KR20160057839A - Method for manufacturing prepreg of finished product - Google Patents

Abstract

The present invention relates to a manufacturing method which enables processes of manufacturing, cutting, and stacking prepreg to automatically proceed in one process, wherein the processes conventionally and individually proceed, thereby having advantages in consistency of products and process control in accordance with automation. According to the present invention, a method for manufacturing prepreg of a finished product comprises the following steps of: manufacturing prepreg; temporarily solidifying the prepreg; loading the prepreg on a cutting plate; cutting and stacking the prepreg; and stacking the cut prepreg.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method of manufacturing a prepreg,

More particularly, the present invention relates to a prepreg manufacturing process, a cutting process for producing a prepreg, and a lamination process in a series of processes, thereby obtaining a prepreg having a predetermined finished product shape The present invention relates to a method and an apparatus for manufacturing a semiconductor device.

The fiber-reinforced composite material is mainly manufactured by a method of preparing a prepreg which is an intermediate substrate impregnated with a resin in a fiber, cutting and laminating the prepreg so as to be a multi-directional finished product, heating and pressing in a desired form to cure the resin .

A thermosetting resin or a thermoplastic resin is used for preparing the prepreg. A prepreg impregnated with a thermosetting resin is usually prepared by impregnating a raw yarn or a fabric into a bath in which a thermosetting resin is contained in a liquid phase, laminating it in the width direction, and then drying and winding into a roll. The prepreg impregnated with the thermoplastic resin can be produced in various ways depending on the melting method such as melting the thermoplastic resin pellet by heating the bath containing the thermoplastic resin pellet and impregnating the raw material or the cloth with the thermoplastic resin pellet or the thermoplastic resin feeding method such as the film method have. Considering economical efficiency, ease of production, and quality of molding materials among various methods, the film method having the highest satisfaction is widely used. According to the film method, a pregreg which is impregnated with a thermoplastic resin is produced by impregnating a thermoplastic resin film with a raw yarn or a raw material by heating / pressing and winding it into a roll. Thus, in the prior art, the prepreg is manufactured only in the roll form of the semi-cured B-stage, and the user further cuts and stacks the prepreg in accordance with the purpose.

Preforms prepared in roll form using thermoplastic resin or thermosetting resin are manufactured in a predetermined form in the cutting process. In order to reinforce the physical properties of the final product, the fiber direction is 0 degree, 90 degree, 45 degree, -45 And so on. A multi-directionally cut sheet of prepregs on a sheet is laminated and then heat pressed to produce a prepreg article.

In the lamination process, the sheet-like prepreg made in the cutting process is made to have a desired thickness and physical properties. The thermosetting or thermoplastic prepreg has no adhesive force, and the thermosetting resin or the thermoplastic resin is pressed in a slightly melted state by applying heat. In general, such a lamination process is often carried out manually, which requires considerable time and manpower, and low productivity. In addition, the lamination accuracy was not high due to bubble generation and an abnormality in the stacking angle, and the physical properties were often lower than the theoretical value.

Therefore, in order to mass-produce the fiber-reinforced composite material with high quality, it is necessary to automate the processes which have been mainly performed in the conventional hand-made process, and shorten the process time.

Accordingly, the present invention provides a method and apparatus for manufacturing a prepreg which is an intermediate substrate in the production of a fiber composite material, wherein the step of cutting into a final finished product shape and the step of laminating are automated.

In order to solve the above-mentioned problems, the present invention provides, as a first embodiment, (a) a step of preparing a prepreg impregnated with a resin by loading a yarn or a fabric; (b) temporary solidifying the prepared prepreg; (c) loading the temporarily solidified prepreg onto a cutting board;

(d) cutting the prepreg loaded on the cutting board into a predetermined shape using a cutting device, and laminating the prepreg on the cutting board as it is; And (e) repeating the steps (a) to (d) on the cut and stacked prepregs to form a cut-off prepreg.

The present invention also provides a method for producing a prepreg comprising the steps of: (a) preparing a prepreg impregnated with a resin by loading a yarn or a fabric; (b) temporary solidifying the prepared prepreg; (c) loading the temporarily solidified prepreg onto a cutting board; (d) repeating the steps (a) to (c) on the prepreg loaded on the cutting board to laminate the temporarily solidified prepreg on the cutting board; And (e) a step of cutting the prepreg laminated in multiple layers on the cutting plate in a predetermined shape using a cutting device.

Preferably, the impregnated resin is a thermosetting resin or a thermoplastic resin.

Preferably, the temporary solidification may be a step of hot-pressing at a temperature of 50 to 100 캜.

Preferably, the temporary solidification may be a step of drying at room temperature for 1 to 2 days. Preferably, the temporarily solidified prepreg can be loaded onto the cutting board at a feed rate of 10 m / sec or less.

Preferably, in the first embodiment, the cutting plate can be rotationally driven from 0 ° to 360 °, and the steps (a) to (d) are rotated once after the step (d) do.

Preferably, in the second embodiment, the cutting plate can be rotationally driven from 0 ° to 360 °, and each time the steps (a) to (c) are performed once, .

Preferably, when the cutting plate is rotationally driven in the step (d) of the first embodiment, the control system for cutting can be rotated in the same manner as the cut plate, and the same type of prepreg can be cut each time.

Preferably, the cutting plate moves horizontally downward toward the ground every time the steps (a) to (d) of the first embodiment are performed once.

Preferably, the cutting plate moves horizontally downward toward the ground every time the steps (a) to (c) of the second embodiment are performed once.

Preferably, each time the cutting plate moves horizontally downward toward the paper, the portion other than the cut portion may be peeled off.

Preferably, the trim plate can be inclined from -90 [deg.] To 90 [deg.] With respect to the ground.

Preferably, the cutting can be done by laser, ultrasonic, thermal or cutting tools.

Preferably, the first layer and the last layer of the laminated prepreg are selected from the group consisting of chemical fibers or films such as polyurethane, polyester, nylon, polyaramid, polyimide, polyethylen, polypropylene, acrylic, rayon; Natural fibers such as cotton, hemp, wool, nuts; Aluminum, iron, silver, gold, zinc, or an alloy thereof.

Preferably, the repetitive execution in the first embodiment and the second embodiment can be performed once to 1000 times.

Preferably, in the first embodiment and the second embodiment, the prepreg produced after the step (e) may further be subjected to a cutting process for form implementation.

According to an embodiment of the present invention, a cutting process for forming a shape may be a process of forming a slope on at least one side of the prepreg, or a process of forming a groove on the prepreg.

According to an embodiment of the present invention, the cutting and lamination in the step (d) of the first embodiment can be performed according to the drawing in which each layer is designed by slicing the 3D drawing.

The present invention can also provide a laminated prepreg having a finished product form.

The present invention also relates to a plate material on which a prepreg is loaded; A motor connected to the plate and rotating the plate about 360 degrees horizontally with respect to the ground, tilting from -90 degrees to 90 degrees perpendicular to the ground, and moving the plate horizontally downward toward the ground; A cut for manufacturing legs and a laminated board can be provided.

According to the present invention, in producing a fiber composite material, it is possible to manufacture a prepreg, cut and laminate in one step, thereby making it possible to produce a fiber composite material having improved productivity and excellent lamination accuracy, Can also be provided. In addition, it has advantages in terms of product consistency and process control due to automation. Finally, a film or fabric for finishing may be attached without further processing.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a view schematically showing a step of molding a fiber composite material with a prepreg impregnated with an epoxy resin, which is a conventional thermosetting resin.
Fig. 2 is a view schematically showing a step of producing a prepreg of a finished product impregnated with a thermosetting resin according to a first embodiment of the present invention. Fig.
3 is a view schematically showing a step of manufacturing a prepreg in the form of a finished product impregnated with a thermoplastic resin according to the first embodiment of the present invention.
Fig. 4 is a view schematically showing a case where prepregs are stacked while the cutting board is rotationally driven at 45 占 according to the first embodiment of the present invention. Fig.
FIG. 5 is a schematic view illustrating a process of slanting a side face of a fiber composite material according to an embodiment of the present invention.
FIG. 6 is a schematic view illustrating a process of manufacturing a prepreg having a bolt inserted therein after forming a groove for inserting a bolt in a fiber composite material according to an embodiment of the present invention. Referring to FIG.
7 is a view schematically showing a step of manufacturing a prepreg in the form of a finished product impregnated with a resin according to a second embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted so as to avoid obscuring the subject matter of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a view schematically showing a step of molding a fiber composite material with a prepreg impregnated with an epoxy resin, which is a conventional thermosetting resin. 1, a yarn or a fabric 11 made of reinforcing fibers is impregnated with an epoxy resin 12 to prepare a prepreg as a roll 13, the prepared prepreg is cut and laminated 14 in multiple directions, A fiber composite is produced through a pre-forming step (15), a compression molding step (16) and a curing step (17) (18). This manufacturing process is proceeding as a separate step for each step. In most cases, the cutting and laminating of the prepreg in the form of a roll is carried out manually by a separate step.

The inventors of the present invention completed the present invention by studying an automation process for cutting and laminating a prepreg at one time in order to solve the problems of the cutting and laminating process which is mainly performed manually by hand during the production of the prepreg. According to the present invention, it is possible to improve the quality and productivity of the fiber composite material by making the prepreg, cutting and laminating in one automated process.

FIGS. 2 and 3 are views schematically showing the steps of manufacturing the prepreg according to the first embodiment of the present invention. Fig. 2 relates to a process for producing a prepreg impregnated with a thermosetting resin, and Fig. 3 relates to a process for producing a prepreg impregnated with a thermoplastic resin. 2 and 3, the prepreg manufacturing method according to the first embodiment of the present invention comprises the steps of (a) loading a yarn or fabric 21, 31, (S1) of manufacturing a leg; (b) temporarily solidifying the prepared prepreg (S2); (c) loading (S3) the temporarily solidified prepreg onto the cutting plates (23, 33); (d) a step (S4) of cutting the prepreg loaded on the cutting board into a predetermined shape using the cutting units (24, 34) and stacking the prepreg on the cutting board as it is; And (e) repeating the steps (a) to (d) on the cut and laminated prepregs to form a laminated prepreg (S5).

The term "prepreg of the finished product" in the present specification means a prepreg in a state in which cutting and laminating are completed in the conventional prepreg manufacturing process and can be provided immediately after heating and press forming.

The manufacturing method according to the first embodiment of the present invention will be described in detail for each step.

(a) The step of preparing a prepreg by loading a yarn or a fabric may use a method generally used in the conventional prepreg production without any particular limitation.

The composition of the yarn or fabric is selected from the group consisting of carbon fiber, aramid fiber, glass fiber, polyester fiber, polypropylene fiber, polyethylene fiber, polyurethane fiber, nylon fiber, PET fiber, celluloid fiber, And the yarn is preferably an unpaired yarn or a flat yarn, and the fabric is preferably a twill type yarn, a twill yarn, or a shirting yarn.

The resin may be a thermosetting resin or a thermoplastic resin known in the art without any particular limitation. As the thermosetting resin, a resin selected from the group consisting of a phenol resin, a melamine resin, a urea resin, an unsaturated ester resin, an epoxy resin, a polyimide resin, a polyurethane resin and a silicone resin may be used. Examples of the thermoplastic resin include polyethylene, polypropylene, polyphenyl sulfone, polyethylene naphthalate (PEN), polyethylene, polyvinylidene fluoride (PVDF), nylon, aramid, polyethylene terephthalate (PET), polyvinyl alcohol Polyurethane (PU) may be used. In this case, the resin may be selected from pellets, powder, nonwoven fabric, yarn, fabric or film.

In order to prepare the prepreg, it is possible to provide each flat flat yarn or fabric to be impregnated with a resin by overlapping with an arbitrary width, thereby controlling the desired physical properties and the thickness of the fiber composite sheet. A resin impregnation process such as a process of impregnating a resin in a bath or impregnating with a film may be used in the same manner as the conventional prepreg manufacturing method.

However, in order to smoothly introduce it into the cutting process after the impregnation process, a temporary solidification step is performed.

(b) Temporary solidification of the prepared prepreg can be performed by a step of sewing, heating at 50-100 ° C. or drying at room temperature for 1-2 days, and the prepreg can be smoothly . The hot pressing process for temporary solidification can use the heat fixers 25 and 35 and / or a roll or a mold.

(c) Loading the temporarily solidified prepreg onto the cutting board will be described. In the step of loading on the cutting board, it is desirable to transfer the yarn or fabric impregnated with the resin at a constant speed to the cutting board, and to minimize the residual stress of the yarn or fabric by advancing the conveying speed to 10 m / sec or less. This is because the residual stress may cause deformation of the fiber composite in the finished product. The feeding for loading onto the cutting board can be performed by a known means such as a one-way robot, a rolling device, or a polygonal transfer device.

(d) A step of cutting the prepreg loaded on the cutting board into a predetermined shape using a cutting device and laminating the prepreg on the cutting board as it is. In the cutting step, the resin-impregnated yarn or fabric loaded on the cutting board is cut by a control system implemented by computer software using a cutting device such as ultrasonic waves, a laser, or a cutting tool such as a knife, The Foundation is established. The cut portion is stacked in such a manner that the upper pressing rollers 26 and 36 are pressed and adhered to the cutting board while the upper pressing rollers 26 and 36 are advanced, and then the prepregs prepared in the step (c) Is preferably peeled and discarded in the same manner as the cutting plate is moved downward. Or cut parts other than the cut part may be adhered on the cutting board and then exposed to the form of peeling separately and discarded. The parts to be disposed of may be collected in the disposal at the end of the process, as shown in Figs.

(e) Repetition of steps (a) to (d) above on the cut and stacked prepregs to laminate the cut prepregs on the cut board will be described. In order to produce a finished prepreg in which the lamination is carried out after being cut, (a) from the prepreg producing step to (d) the cutting and laminating step is repeatedly carried out until predetermined thickness is obtained by predetermined lamination . it is possible to make a plurality of prepregs cut in a predetermined shape through repeating the steps (a) to (d), and each time the steps (a) to (d) are performed once, The prepregs cut in the above-described embodiment are laminated on the prepreg.

For stacking, the cutting board can be moved up and down with respect to the ground, and is adjusted to move horizontally downward toward the ground every time step (a) to step (d) is performed.

In addition, the cutting plate can be driven to rotate up to 360 °, and the multi-directional lamination is rotated after step (d) by a predetermined angle by the control system every time steps (a) to (d) do. At this time, also in the control system, the slice drawing of the next layer is read, and the predetermined design drawing such as the rotation of the cutting plate is rotated so that it exactly coincides with the shape of the cutting plate. Thus, the same type of prepreg is cut each time.

A case where the cutting board is rotated and driven at 45 degrees according to the first embodiment of the present invention is shown in Fig. 4, in step (d), the prepreg is cross-cut in the normal direction (0 °) and then the first layer prepreg 401 is adhered to the cutting board, and again from step (a) , The prepreg is loaded on the cutting plate rotated 45 ° after the first time and cut by the cutting device in the form of being rotated by 45 ° by the design drawing rotated in the same manner as the cutting plate rotation, And the second layer prepreg 402 is laminated on the first layer prepreg 401 which is adhered. Next, when the third time from the step (a) to the step (d) is carried out, the prepreg is loaded again on the cutting board rotated 45 degrees again after the second execution, And the third layer prepreg 403 is laminated on the second layer prepreg 402 which is simultaneously adhered. Through such a process, it is possible to obtain a multi-directional prepreg in which the cutting and lamination are performed at once.

The steps (a) to (d) may be repeatedly carried out until a predetermined form and physical properties are secured, for example, about 1 to 1000 times.

Further, according to the present invention, after the step (e), a cutting step may be further performed to obtain a predetermined shape. As a result, a finished prepreg having a sloped surface as shown in FIG. 5 can be manufactured. Alternatively, as shown in FIG. 6, a coupling member such as a bolt or a nut It is possible to manufacture a prepreg having a groove for use. A prepreg having a sloped surface can be produced by a process called a " tilt process ". As shown in FIG. 5, after cutting a raw material or cloth adhering to the cutting plate to a predetermined shape by a pressing process, working the cutting plate in a tilted state, and making the cutting plate parallel to the ground again, have. To this end, the trim plate is designed to be tilted within a range of -90 ° to 90 ° with respect to the ground. Alternatively, a stereoscopic shape can be implemented by a method of slicing a 3D drawing and cutting and laminating it.

In the step of forming the grooves in the prepreg as shown in Fig. 6, the cutting apparatus of the present invention can be used as it is.

In the lamination step, a honeycomb-type reinforcing material can be disposed in the middle, and finally, a film or a fabric serving as a finishing material can be laminated. In particular, the initial and final lamination treatment of the laminated structure may be carried out using chemical fibers or films such as polyurethane, polyester, nylon, polyaramid, polyimide, polyethylen, polypropylene, acrylic, rayon; Natural fibers such as cotton, hemp, wool, nuts; And a foil made of aluminum, iron, silver, gold, zinc or an alloy thereof.

By repeating the loading, cutting and laminating steps of the prepreg as described above several times, it is possible to manufacture an intermediate material of a fiber composite material having a predetermined finished product shape having a desired thickness or physical properties, And heat is applied to finally fix the shape.

On the other hand, a method of manufacturing the prepreg according to the second embodiment of the present invention will be described.

7 showing a method of manufacturing a prepreg according to the second embodiment by impregnating a thermosetting resin, a preliminarily solidified prepreg having a predetermined size is laminated in advance to a desired thickness, and finally, It is also possible to produce prepregs of the type described in Fig. According to the method, (a) preparing a prepreg impregnated with a resin 72 by loading a yarn or a fabric 71 (S1 '; (b) temporarily solidifying the prepared prepreg S2'; (c) loading the temporarily solidified prepreg onto the cutting board (73) and stacking it on the cutting board as it is (S3 ' (S4 ') of stacking temporarily solidified prepregs by repeating the steps of (a) to (c); (e) cutting the prepregs laminated on the cutting board in a predetermined shape using a cutting device 74 Lt; RTI ID = 0.0 > (S5 '). ≪ / RTI >

At this time, the cutting plate can be rotated to ~ 360 °, and the cutting plate is rotated after step (c) by a predetermined angle by the control system every time the step (a) to step (c) is performed once. Through this, the multi-directional lamination can be carried out and desired physical properties can be secured. Also, in step (c) for the lamination, the cutting board is adjusted to move horizontally downward toward the ground every time the steps (a) to (c) are performed once.

(e) In the cutting step, cutting is performed by the cutting device in a predetermined form by the control system.

As in the first embodiment, a tilt process, a 3D drawing process, and a process for forming a bolt or a nut may be further performed to realize a three-dimensional shape.

The other unexplained processes are applied in the same manner as in the first embodiment.

On the other hand, the present invention provides a cutting and laminating apparatus capable of producing a prepreg in a finished product form. The present cutting and laminating apparatus includes a plate on which a prepreg is loaded so that cutting and laminating can be simultaneously performed; A cutter comprising a motor connected to the plate and rotating the plate about 360 degrees horizontally with respect to the ground, tilting from -90 degrees to 90 degrees perpendicular to the ground, and moving the plate horizontally downward toward the ground, And a laminating plate and a cutting device. The cutting device may be an ultrasonic, laser, or cutting tool such as a knife, saw, or scissors.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation in the present invention. Various changes and modifications will be possible.

21, 31, 71: yarn or fabric
22, 32, 72: Resin
23, 33, 73: Cutting board
24, 34, 74: Cutting device
25, 35, 75: Thermal fixture
26, 36, 76: pressure roller

Claims (21)

(a) preparing a prepreg impregnated with a resin by loading a yarn or a fabric;
(b) temporary solidifying the prepared prepreg;
(c) loading the temporarily solidified prepreg onto a cutting board;
(d) cutting the prepreg loaded on the cutting board into a predetermined shape using a cutting device, and laminating the prepreg on the cutting board as it is; And
(e) repeating the steps (a) to (d) on the cut and laminated prepregs to form a laminate of the cut prepregs.
(a) preparing a prepreg impregnated with a resin by loading a yarn or a fabric;
(b) temporary solidifying the prepared prepreg;
(c) loading the temporarily solidified prepreg onto a cutting board;
(d) repeating the steps (a) to (c) on the prepreg loaded on the cutting board to laminate the temporarily solidified prepreg on the cutting board; And
(e) a step of cutting the prepreg laminated on the cutting plate in a multilayer structure to a predetermined shape using a cutting device.
3. The method according to claim 1 or 2,
Wherein the resin in step (a) is a thermosetting resin or a thermoplastic resin.
3. The method according to claim 1 or 2,
Wherein the temporary solidification in the step (b) is a step of hot-pressing at a temperature of 50 to 100 ° C.
3. The method according to claim 1 or 2,
Wherein the temporary solidification in the step (b) is a step of drying at room temperature for 1 to 2 days.
3. The method according to claim 1 or 2,
Wherein the temporarily solidified prepreg in the step (c) is loaded on the cutting board at a feed speed of 10 m / sec or less.
The method according to claim 1,
Characterized in that the cutting plate is rotatably driven from 0 ° to 360 ° and rotates after step (d) at a predetermined angle every time the steps (a) to (d) are performed once. Gt;
Wherein the cutting plate is rotatable from 0 ° to 360 °, and the step is rotated after step (c) at a predetermined angle every time the steps (a) to (c) are performed once. .
The method according to claim 1,
If the cutting plate is rotationally driven in the step (d), the control system for the cutting operation rotates in the same manner as the cut plate, and the same type of prepreg is cut each time.
The method according to claim 1,
Wherein the cutting plate moves horizontally downward toward the ground every time the steps (a) to (d) are performed once.
3. The method of claim 2,
Wherein the cutting plate moves horizontally downward toward the ground every time the steps (a) to (c) are performed once.
The method according to claim 10 or 11,
Wherein a portion other than the cut portion is peeled off every time the cutting plate moves horizontally downward toward the paper surface.
3. The method according to claim 1 or 2,
Wherein the cutting plate can be inclined from -90 DEG to 90 DEG with respect to the paper surface.
3. The method according to claim 1 or 2,
Wherein the cutting is performed by means of laser, ultrasonic, thermal or cutting tools.
3. The method according to claim 1 or 2,
The first layer and the last layer of the laminated prepreg may be formed of a chemical fiber or film such as polyurethane, polyester, nylon, polyaramid, polyimide, polyethylen, polypropylene, acrylic, rayon; Natural fibers such as cotton, hemp, wool, nuts; Wherein the foil is treated with a foil made of aluminum, iron, silver, gold, zinc or an alloy thereof.
3. The method according to claim 1 or 2,
Wherein the repetition is performed once to 1000 times.
3. The method according to claim 1 or 2,
Wherein the step (e) further comprises a cutting step for forming the prepreg.
18. The method of claim 17,
Wherein the cutting step for forming the shape is a step of forming a slope on at least one side of the prepreg or a step of forming a groove on the prepreg.
The method according to claim 1,
Wherein the cutting and laminating in the step (d) is performed according to a drawing in which each layer is designed by slicing the 3D drawing.
A laminated prepreg having a finished product shape produced according to claim 1 or 2.
A plate on which the prepreg is loaded;
A motor connected to the plate and rotating the plate about 360 degrees horizontally with respect to the ground, tilting from -90 degrees to 90 degrees perpendicular to the ground, and moving the plate horizontally downward toward the ground; Cuts and laminates for making legs.

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