apparatus for producing a fiber-reinforced resin sheet, comprising: a resin impregnating section having an extruder and a die; and a taking-off section that cools and takes off the woven fabric that has passed through the impregnating section. (5) The resin impregnation section has one resin coating film application roll, an extruder and a die for applying a thermoplastic resin coating film to the roll, and after the resin coating film application roll, a thermoplastic resin coating film is applied. 5. The apparatus for producing a fiber-reinforced resin sheet according to claim 4, further comprising one or more heating rolls heated to a temperature higher than the softening point of the plastic resin.