KR910005157B1 - Method for manufacturing a sheet pregreinforced with fibers and apparatus for the same - Google Patents

Abstract

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Description

Method for manufacturing fiber reinforced resin sheet and apparatus therefor

1 is a schematic side view showing an embodiment of the present invention.

2 is a cross-sectional view showing a mounting structure of a bobbin wound with continuous fibers.

3 is a front view of an aligner for collecting and arranging continuous fibers to form a fiber sheet.

4 is a plan view of the statue (only half of the fibrous sheet is displayed).

Figure 5 is a side view showing the main portion showing an example when applied to the woven fabric of the present invention.

6 is a schematic side view showing an anomaly with improved resin impregnation.

7 is a side view showing another example of the resin impregnation part.

8 is a schematic cross-sectional view of a cooling device.

9 is a schematic side view.

10 is a detailed view showing another example of the resin impregnated part.

* Explanation of symbols for main parts of the drawings

1 fiber feeding unit 2 supply unit

3: resin impregnation part 4: receiving part

6 bobbin 7 continuous fiber

8: guide roller 9: sorter

10: fiber sheet 11: tension adjusting roll

12 brake 13 die

14: upper belt 15: lower belt

16: drive motor 16a: transmission

17: 1st heating roll 18: 2nd heating roll

19: lower pull 20: first nip

21: Upper belt tension adjusting roll 22: Lower pull roller

23: heating resin supply roll 24: lower belt tension adjustment roll

26: cooling device 27: take over roller

28: motor 29: winding shaft

30, 31, 32, 33, 34: Impregnation Promotion Roll

35, 36: Zigzag row control roller 50, 51: Heating roll

50A, 50A: Gear 61: Bobbin Body

62: shaft 63: bearing

64: brake belt 91: steel wire

92: bearing 93: set screw

261: Low 262: Hiburouul

263: tank 264: upper roller group

The present invention relates to a method for producing a fiber reinforced resin sheet-shaped prepreg and an apparatus thereof.

The fiber reinforced sheet-shaped prepreg of this invention is used as a kind of industrial material which forms a red insecticide. As a method of manufacturing a fiber reinforcement composition by impregnating a thermoplastic resin in a fiber, as described in Japanese Patent Application Laid-Open No. 61-229534, Japanese Patent Application Laid-Open No. 61-229535, Japanese Patent Application Laid-Open No. 61-229536 The sheet or woven fabric is guided to a coating roll coated with a thermoplastic resin on the surface, and the thermoplastic resin applied to the coating roll is transferred to a fibrous sheet or woven fabric, and then the front and back surfaces of the fibrous sheet or woven fabric are heated. It is known to increase the degree of impregnation of the resin by contacting the roll.

In the apparatus according to the conventional method described above, an air shielding member such as a belt is not present on the back surface of the fiber sheet or the woven fabric contacting the application roll and is in a released state.

In addition, since the application rolls and the heating rolls adjacent thereto are discontinuous, the resin immediately after extrusion is continuously supplied to the application rolls, and the application rolls are successively applied to the fibrous sheet or the woven fabric to transfer to the adjacent heating rolls. For this reason, the resin on the surface of the application roll is less deteriorated in appearance, but the amount of the resin is very small since the transfer of the resin immediately after extrusion to the surface of the heating roll adjacent to the application roll is performed only by a fiber sheet or a woven fabric. For this reason, the resin transferred to the surface of the heating roll remains as it is without shifting most of the adjacent heating rolls. Therefore, the resin transferred to the surface of these heating rolls stays in a high temperature and in contact with air in the heating rolls without being replaced with the water immediately after extrusion. Since it is extremely difficult to completely remove the resin transferred to the heating roll, the retained resin may be deteriorated due to thermal deterioration, oxidative deterioration, or crosslinking (crosslink) of the resin along with the operating time. there is a problem.

In addition, since the resin in the obtained sheet is thermally deteriorated and oxidatively deteriorated as described above, there is a problem such as not maintaining sufficient strength properties and even deteriorating sheet performance.

Accordingly, the present invention aims to provide a method and apparatus for producing a high performance fiber reinforced resin sheet which is capable of stable continuous motion and has little resin degradation.

Other objects and advantages of the present invention will become apparent from the following description.

The main feature of the present invention is to pass a fibrous sheet or woven fabric between a pair of belts heated above the softening point of the thermoplastic resin and having the thermoplastic resin coating film and surface-welded to the heating roll.

The belt is continuous, even when the impregnated fibrous sheet or woven fabric is transferred to the belt surface when some resin is transferred to the belt surface when it is separated from the belt at the impregnation outlet, for example, the belt is impregnated. When returning to the inlet again, the solidified transfer resin is reheated and melted and fuses with a large amount of resin immediately after extrusion, so that the resin does not stay between the belts.

For this reason, the thermal deterioration, the oxidation deterioration, and the gelation of the resin are not mentioned in addition to the operation time which is a problem in the case of the conventional roll coating, and thus a long continuous operation is possible. In addition, as described above, thermal deterioration, oxidative deterioration, and the like are not caused, so that a sheet of high performance can be obtained.

In the application of the present invention, the object to impregnate the resin is a fibrous sheet or a woven fabric.

In the present invention, a plurality of continuous fibers are a plurality of what are known by the name of roving, yarn and tow, which are aggregates of filaments constituting the fiber, and the filaments are sufficiently long, and the molten thermoplastic resin film It has enough strength to touch it. Preferred materials include glass fibers, carbon fibers, and high elastic synthetic resin fibers. However, metal fibers such as carbon carbide fibers, alumina fibers, titanium fibers, boron fibers, and stainless steel may be used.

It is preferable that the synthetic resin fibers are surface-treated to have adhesion to the impregnated thermoplastic resin, and it is necessary that the performance such as strength does not change at the melting temperature of the thermoplastic resin to be used. Examples of the synthetic resin fibers include aramid fibers (registered trademark " Kevlar ", etc.).

It is preferable that the glass fiber and the carbon fiber be coated with a surface treatment agent such as a silane-based or titanium-based binder on the surface of the fiber in order to improve the adhesiveness with the resin in accordance with the thermoplastic resin to be used. In addition, a binding agent may be used so that rovings and tows do not loosen when handled within a range that does not prevent obstacles during impregnation.

In the present invention, a plurality of continuous fibers, for example, are arranged in parallel in one direction in the machine direction, controlled so as not to cross each other, widened in the width direction, and adjusted to an appropriate thickness to form a sheet like a warp of the loom. Is formed. Specifically, the continuous fibers are wound on the plural extra bobbins, and the fibers are released while applying the appropriate tension from the respective bobbins, and then pass through an aligner having a sieve-like shape in a row with a suitable width in the machine direction. It is preferable to arrange | position in sheet shape.

The thickness of the sheet depends on the thickness of the fibers (roving or toe) used, but can be controlled by the array density in the width direction of the roving or toe. Since the thickness precision is affected by the unevenness of the impregnated state, it is desirable to be within ± 10% of the target thickness meter. There is no particular limitation on the thickness, but when the thickness is larger than 10 µm, the breakage of the fiber can be prevented. On the other hand, when the thickness is thinner than 1000 µm, the impregnation degree of the resin is increased, so that voids are small and molding defects do not occur.

When arranging the fibers in a sheet form, it is effective to raise the temperature of the working environment in order to prevent the filaments of the fibers from being broken by the friction in the guide rollers or through the aligners.

The sheet thus obtained needs to be given uniform tension to each roving or toe so that each roving or toe does not intersect.

The fibrous sheet may be arranged by pulling a plurality of continuous fibers as shown in the examples described later, but using a so-called beam yarn (Beamedyarn) in which a required number of continuous fibers are wound in a single direction in a direction such as a warp in advance. It is also possible. The said yarn is widely used as a warp yarn when making a continuous fiber into a woven fabric. In the present invention, the woven fabric refers to a cloth processed using the continuous fibers described above, and the method of organizing the fibers is arbitrary. Therefore, the woven fabric used in the present invention includes those obtained by a tissue method generally referred to as plain weave, runner weave, twill weave, and tritwill weave, as well as mated nonwoven fabric and needling processing on the mat nonwoven fabric. Include.

Hereinafter, the case where this invention is applied to a fiber sheet is demonstrated.

In impregnating the thermoplastic resin into the fibrous sheet, the thermoplastic resin used is polystyrene, polyvinyl chloride, high density polyethylene, polypropylene, nylon, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, and the like. It is not limited to these.

In addition, when the resin sheet obtained by the present invention is used for applications requiring structural strength, it is preferable that the resin has high elastic modulus and high tensile strength. Specific examples thereof include polyether sulfone, polysulfone, and polyphenyl. High-grade engineering resins such as rensulphides, thermoplastic polyamides, and polyetherimide (trade name: ULTEN® polyether ether ketones) are suitable.

When using these resins, it is preferable to dry beforehand, and it is more preferable to add a binder, such as a titanium system, to resin for the purpose of the adhesive improvement with a fiber.

The thermoplastic resin is melted inside the extruder, extruded from a die placed at its tip, and applied to the surface of a pre-heated lower belt, for example. The resin temperature is determined according to each resin characteristic so that a uniform resin coating film is formed. The width of the resin coating film may be equal to or larger than the width of the fiber sheet, and the thickness of the coating film is adjusted to an appropriate thickness corresponding to the thickness of the fiber sheet. This thickness is a value determined experimentally by the set target value of the resin content in the fiber reinforced sheet finally obtained. 10-1000 micrometers is preferable and, as for a coating film thickness, 20-200 micrometers is more preferable. On the other hand, since the thickness precision is greatly influenced by the above-described resin content in the width direction, ± 10% is preferable with respect to the set thickness, and more preferably ± 5% or less.

Thus, as a coating method of improving the thickness precision of a coating film, a conventional method can be used.

In this way, the fibrous sheet is press-contacted to the roll through a lower belt provided with a resin coating film, for example, and the fiber is impregnated with resin. Since impregnation is achieved as the resin coating film passes between the filaments constituting the fiber sheet and reaches the back surface of the fiber sheet, the contact pressure of the fiber sheet to the belt, and further to the roll, causes the sheet to push back the resin coating film and lower belt. It is enough to reach the surface, and this contact pressure is controlled by the tension on the fibrous sheet. If the tension is too strong, the resin coating film does not pass between the filaments of the fiber sheet and is pushed in the width direction of the fiber sheet, so the tension must be determined according to the viscosity of the resin to be used.

In this invention, 500-50000 poses of the viscosity of resin are preferable, More preferably, it is 1000-5000 poses.

Moreover, in this invention, 1-10000 g / piece of fibrous sheets is preferable, and, as for the tension applied to a fiber sheet (or woven fabric), 10-5000 / piece is more preferable. Moreover, as for the tension in the case of a woven fabric, 5-100000 g / cm width is preferable, More preferably, it is 50-20000 g / cm width.

The fibrous sheet to which the resin is applied is then conveyed in a state sandwiched between the upper and lower belts, pressed against, for example, one or two heating rolls, and improved after the impregnation efficiency, and then cooled and harvested. . The temperature of these heating rolls is more than the softening point of resin to impregnate.

In the present specification, the softening point refers to the lowest temperature that can be measured at a load of 5 kg using a melt inx meter.

If the surface of the fibrous sheet is the surface that is in contact with the lower belt at the beginning of heating, the lower belt and the upper belt are alternately the surface of the next heating roll via the upper belt and the next heating roll via the lower belt. The resin present on the surface or on the back surface is pressed through the lower or upper belts so that the resin flows between the filaments of the fibrous sheet in the alternating direction from the surface to the back surface and then from the back surface to the surface via the lower or upper belt. It is preferable to press-fit the fiber sheet to the roll via the belt, and in this way, the degree of impregnation can be improved.

In the present invention, the number of rolls should be determined by the characteristics of the resin to be used, and it is extremely effective to adjust the number of rolls to be heated to the required number according to the type of resin to be used.

In the application of the present invention, removing the resin adhering to the belt surface with a doctor plate or the like has the effect of adjusting the resin content and smoothing the surface of the fibrous sheet, which is preferable. In addition, the resin can be removed in either the molten or solidified state, but the state should be determined according to the characteristics of the resin.

Next, the cooling of the fibrous sheet impregnated with resin affects the degree of crystallization and the grain size of the crystalline resin, so that the cooling rate is adjusted in accordance with the resin to be used. It is desirable to control the degree of crystallization and grain size. As a method of adjusting the cooling rate, a heating stand is disposed between the impregnation part and the take-up machine, and is cooled by attaching a temperature gradient to the heating stand, or by quenching a cooling medium such as cooling air directly onto the fiber sheet. We can adopt how to do.

On the other hand, when the fiber sheet is separated from the impregnated portion in the molten state of the impregnated resin as described above, depending on the type of the impregnated resin, the resin portion may deteriorate due to contact with air or the like during cooling. In this case, it is more preferable to provide a cooling device for cooling the belt below the softening point of the thermoplastic resin in the resin impregnation portion.

In this case, the fibrous sheet impregnated with the thermoplastic resin is subsequently cooled to less than the softening point of the resin in the state sandwiched between the belts and then taken over to the take-up part.

As a cooling method, the method of slow cooling in air | atmosphere, the method of forcibly cooling the upper and lower belts by air injection, water, etc. are mentioned. During the cooling, cooling the fibrous sheet while pressurizing the fibrous sheet through the upper and lower belts through pressurization, for example, a pair or a plurality of pairs of cooling nip rolls, and through the upper and lower belts, improves the appearance of the fiber sheet. It is preferable in terms of defoaming, and also contributes to improvement of mold release property of the fiber sheet from the belt.

It is particularly preferable to perform the release treatment on the belt surface before or during the operation in view of improving the releasability of the fiber sheet.

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

First, an example in which the present invention is applied to a fiber sheet composed of a plurality of continuous fibers will be described.

As shown in FIG. 1, the manufacturing apparatus for implementing this invention method consists of the feed | feeding-out part 1, the supply part 2, the numerical value part 3, and the acquisition part 4 of a fiber unwinding.

[Feeder]

The fiber feeding part 1 is a means for supplying a plurality of continuous fibers, for example, a plurality of bobbins 6, a mechanism for adjusting the tension at the time of fiber feeding, for example the brake for tension adjustment shown in FIG. It has a belt 64.

In the fiber feeding section 1, only the necessary number of fibers is released from the continuous fibers 7 wound on a plurality of bobbins attached to the apparatus table 5. As shown in FIG. 2, the bobbin body 1 is fixed to the shaft 62, and the shaft 62 is rotatably mounted to the bearing 63. The shaft 62 is equipped with a tension adjusting brake belt 64 for adjusting the tension with which fibers are released from the bobbin 6.

[Supply section]

The supply part 2 arranges the continuous fibers 7 to be released from the bobbin body 61 horizontally by the guide rollers 8, and aligns them at arbitrary fiber intervals and arbitrary widths by the aligner 9. It has a function of forming the fiber sheet 10. As shown in FIGS. 3 and 4, the aligner 9 extends a plurality of stiffnesses 91 in a frame-shaped frame, and the continuous fibers 7 each have a space between the gaps of the steel wires 91. By passing through it is aligned. The aligner 9 has a bearing 92, and as shown in FIG. 4, has a structure in which the angle can be changed in the direction of the arrow, and the continuous fibers 7 are also spaced by the angle change. Can be adjusted to adjust the width and thickness of the fiber sheet 10. Reference numeral 93 is a fixing screw for selecting and fixing an arbitrary angle of the aligner 9.

The fibrous sheet 10 is then controlled by the tension adjusting roll 11 with the brake 12 to a uniform tension over the entire width and supplied to the numerically impregnated portion 3. The surface of the tension adjusting roll 11 preferably uses rubber or the like as a material so as to facilitate tension adjustment by frictional resistance. The tension is not particularly limited, and the fiber sheet 10 may be such that there is no disturbance between the fibers during the impregnation of the resin impregnated portion 3. In addition, the tension adjusting roll 11 does not need to be used as long as uniform tension adjustment is possible with respect to the entire bobbin 6 in the feeding section 1.

[Resin compartment]

The resin impregnation portion 3 has a pair of belts, that is, the upper belt 14 and the lower belt 15, and along the conveying center of the fiber sheet, the first heating roll (inlet heating roll) ( 17), the second heating roll 18 and the lower pull roll (outlet roll) 19 are provided in parallel. The first nip roller 20 is disposed above the first heating roll 17, and the upper pull roller 22 is disposed above the lower pull roller 19. Reference numeral 21 denotes an upper belt tension adjustment roll 23, a heated resin supply roll, and 24 a lower belt tension adjustment roll. Denoted at 13 is a resin supply die 16 as a drive motor.

As the heating means for the belt, a method of thermally conducting the heat of the heated rolls 17, 18, 19, 20, 22, and 23 to the belt in surface contact with these rolls is used.

The thickness of the fiber reinforced sheet-shaped prepreg obtained by adjusting the gap between the exit rolls 19 and 22 can be adjusted.

In addition, the upper and lower belts 14 and 15 are preferably provided with a scraper (not shown) for dropping the resin coating film attached to the surface, and both the belts are always on the resin and the fiber sheet 10 with a clean surface. It is preferable that the resin impregnation amount to the fiber sheet is not changed by contact.

When the fibrous sheet 10 enters the resin impregnated portion 3 having the above configuration, the plastic film thermoplasticized by an extruder (not shown) is applied to the surface of the resin via a die 13, and the lower portion of the resin film is coated on the surface thereof. It is in contact with the belt 15 and is pressed against the heating roll 17 via the belt 15 to impregnate the resin, and then through the upper belt 14 to the heating roll 18 and the lower belt. It is pressed against the lower pull roller (heating roll) 19 via (15). In this way, resin impregnation is sufficiently performed.

The resin impregnated part of the present invention can be improved as shown in FIG. 6 from the viewpoint of improving the impregnation effect under high speed. 6, the 3rd heating roll 50 and the 4th heating roll 51 are added to the resin impregnation part of FIG.

First of all, the first improvement is to arrange the first resin impregnation promoting roll 30 at the inlet of the resin impregnated portion 3.

The position in which the roll 30 is disposed is preferably a position where the fibrous sheet is more strongly press-contacted to the first heating roll 17, the viscosity of the resin or the first heating roll 17 and the second heating roll 18. The desired position can be determined by the direction of test between and.

In the illustrated embodiment, it is disposed at a position lower than the upper end of the first heating roll 17, and the lower left and the second in the drawing on the side where the roll 30 is disposed around the first heating roll 17. In the side in which the heating roll 18 was arrange | positioned, it is comprised so that each tension of the upper and lower sides of a figure may act.

Although the distance between the center of the roll 30 and the 1st heating roll 17 is not specifically limited, It is preferable that it is close as shown. When the roll 30 and the first heating roll 17 are slightly spaced apart, another roll may be interposed between the rolls 30 and 17 to show a cooperation with the roll 30. have. The roll 30 is preferably provided with a roll position adjusting mechanism for bringing the first heating rod 17 closer or away from the first heating rod 17.

The direction of introduction of the fibrous sheet 10 into the impregnation portion 3 is not limited to the horizontal direction as shown in the usual figure, but may be any one of an upper top shape and a front downward direction in a horizontal state. It goes without saying that the sheet 10 may be provided with a plurality of guide rollers within a range that does not impair the effects of the present invention.

In addition, when the sheet 10 is introduced in the upward direction, it may be the same as or approximately equal to the inclination of the sheet 10 between the roll 30 and the roll 17, in which case The roll 30 may also exhibit cooperative operation with the guide roll interposed in the sheet 10.

In addition, the diameter (size) of the said roll 30 is not limited.

By disposing the first resin impregnation promoting roll 30 as described above, it is possible to promote the resin impregnation to the fiber sheet 10 even under high speed conveyance, and also to degas the air in the fiber at the initial stage of impregnation, You can get a product.

The second improvement is to arrange the outlet impregnation promoting roll 31 at the outlet of the resin impregnated portion 3.

The position of the roll 31 is a position lower than the upper end of the outlet roll (lower pulley) 19 in the illustrated embodiment, and preferably the position where the fiber sheet 10 can be pressed against the outlet roll 19. Do. The roll 31 is preferably provided with a roll position adjusting mechanism for bringing the roll 19 closer or away from the roll 19.

The roll 31 and the exit roll 19 need only be located nearby, and the center distance thereof is not particularly limited, but is preferably close as shown. In the case where the roll 31 and the exit roll 19 are slightly spaced apart, another roll may be interposed between the roll 31 and the exit roll 19 to cooperate with the roll 31. .

The direction of derivation from the impregnation part 3 of the fiber sheet 10 is a horizontal direction as shown normally. The present invention is not limited to this, and depending on the winding position, either the front upward or the forward downward light may be used. In that case, the guide 10 may be provided with a plurality of guide rollers within a range that does not impair the effects of the present invention. Of course it is good.

Moreover, when the said sheet | seat 10 is led forward and downward from the exit roller 19, the inclination inclination of the sheet | seat 10 is equal to the inclination of the sheet | seat 10 between the roll 31 and the exit roller 19. As shown in FIG. Alternatively, there may be approximately the same case, in which case the roll 31 may exhibit co-operation with other guide rollers interposed in the sheet 10.

The shape of the roll 31 is not limited to a flat shape, the cross section may be a curved shape or the like, and the diameter (size) of the roll 31 is not limited.

In the case where the outlet impregnation promoting roll 31 as described above is disposed, there is an effect that the unevenness of the resin impregnation degree is eliminated even under high speed, so that cracks (so-called splits) split in the fiber direction between the fiber sheets are not generated.

The third improvement includes impregnating acceleration rolls 32 and 33 in each of the second heating roll 18, the third heating roll 50 and the fourth heating roll 51 (these are called intermediate heating rolls). , (34) is the contact excretion.

The second heating roll 18 and the fourth heating roll 51 are tensioned upward in this embodiment, and the impregnating acceleration rolls 32 and 34 are the second and fourth heating rolls 18, respectively. ), It is preferable to be disposed under contact with (51). Likewise, the impregnation promoting roll 33 is preferably disposed in contact with the upper portion of the third heating roll 50.

The size of the impregnation promoting rolls 32, 33 and 34 is not particularly limited, but is preferably smaller than the heating rolls 18, 50 and 51. The position at which the impregnation promotion rolls 32, 33, and 34 are disposed is not limited to just below or directly above the heating rolls 18, 50, and 51, but is shifted to some extent before and after (left and right). You may be.

By disposing the impregnation promoting rolls 32, 33, and 34 above, even if the conveyance speed is increased, the non-uniformity of resin impregnation on the fiber sheet 10 can be eliminated and the product thickness can be adjusted.

The 4th improvement is to arrange | position the zigzag row adjustment rollers 35 and 36 between the roll 21 and the roll 22, and between the roll 19 and the roll 24, respectively.

The rolls 35 and 36 are tensioned by the belts 21 and 24 while the rolls 21 and 24 form tension by moving in the up-down direction in the drawing, while only one end of the roll moves in the left-right direction in the drawing. Adjust to that.

The means for moving the rolls 35 and 36 in the horizontal direction is not particularly limited, and various slideers and the like can be used, for example.

Further, although not shown, the rolls 35 and 36 are disposed at positions contacting to the outside of the belts 14 and 15, and the belts 14 and 15 are pushed from the outside to jig. You're supposed to adjust the line. In this case, the materials of the rolls 35 and 36 are preferably soft such as aluminum. The rolls 35 and 36 may be disposed between the rolls 20 and 21 and between the rolls 23 and 24, respectively.

In addition to the rolls 35 and 36, one or two or more rolls capable of moving in the same direction or in a different direction from the rolls 35 and 36 may be added.

Further, only one end of each of the rolls 18, 22, or the rolls 17, 20 may be moved to the left or right, so that the above-described zigzag row adjustment function may be provided to the rolls.

By arranging the above-described zigzag row adjusting rollers 35 and 36, the zigzag row of the belt, which may have occurred when it was only a tension roller, can be prevented, and the resin impregnation degree can be improved even at a high speed.

The 5th improvement is to arrange | position the tension adjusting means T for making it larger than the tension | tensile_strength of the belt By of the back of the roll 51 in front of the exit roll 19. As shown in FIG.

The tension adjusting means T is, for example, a drive motor 16 directly connected to the outlet roll 19 and a transmission 16A directly connected to the roll 51 in front of one of the outlet rolls 19. It is preferably configured to vary the number of revolutions of the roll 51 in front of the outlet roll 19, that is to be configured to transmit the driving force of the transmission (16A) to the roll (51).

As the transmission 16A, it is possible to change continuously or stepwise, and any of automatic, semi-automatic and manual type may be used. The shift method may be any of belt type and gear type, for example. Although the adjustment range of a transmission is not specifically limited, 10 to 95% of drive motor rotation (number) is preferable.

In the present invention, it is preferable to adjust the speed of the transmission 16A so as to speed up the rotation of the exit roll 19 and slow down the rotation of the roll 51 before the one.

To transmit the driving force to the upper and lower exit rollers (up and down pull rollers) 19 and 22, a drive gear 19A connected to the drive motor 16 is installed, and a gear 22A connected to the drive gear 19A. ) Can be installed and transferred from the drive gear 19A to the exit roll 19 and from almost 22A to the roll 22.

In addition, each of the gears 50A and 51A is engaged with the third heating roll 50 and the fourth heating roll 51.

As a result of connecting each roll to the driving source as described above, the rolls 50, 51, 19, and 22 function as driving rollers, and the rolls 17, 18, 20, and 21 ), (23), (24), (32), (33), (34), (35) and (36) function as driven rollers. It is also possible to drive the rolls 35 and 36 slightly faster than the outlet up and down rolls 19 and 22, and in this case, the above-described zigzag row adjustment function can be further improved.

In the present embodiment, the rotation of the roll 51 in front of the exit roll 19 is changed (including control), so that the tension of the belt before and after the roll 51 is varied. Deterioration of the resin described above can be prevented with only this configuration. Therefore, the rotational speeds of the rolls 17 and 18 in front of the roll 51 are not a problem.

As described above, by arranging a drive source with a deceleration mechanism for varying the rotation between the exit roll and the roll in front of one of the rolls, the tension applied to the belt between the rolls can be freely changed, and the belt tension is sequentially moved from the exit toward the entrance. When weakened, the belt can be prevented from opening and resin deterioration due to inhalation of outside air can be prevented.

[Cooling unit]

As described above, the fiber sheet 10 impregnated with resin is cooled to less than the resin softening point while passing through the cooling device 26 disposed in the cooling unit.

The cooling device 26 can be configured to be cooled at a cooling rate depending on the resin used. As a control method of a cooling rate, it is preferable to apply a temperature gradient using a heater, a hot wind, a cold wind, etc. toward the exit from a cooling apparatus.

As shown in FIG. 1, the cooling device 26 may be disposed in a subsequent step of the resin impregnated part 3, but is not limited thereto, and the resin impregnated part 3 is shown in FIG. You can also excrete inside.

According to FIG. 8 which shows the detail, the cooling device 26 shown in FIG. 7 is comprised by the pair 2 or a pair of roll 261, and the lower roll group 262 is the water tank 263. As shown in FIG. It is cooled by the water stored in it. The upper roll group 264 is cooled by water sprayed from the nozzle 265. It is preferable to attach a water-retaining member such as asbestos to these roll surfaces from the viewpoint of cooling efficiency.

The upper and lower belts 14 and 15 are cooled by these cooled lower and upper roller groups 262 and 264, whereby the fiber sheet 10 is cooled. The upper roll groups 262 and 264 can arbitrarily adjust the nip pressure of the roll group by tightening the bolt and nut 266 shown in FIG.

When cooling in such a resin impregnated part, contact with air is prevented even during this cooling, and the oxidation deterioration prevention can be completed. In addition, when the cooling is provided through the upper and lower belts, there is no fear of contamination of the fibrous sheet or the woven fabric by the cooling medium, and therefore, inexpensive water cooling and the like can be employed, and thus the process versatility is high.

By further improving the above-described embodiment of FIG. 7 and configuring it as in FIG. 10, high-speed impregnation is possible as in the embodiment of FIG.

In addition, since the site | part of the code | symbol same as the code | symbol shown in FIG. 1 or 6 in FIG. 7 and FIG. 10 is the same structure, the description is abbreviate | omitted.

7 and 10, the roll 50 is heated, but the rolls 19 and 22 are not heated. This is because heating after cooling is undesirable.

[Acquisition department]

The fibrous sheet 10 cooled in this manner is received while applying tension in the take-up roll 27 of the take-up part 4, and wound around the take-up shaft 29. Reference numeral 28 denotes a motor for the take-up roll 27 and the take-up shaft 29.

As mentioned above, although embodiment of this invention was described, it is not limited to these, For example, instead of the fiber feeding part 1 shown in FIG. 1, a beam yarn is used as a fiber sheet set part, and this beam yarn It is also possible to set this in an apparatus stand, to supply a fiber sheet from this beam yarn, and to process similarly below. In this case, it is desirable to control the rotation of the beam yarn so that the fibers are properly tensioned. The above embodiment shows a case where the present invention is applied to a fiber sheet obtained from a plurality of continuous fibers, but when the present invention is applied to a woven fabric (sheet), the feeding section 1 shown in FIG. 1A of woven fabric set parts are arrange | positioned, a red fabric fabric is set to this set part 1A, and this woven fabric is supplied to the said resin impregnation part 3 via the woven fabric supply part 2A, and the said embodiment is carried out. Can be impregnated as

In the above embodiment, the resin is supplied from the die 13 to the lower belt 15. However, the present invention is not limited thereto, and the resin is supplied from the die 13 to the upper belt 14. You may carry out. In this case, the roll arrangement and the tension direction are inverted with respect to the center of the conveying system of the fibrous sheet 10 in the example shown in the figure, so that the same effect can be exhibited.

In FIG. 5, since portions having the same reference numerals as those shown in FIG. 1 have the same configuration, description thereof is omitted. In addition, since the resin impregnation part 3 and the acquisition part 4 are the same as that of Example 1, illustration is abbreviate | omitted.

Hereinafter, an Example demonstrates this invention.

Example 1

, 로울 17~24의 폭 400mm, 로울 직경 240mm

, 상하부벨트(14), (15)의 두께 0.5mm, 폭 350mm인 것을 사용하였다.Specifications of each part of the apparatus shown in FIG. 1 are 100 bobbins, extruder 30mm

, Rolls 17 ~ 24, width 400mm, roll diameter 240mm

The upper and lower belts 14 and 15 had a thickness of 0.5 mm and a width of 350 mm.

Carbon fiber (Bestite HTA-7-3000) was used for continuous fiber, and polyether ether ketone (VICTREX PEEK, ICI company) was used as a thermoplastic resin. The viscosity of this polyether ether kenone was 7000 poises at the shear rate of 100 sec ^-1 at the temperature of 380 degreeC.

The continuous fibers released from the 100 bobbins were aligned to form a fibrous sheet having a width of 15 cm. On the other hand, polyether ether ketone heated and melted at 380 ° C. in an extruder was applied at a thickness of 60 μm to a lower belt moving at a rate of 50 cm / min on the 23rd roll heated at 400 ° C. from the coot hanger die. The fibrous sheet with a tension of 150 kg was placed between the upper and lower belts 14 and 15, and between the rolls 17, 18, 19, 20, and 22 heated to 400 ° C. Was passed in the state shown in FIG. 1, the polyether ether ketone in the fibrous sheet was impregnated, and slowly cooled in a slow cooling furnace maintained at 140 ° C, and then wound up by a transfer machine.

Although the above operation was continuously performed for 24 hours, it was possible to operate smoothly without the phenomenon of crosslinking due to heat of resin and oxidative degradation.

The sheet thus obtained had a resin content of 35% by weight, a thickness of 0.13 mm, no disturbance in the fibers, and no voids between the fibers. Moreover, it was 95% when the resin molecular weight retention rate in the obtained sheet was measured. In addition, the resin molecular retention rate here is a relative molecular weight percentage when the resin molecular weight before heating is made into 100.

[Comparative Example]

The sheet was obtained by the apparatus and manufacturing conditions shown in Example 1 of Japanese Patent Laid-Open No. 61-229535. The resin on the roll was ineligible due to heat and oxidative degradation along with the operating time, and after about 3 hours, the flow of the resin became difficult and impaired due to impregnation and breakage of the fiber filament.

The obtained sheet had a resin amount of 36% by weight and a thickness of 0.13 mm. In addition, although there was no disorder in the fibers and no voids between the fibers, the resin molecular weight retention rate in the sheet was measured. As a result, it was found that the resin was deteriorated at the time of impregnation.

EXAMPLES 2-4

The resin impregnated sheet was obtained by changing the type and operation conditions of the resin in Example 1 as shown in Table 1.

Table 1

* ¹ Tension: The value obtained from the relationship between the deformation of the belt and the longitudinal modulus of elasticity. Moreover, it was 18,500 kg / cm when the Young's modulus (Young's modulus) of the used belt was measured.

* ² Resin Molecular Weight Retention Rate: The relative molecular weight% when the molecular weight of resin before heating is 100.

As is apparent from Table 1, it can be seen from the present invention that a good impregnation sheet with almost no resin deterioration can be obtained by using any resin.

Example 5

, 로울 17~24의 폭 400mm, 로울직경 240mm

, 상하부벨트(14), (15)의 두께 0.5mm, 폭 350mm인 것을 사용하였다.Specifications of each part of the apparatus shown in FIG. 5 are extruder 30 mm

, Rolls 17 ~ 24 width 400mm, roll diameter 240mm

The upper and lower belts 14 and 15 had a thickness of 0.5 mm and a width of 350 mm.

The continuous fiber was a carbon fiber plain woven fabric (Vestite W-1103) and adjusted to a width of 200. In addition, the polyether ether ketone similar to Example 1 was used for the thermoplastic index.

The woven fabric was placed on the woven fabric set portion 1A, and a tension of 30 kg was applied in the take-up direction by the tension adjusting roll.

On the other hand, in the extruder, polyether ether ketone heated and melted at 380 ° C. was applied to the lower belt moving at a speed of 50 cm / min on the 23rd roll heated at 400 ° C. from the coat hanger die at a film thickness of 60 μm. The tensioned woven fabric 10 is sandwiched between upper and lower belts 14 and 15 and rolls 17, 18, 19, 20, and 22 heated to 400 ° C. Passed in the state shown in FIG. 5, the polyether ether ketone of the woven fabric was impregnated, and slowly cooled in a slow cooling furnace maintained at 140 ° C, and then wound up by a transfer machine.

Although the above operation was continuously performed for 24 hours, it was possible to operate smoothly without the phenomenon of gelation due to heat of resin and oxidative degradation.

The obtained fiber-reinforced resin sheet had a resin weight of 35% by weight, a thickness of 0.13 mm, no disorder in the fibers, and no voids between the fibers. Moreover, it was 95% when the resin molecular weight retention rate in the obtained fiber reinforced resin sheet was measured.

[Examples 6-15]

, 로울(17), (18), (19), (20), (21), (22), (23), (24), (50), (51)의 폭 400mm, 로울직경 240mm

, 상하부 벨트(14) 및 (15)의 두께 0.5mm, 폭 350mm인 것을 사용하였다.Specifications of each part of the apparatus in which the resin impregnated part in FIG. 1 is shown in FIG. 6 (except rolls 30, 32, 33, 34, 35, 36, and outlet impregnation promotion) For the roll 31 and the reducer 16A, change as shown in Table 2) 100 bobbins, extruder 30mm

, Rolls (17), (18), (19), (20), (21), (22), (23), (24), (50), (400) width 400 mm, roll diameter 240 mm

And 0.5 mm in thickness and 350 mm in width of the upper and lower belts 14 and 15 were used.

의 것을 사용하고, 또 함침촉진로울(32), (33), (34)는 로울폭 400mm, 로울직경 120mm의 것을 사용하였다. 로울(19)과 (51)의 회전수는, 표 2와 같이 설정하였다. 또한 감속기(16A)로서 파우더클러치를 사용하였다.The impregnation promotion roll 30 has a roll width of 400 mm and a roll diameter of 100 mm.

In addition, the impregnation promoting rolls 32, 33, and 34 used a roll width of 400 mm and a roll diameter of 120 mm. The rotation speed of the roll 19 and 51 was set as Table 2. Also, a powder clutch was used as the reducer 16A.

Carbon fiber (Bestite HTA-7-3000) was used for continuous fiber, and what was shown in Table 2 was used as a thermoplastic resin.

The continuous fibers released from the 100 bobbins were aligned to form a fibrous sheet having a width of 15 cm.

On the other hand, the film thickness of the resin shown in Table 2 melted in the extruder from the coat hanger die to the lower belt 15 to move at a rate of 75 cm / min on the heated roll 23 as shown in Table 2 Table 2 The thickness was applied. The fibrous sheet with a tension of 150 kg was loaded between the upper and lower belts 14 and 15, and the rolls 17, 18, 20, 50 and 51 heated as shown in Table 2. ), (19) and (22) were let through in the state shown to FIG. 1, FIG. 6, and the resin shown in Table 2 in a fiber sheet was impregnated. Next, after slow cooling by the cooling apparatus maintained at the temperature shown in Table 2, it wound up by the receiver.

Although the operation was continuously performed for 24 hours, the phenomenon of gelation due to heat of the resin and oxidative degradation was not seen at all, and the operation could be performed smoothly.

Table 2 shows the experimental conditions and the results. In addition, * mark in a table | surface is as follows.

* ³ If there is no reduction gear 16A, it was installed separately from the drive motor 16 for driving the rolls 17, 18, 50, and 51.

* ⁴ void ratio: The value calculated from the specific gravity of the resin impregnated sheet and the fiber content weight percentage.

[Table 2]

Example 16

It carried out using the apparatus which changed the drawing | feeding-out part 1 and supply part 2 of FIG. 1 as FIG. In addition, each specification of the resin impregnation part was the same as that of Example 6.

The continuous fiber used was a carbon fiber plain woven fabric (Bestite W-1103) adjusted to a width of 200 mm. In addition, the polyether ether ketone similar to Example 6 was used for the thermoplastic index.

The woven fabric was placed on the feeding section 1, and the tension in the take-up direction 30 kg was applied by the tension adjusting roll. Subsequently, after impregnation on the conditions similar to Example 6, it cooled slowly in the slow cooling furnace and obtained the resin impregnation sheet. The obtained resin impregnated sheet had a thickness of 0.13 mm, a void ratio of 0.4%, and a resin molecular weight retention of 98%.

Example 17

Impregnation, cooling, and winding were performed in the same manner as in Example 1 using the apparatus in which the resin impregnation portion and the cooling device shown in FIG. 1 were changed as in FIG.

The above operation was continuously performed for 24 hours, but the phenomenon of gelation due to heat of the resin and oxidative degradation was not seen at all, and the operation was performed smoothly.

The sheet thus obtained had a resin weight of 35% by weight, a thickness of 0.13 mm, no disorder in the fibers, and no voids between the fibers. Moreover, it was 97% when the resin molecular weight retention rate in the obtained sheet was measured.

[Examples 18-20]

In Example 17, the resin impregnated sheet was obtained by changing the type of resin and the operating conditions as shown in Table 3.

Table 3

* 5 The temperature of the chiller is the temperature of the belt at the outlet of the chiller.

As apparent from Table 3, according to the present invention, it can be seen that a better impregnation sheet having almost no resin deterioration can be obtained by using any resin.

Example 21

It carried out using the apparatus which changed the drawing | feeding-out part 1 and supply part 2 of FIG. 1 as FIG. In addition, each specification of the resin impregnation part was the same as that of Example 17.

As the continuous fiber, a carbon fiber plain woven fabric (Bestite W-1103) was used to adjust the width to 200 mm. In addition, the thermoplastic resin used the same polyether ether ketone as Example 17.

The woven fabric was placed on the feeding section 1A, and a tension of 30 kg was applied in the take-up direction by the tension adjusting roll. Subsequently, after impregnation on the conditions similar to Example 17, it cooled slowly in the slow cooling furnace and obtained the resin impregnation sheet.

The obtained sheet had a resin weight of 35% by weight, a thickness of 0.13 mm, no disturbance in the fibers, and no voids between the fibers. Moreover, it was 97% when the resin molecular weight retention rate in the obtained sheet was measured.

Claims (21)

A method of producing a fiber-reinforced sheet-shaped prepreg by heating at or above the softening point of a thermoplastic resin and applying it to at least one belt of a pair of belts and impregnating the fiber with a thermoplastic resin by passing the fiber sheet between a pair of belts facing each other. The method for producing a fiber-reinforced sheet-shaped prepreg according to claim 1, wherein the fiber sheet is formed in a direction with a plurality of continuous fibers in one direction as inclined looms. The method for producing a fiber-reinforced sheet-shaped prepreg according to claim 1, wherein the fiber sheet is a woven fabric. The method of manufacturing a fiber reinforced sheet developing prepreg according to claim 1, wherein the fiber sheet or woven fabric is cooled after passing between the pair of belts. The method of manufacturing a fiber-reinforced sheet-shaped prepreg according to claim 1, wherein the fibrous sheet or woven fabric is cooled between the belts after resin impregnation between the pair of belts. The method of manufacturing a fiber-compensated sheet prepreg according to claim 1, wherein the thickness of the thermoplastic resin coating film supplied between the pair of belts is 10 to 1000 µm. The method of manufacturing a fiber-reinforced sheet-shaped prepreg according to claim 1, wherein the thermoplastic resin supplied between the pair of belts has a viscosity of 500 to 50000 poise. The method of manufacturing a fiber-reinforced sheet-shaped prepreg according to claim 1, wherein the tension applied to the fiber sheet is between 1 and 10,000 g / s between the pair of belts. The method of manufacturing a fiber-reinforced sheet-shaped prepreg according to claim 1, wherein the tension applied to the woven fabric between the pair of belts is 5-100000 g / cm wide. Takeover after passing through the resin impregnation part having an extruder and a die for supplying a fibrous sheet, a pair of belts heated above the softening point of the thermoplastic resin, and a thermoplastic resin coating film on at least one side of the belt. Apparatus for producing a sheet-shaped prepreg comprising a portion. The fiber reinforced sheet-shaped prepreg of claim 10, further comprising a fiber supply unit having a plurality of bobbins for supplying fibers, a mechanism for adjusting tension during fiber feeding, and a mechanism for aligning fibers in one direction. Manufacturing equipment. 12. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 11, further comprising means for setting fibers including pipe means for winding the fiber sheet. 11. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 10, comprising means for supplying a woven fabric. 11. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 10, further comprising a cooling section for cooling the thermoplastic resin below the softening point of the resin between the resin impregnation section and the delivery section. 11. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 10, wherein the resin impregnated portion has a cooling portion for cooling the thermoplastic resin below the softening point of the resin. 11. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 10, wherein at least one belt is supported by an inlet heating roll disposed in correspondence with the resin impregnated promotion roll for pressing the fiber sheet into the inlet heating roll. . 11. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 10, wherein at least one belt is supported by an outlet heating roll disposed in correspondence with the resin impregnated promotion roll for pressing the fiber sheet to the outlet heating roll. . The fabricated sheet according to claim 10, wherein at least one belt is supported by a plurality of intermediate heating rolls arranged in correspondence with the resin impregnated acceleration rolls for pressing the fiber sheets to the heating rolls. Device. 11. The apparatus for producing a fiber-reinforced sheet-shaped prepreg according to claim 10, comprising means for adjusting the tension of the belt and means for regulating the zigzag line of the belt. 12. The roller according to claim 10, wherein a plurality of rolls for supporting the belt and tension adjusting means for increasing the tension of the belt in front of the roll in front of the outlet roll is greater than the tension of the belt in the rear of the roll in front of the roll. An apparatus for producing a fiber reinforced sheet-shaped prepreg, characterized in that. A means for supplying the fibrous sheet, a pair of belts heated above the softening point of the thermoplastic resin and supported by the inlet roller, the outlet roller, and the intermediate roller, and an extruder for applying the film of the thermoplastic resin to the at least one pair of belts. A resin impregnation portion having a die, a first resin impregnation promotion roll disposed in correspondence with the inlet roll, a second resin impregnation promotion roll disposed in correspondence with the intermediate roll, and an outlet roll A third resin impregnation promoting roll, a means for adjusting the tension of the belt, a tension adjusting means for increasing the tension of the belt in front of the roll in front of the roll in front of the exit roller, Means for cooling the impregnated sheet of thermoplastic resin, and means for winding the thermoplastic resin impregnated fiber sheet passed between the resin impregnated portion and the belt. Fiber-reinforced sheet manufacturing apparatus of the shaped prepreg with.

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