JPS6227142B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention involves manufacturing a prepreg sheet by plasma spraying uniformly spread fibers, and then laminating and heating an appropriate number of prepreg sheets manufactured in the same process as this prepreg sheet. , relates to a method for producing a fiber reinforced material under pressure.

As a conventional method of this type, there is a method in which prepreg sheets are manufactured by ion plating, in which a matrix material is ionized and vapor-deposited, and a suitable number of prepreg sheets are laminated and molded by hot pressing.
In order to vaporize and ionize the matrix material and coat the fiber surface, it must be carried out in a vacuum, which is extremely disadvantageous when continuous production is desired. If we tried to perform ion plating and hot pressing continuously in a vacuum, large equipment would be required, and it would be extremely difficult to control the ion plating speed and hot pressing speed, making continuous operation impossible, so a batch system would be required. This is a major cause of high costs.

In addition, various methods such as solution infiltration method, extrusion method, and pultrusion method have been tried as methods that enable continuous production, but when using a matrix as a molten metal, for example, carbon fibers are inevitably produced by the matrix metal. It was not possible to prevent the temperature from rising to the melting temperature and the formation of metal carbides on the surface. This metal carbide is brittle and breaks the adhesion between the carbon fiber and the metal matrix when stress is applied, causing a decrease in the strength of the composite material. Furthermore, it is not possible to directly control the distribution of reinforcing fibers at the time of solidification of the matrix, which poses a problem in terms of uniform dispersion of the fibers in the composite material.

The present invention solves the above-mentioned drawbacks, and first, the apparatus used in the method of the present invention will be explained with reference to the drawings.

A take-up roll 2 winds up a fiber bundle 1 made of a large number of long fibers for reinforcing composite materials such as carbon fibers, boron fibers, glass fibers, etc., and a lateral flow is generated to uniformly spread out the fiber bundle 1. a lateral flow generating device 3 for taking the uniformly spread fibers 4; a driving spreading drum 5 for taking the uniformly spread fibers 4; and a plasma spraying device 7 for plasma spraying a matrix material onto the fibers 4 evenly spread on the driving spreading drum 5. As shown in FIG. 1 and FIG.
Manufacture... The heating device 8 heats the appropriate number of prepreg sheets 6, 6, 6... in a state where they are overlapped with each other, and the appropriate number of overlapped prepreg sheets 6, 6, 6... are bonded together under pressure. The pressure molding device 9 constitutes a fiber reinforced composite material manufacturing device. Further, to explain each of the above-mentioned devices in more detail, the lateral flow generating devices 3 are arranged between the guide roll 10 and the driving spreading drum 5 and at symmetrical positions with the fiber bundle 1 as the center, and are used to supply compressed air. It is composed of a pipe 11, a nozzle 12 for ejecting compressed air, and the like. The plasma spraying device 7 includes a plasma spray main body 13, a material supply pipe 14 for supplying matrix materials such as Al, Ti, or in some cases plastic, a gas supply pipe 15 for supplying Ar--He gas, and a plasma spray main body 13. A cooling water supply pipe 16 for supplying cooling water to cool the inside of the spray main body, a drainage pipe 17 for discharging the cooling water, and support legs 18 for supporting the spray main body 13 while adjusting its height. Spray main body 13
The pedestal 21 is equipped with wheels 19 and 20 for moving the plasma back and forth, and the pedestal 21 is automatically moved back and forth by a driving means 22 to control the plasma spraying conditions. 23 is a nozzle attached to the plasma spray main body 13, and 24 is a rolling roll for controlling the thickness of the prepreg sheet 6. The heating device 8 includes a heating device 27 having a built-in heating heater 25, a gas burner 26, etc., and a stack of prepreg sheets for guiding an appropriate number of prepreg sheets 6, 6, 6... to the heating device 27 in an overlapping state. It is composed of adjustment rolls 28 and 29. In addition, the pressure molding device 9 is configured to produce an appropriate number of prepreg sheets 6, 6, 6, . . .
It is composed of pressure rolls 30, 31 whose pressure can be adjusted for integrally pressurizing and crimping, and 32 is a fiber-reinforced composite material made by pressurizing and crimping an appropriate number of prepreg sheets 6, 6, 6, ... It is. In another embodiment, an appropriate number of pressure rolls 30 and 31 of the pressure molding device 9 are arranged vertically or horizontally, and a heating device 8 is arranged between them to repeat heating-rolling-heating-rolling. It is also possible to manufacture flat fiber-reinforced composite materials with a predetermined thickness and width.
Furthermore, by using deformed rolls instead of the pressure rolls 30 and 31, it is also possible to manufacture fiber-reinforced composite materials such as L-shaped and H-shaped. As yet another example, in the process of laminating an appropriate number of prepreg sheets, a stainless steel plate is inserted between the prepreg sheets.
A method of interposing a metal mesh, carbon powder, etc., a method of interposing an appropriate number of prepreg sheet plates reinforced by horizontal fibers between prepreg sheets reinforced by vertical fibers in a sandwich trench, and a method of plasma spraying. It is also possible to further strengthen the strength of the fiber-reinforced composite material by spraying short fibers with it during the process.
It is also possible to arrange a press device in the heating device 8 and press the material simultaneously with heating to manufacture a composite material.

Next, a method for manufacturing the fiber reinforced composite material of the present invention will be explained.

First, a fiber bundle 1 made of suitable fibers 4 for reinforcing composite materials such as carbon fibers, boron fibers, glass fibers, etc. is wound around a winding roll 2.
When one end is stretched over the driving developing drum 5 and compressed air is supplied from the supply pipe 11 to the lateral flow generator 3 while driving the drum 5, the lateral flows are arranged at opposite positions centering on the fiber bundle 1. The compressed air ejected from the generator 3 collides with each other to generate a lateral flow, and this lateral flow causes the fiber bundle 1 to spread out evenly, and the uniformly spread fibers 4 to be stretched to an appropriate tension. In this step, the plasma spray main body 13 is supplied with a molten metal matrix material of, for example, Al through the material supply pipe 14, and Ar-- When He gas is supplied, matrix material is continuously sprayed in the form of fine particles from the nozzle 23 of the plasma spray main body 13 onto the uniformly spread fibers on the driving spreading drum 5, and this matrix material is sprayed uniformly on the spreading drum 5. The prepreg sheet 6 is deposited by entering between the spread fibers 4 and from the sides and forming a spongy upper surface and denser on the drum surface side, and the thickness and width of the prepreg sheet 6 are further made uniform by the rolling roll 24. 50
Thin prepreg sheets 6 of μ to 100 μ are continuously produced. Optionally, this roll 24 may act merely as a guide roll. Next, this prepreg sheet 6 and an appropriate number of prepreg sheets 6, 6, 6, ... manufactured by other similar prepreg sheet manufacturing equipment are laminated with each other by prepreg sheet lamination adjustment rolls 28, 29, and this laminated When the prepared prepreg sheet is guided to the heating device 27,
The laminated prepreg sheets 6, 6, which are heated and softened by the heating device 27 to the softening temperature of Al,
6, . . . are further sent to the next pressure molding device 9 and integrated by pressure rolls 30, 31 to continuously produce a flat fiber reinforced composite material 32. In addition, other metals such as Ti may be used instead of Al depending on the purpose as a matrix material, and among the appropriate number of manufacturing apparatuses for the prepreg sheet 6, for example, one that sprays an Al matrix material and another that sprays a Ti matrix material. It is also possible to produce a fiber-reinforced Al--Ti composite material by appropriately combining these materials.

Since the present invention is comprised of the above-described method, it exhibits the following unique functions and effects.

(b) Since the fiber bundle can be spread uniformly and continuously in a short time and in a simple manner, and the matrix is attached while maintaining the same state, uniform distribution of reinforcing fibers in the prepreg sheet is guaranteed.

(b) Plasma spraying can be performed in the air at low temperatures, so intermetallic compounds are not generated at the interface between the fibers and the metal matrix material, so there is no risk of deterioration in the strength of the prepreg sheet, and it does not require large equipment compared to conventional methods. Significant cost reductions can be expected.

C. Since fiber-reinforced composite materials can be manufactured continuously, it is suitable for mass production.

D. The surface of the prepreg sheet is shaped like a sponge, so when an appropriate number of prepreg sheets are stacked and pressed together, the adhesion between them is extremely good.
In particular, it can be applied to crimping of dissimilar metals that are not compatible with each other.

For example, if a composite material is produced by laminating an Al matrix prepreg sheet and a Ti matrix prepreg sheet, a composite material with strength close to that of a Ti matrix can be produced, and costs can be expected to be reduced by the use of inexpensive Al.

By manufacturing a composite material by laminating prepreg sheets with different fiber directions, strength in the vertical and horizontal directions can be strengthened.

The method of spraying short fibers in the plasma spraying process not only strengthens the strength of the composite material in the direction perpendicular to the fibers, but also is more suitable for continuous production of composite materials than the above methods.

H. Composite materials with irregular cross-sections can be easily manufactured by replacing the rolls of the pressure molding device.

Reinforcement material can be inserted between prepreg sheets to increase the strength of the composite material.

The fiber-reinforced composite material continuously manufactured by the manufacturing method of the present invention can be used as a light and strong material such as space materials, aircraft materials, automobile materials, ship materials, and building materials.

Prepreg sheets formed by plasma spraying have extremely low strength in the direction perpendicular to the fibers, which poses a problem in batch processing, but in the present invention, the fibers with high strength are continuous. , so there are no handling problems.

[Brief explanation of the drawing]

FIG. 1 is a schematic side view of an apparatus used in the method for manufacturing a fiber-reinforced composite material of the present invention, and FIG. 2 is a perspective view of FIG.
Winding roll, 3... Lateral flow generator, 4... Uniformly spread fiber, 5... Driving developing drum, 6... Prepreg sheet, 7... Plasma spraying device, 8... Heating device, 9... Pressure molding device, 10 ... Guide roll, 11 ... Supply pipe, 12 ... Nozzle, 13 ... Plasma spray main body, 14 ... Material supply pipe, 1
5... Gas supply pipe, 16... Cooling water supply pipe,
17... Drain pipe, 18... Support leg, 19, 20...
Wheel, 21... Pedestal, 22... Drive means, 23... Nozzle, 24... Roll roll, 25... Heater, 2
6... Gas burner, 27... Heating equipment, 28, 29
... Lamination adjustment roll, 30, 31 ... Pressure roll, 3
2... Indicates a fiber reinforced composite material.

Claims (1)

[Claims] 1. The first step is to uniformly unfold the long fiber bundle wound on a take-up roll and arrange the fiber bundle on a base such as a roll under the action of an appropriate tension. The second step is to produce a prepreg sheet by plasma spraying the matrix material, the third step is to heat or stack the required number of prepreg sheets, and the third step is to continuously press the stacked prepreg sheets with rollers. A continuous manufacturing method for a fiber-reinforced composite material, characterized by continuously performing four steps.