TWI526312B - Apparatus and process for producing laminated sheet - Google Patents

Description

Manufacturing device of laminated sheet and manufacturing method of laminated sheet

The present invention relates to a manufacturing apparatus of a laminated sheet and a method of manufacturing a laminated sheet.

In recent years, in order to reduce the size and thickness of electronic components and electronic devices, it is required to reduce the size and thickness of circuit boards used. In response to this requirement, a multi-layered circuit substrate is used and the layers thereof are thinned.

In the circuit board of the multilayer structure, for example, a sheet in which a resin composition sheet (resin layer) is laminated and adhered on both surfaces of the fiber base material is used (for example, see Patent Document 1).

This sheet is produced by superposing a B-stage resin composition sheet on both sides of a fibrous base material and pressurizing the laminated body.

(Patent Document 1) Japanese Patent Laid-Open Publication No. 2003-340952

However, in such a production method, there is a possibility that the pressure of the fiber base material of the resin layer is insufficient, and as a result, the resin layer is peeled off from the fiber base material.

Further, such a problem is not limited to the case where the fiber base material and the resin layer are laminated, and even when the resin layers are laminated to each other, and the prepreg containing the fiber base material is laminated to each other.

According to the present invention, there is provided a manufacturing apparatus for a laminated sheet which is obtained by bonding the resin layer of a thin plate-shaped sheet having a resin layer on one side to one side or both sides of a long-length thin plate-shaped substrate to produce a laminated sheet. ; it has: according to the above a conveying means for conveying the substrate and the substrate along the longitudinal direction of the substrate, and the sheet and the substrate conveyed by the conveying means a chamber for passing the above-mentioned relative state; a pressure reducing means for decompressing the chamber; a heating means for heating the substrate and the sheet in the chamber; and the chamber a pressing means for pressurizing the substrate and the sheet in a relative state in a thickness direction thereof; and the substrate and the sheet which are carried by the conveying means in the chamber The conveyance is temporarily stopped, and in the stopped state, the substrate and the sheet in the opposing state are added by the pressing means and the heating means while decompressing the chamber by the decompression means. The resin layer is pressure-bonded to the substrate by pressing and heating.

According to the present invention, the pressure-bonding between the substrate and the resin layer caused by the action of the pressurizing means, and the pressure-bonding between the substrate and the resin layer caused by the pressure reduction generated in the chamber by the action of the decompression means The bonding between the substrate and the resin layer is strengthened.

Furthermore, according to the present invention, a method of manufacturing a laminated sheet using the above laminated sheet manufacturing apparatus can also be provided.

Furthermore, a method for producing a laminated sheet may be provided, wherein the resin layer of a sheet having a resin layer on one side is bonded to one side or both sides of a long-length sheet-shaped substrate to produce a laminated sheet; The method includes: in the chamber, the substrate and the resin layer are opposed to each other, and the sheet is conveyed a step of transporting the substrate; the substrate and a portion of the substrate facing the sheet are located in the chamber, and the substrate on the upstream side and the downstream side in the transport direction of the portion of the substrate a step of stopping the conveyance of the sheet and the substrate in a state in which the other portion is located outside the chamber; and depressurizing the chamber to heat a portion of the substrate and the sheet in the chamber, and A step of pressurizing a portion of the substrate and the sheet.

According to the invention, there is provided a laminated sheet manufacturing apparatus and a method for producing a laminated sheet in which a base material and a resin layer are firmly fixed.

Hereinafter, embodiments of the present invention will be described based on the drawings. In the drawings, the same components are denoted by the same reference numerals, and the detailed description is omitted as appropriate.

Hereinafter, the laminated sheet manufacturing apparatus, the laminated sheet manufacturing method, and the laminated sheet of the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.

1 to 6 are schematic cross-sectional side views showing an operation state of the laminated sheet manufacturing apparatus (first embodiment) of the present invention, and FIG. 7 is a view showing a laminated sheet manufacturing apparatus (second embodiment) of the present invention. A schematic cross-sectional side view; Fig. 8 is a cross-sectional view showing a laminated sheet of the present invention. In the following description, for convenience of explanation, the upper side in FIGS. 1 to 6 and 8 is referred to as "upper" or "upper", and the lower side is referred to as "lower" or "lower". In addition, FIG. 8 is an exaggerated expansion of the thickness direction (upward and downward directions in the drawing). Figure 9 shows the intermittent on the substrate A plan view of the state in which a plurality of sheets are disposed.

10 is a cross-sectional view taken along line X-X of FIG. 4. FIG. 11 is a cross-sectional view along the longitudinal direction of the fiber base material 2, and schematically shows a cross-sectional view of a state in which the sheet portion is disposed apart from the fiber base material 2.

The laminated sheet manufacturing apparatus 30 shown in Figs. 1 to 7 is an apparatus for manufacturing the laminated sheet 40 having the configuration shown in Fig. 8.

<Laminated film>

First, the laminated sheet 40 will be described with reference to Fig. 8 . Moreover, when the laminated sheet 40 is cut into a predetermined size in the longitudinal direction, the prepreg 1 is obtained.

The laminated sheet 40 shown in Fig. 8 has a strip shape (long scale) as a whole, and has a thin plate-like (flat-plate) fibrous base material (substrate) 2; one surface (upper surface) of the fibrous base material 2 a first resin layer (resin layer) 3 composed of a solid or semi-solid first resin composition, and a second resin composition which is solid or semi-solid on the other surface (lower surface) side of the fiber substrate 2 The second resin layer (resin layer) 4 to be formed; the metal layer 12 formed on the first resin layer 3 and the second resin layer 4, respectively. The laminated sheet 40 is cut into a predetermined size and used.

As shown in FIG. 9, the laminated sheet 40 is configured such that the sheet portion 5a composed of the first resin layer (resin layer) 3 and the metal layer 12 is formed on one surface of the long-length fibrous base material 2 ( The first sheet portion is arranged in a plurality of places.

In addition, the sheet portion 5b composed of the second resin layer (resin layer) 4 and the metal layer 12 is formed on the other surface of the long-length fiber base material 2 (the second sheet) Department) Multiple separation configuration.

The first sheet portion 5a and the second sheet portion 5b are placed at the opposing positions by sandwiching the fiber base material 2.

The prepreg 1 is obtained by cutting the fiber base material 2 between the fiber base material 2 and the second sheet portion 5b between the first sheet portions 5a. Further, each of the resin layers 3 and 4 is in a B-stage state.

This prepreg 1 is used for a multilayer printed wiring board (circuit board) and becomes a core material. The metal layer 12 of the prepreg 1 is selectively removed to form a circuit layer, and then another prepreg and a circuit layer are alternately laminated on the front and back surfaces of the prepreg 1, thereby obtaining a multilayer printed wiring (circuit substrate) ).

Further, each of the resin layers 3 and 4 is in a B-stage state, and when used as a core material, the prepreg 1 is heat-cured to completely cure the resin layers 3 and 4 (C-stage).

The fibrous base material 2 has a function of enhancing the mechanical strength of the laminated sheet 40.

The fiber base material 2 may, for example, be a glass fiber base material such as a glass woven fabric or a glass nonwoven fabric, and may include a polyamide resin fiber, an aromatic polyamide resin fiber, or a wholly aromatic polyamide resin fiber. Polyurethane resin fiber such as amine fiber, polyester resin fiber such as polyester resin fiber, aromatic polyester resin fiber or wholly aromatic polyester resin fiber, polyparaphenylene benzobis a synthetic fiber base material composed of a woven fabric or a non-woven fabric such as a azole, a polyimide resin fiber or a fluororesin fiber, and a paper mainly composed of kraft paper, cotton wool paper, mixed paper of cotton velvet and kraft pulp, and the like A fiber base material such as an organic fiber base material such as a fiber base material.

In addition, any of the above fibers may be used as the fiber base material, and two or more types may be used.

Among these, the fibrous base material 2 is preferably a glass fiber base material. By using such a glass fiber base material, the mechanical strength of the prepreg 1 obtained by cutting the laminated sheet 40 can be further enhanced. Further, there is an effect that the coefficient of thermal expansion of the prepreg 1 can be reduced.

Examples of the glass constituting the glass fiber substrate include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, H glass, Q glass, and quartz glass. Among these, the glass is preferably S glass, T glass, quartz glass or Q glass. Thereby, the coefficient of thermal expansion of the glass fiber substrate can be relatively reduced, so that the coefficient of thermal expansion of the laminated sheet 40 can be reduced as much as possible.

The average thickness T of the fiber base material 2 is not particularly limited, but is preferably 150 μm or less, more preferably 100 μm or less, still more preferably about 10 to 50 μm. By using the fiber base material 2 having such a thickness, the mechanical strength of the prepreg 1 (the laminated sheet 40) can be ensured and the thickness thereof can be reduced. Further, the workability and dimensional stability of the prepreg 1 can be improved.

The first resin layer 3 is provided on one surface side of the fiber base material 2, and the second resin layer 4 is provided on the other surface side. Further, the first resin layer 3 is composed of a first resin composition, and the second resin layer 4 is composed of a second resin composition. The first resin composition and the second resin composition may be the same composition or may be different. In the present embodiment, the same composition is used.

In the present embodiment, the metal layer 12 is formed on each of the first resin layer 3 and the second resin layer 4. The metal layer 12 is formed as a wiring portion (conductor pattern) by applying, for example, etching or laser processing. Therefore, the first resin composition and the second resin composition are set to have a superior adhesion to the metal.

As shown in Fig. 8, in the present embodiment, the first resin composition (first resin layer 3) is impregnated in one of the thickness directions of the fiber base material 2 (hereinafter, this portion is referred to as "first impregnation portion 31"). The second resin composition (second resin layer 4) is impregnated into the remaining portion of the fibrous base material 2 which is not impregnated with the first resin composition (hereinafter referred to as "second impregnation portion 41"). Thereby, the first impregnation portion 31 of one of the first resin layers 3 and the second impregnation portion 41 of one of the second resin layers 4 are placed in the fiber base material 2. In the fiber base material 2, the first impregnation portion 31 (the lower surface of the first resin layer 3) is brought into contact with the second impregnation portion 41 (the upper surface of the second resin layer 4). In other words, the first resin composition is impregnated into the fiber base material 2 from the upper surface side of the fiber base material 2, and the second resin composition is impregnated into the fiber base material 2 from the lower surface side of the fiber base material 2, whereby the resin composition is obtained. The voids in the fibrous substrate 2 are filled.

In the present embodiment, the thickness of the first impregnation portion 31 is equal to the thickness of the second impregnation portion 41.

In addition, the thickness of the portion (the first non-impregnated portion 32) excluding the first impregnation portion 31 of the first resin layer 3 and the portion excluding the second impregnation portion 41 of the second resin layer 4 (the second non-impregnation portion 42) ) the thickness is equal. The thickness of the first non-impregnated portion 32 and the thickness of the second non-impregnated portion 42 are, for example, 2 to 20 μm. Again, the first The thickness of the impregnation portion 31 and the thickness of the second impregnation portion 41 may be different, and the thickness of the first non-impregnated portion 32 and the thickness of the second non-impregnation portion 42 may be different. Further, reference numeral 20 in Fig. 8 schematically shows the boundary between the impregnation portion 31 and the impregnation portion 32.

As shown in FIG. 1, the first resin layer 3 is supplied to the laminated sheet manufacturing apparatus 30 as a sheet-shaped first sheet portion (sheet portion) 5a in a state in which the metal sheet 12 is laminated. The second resin layer 4 is also supplied to the laminated sheet manufacturing apparatus 30 as a second sheet portion (sheet portion) 5b in a thin plate shape in a state in which the metal sheet 12 is laminated.

The metal layer 12 is processed into a portion of the wiring portion as described above, and is made of a conductive metal material. For example, a metal foil such as a copper foil or an aluminum foil is bonded to a corresponding resin layer, or copper or aluminum is used. The metal foil is formed by plating on the surface of the corresponding resin layer. Further, in the present embodiment, since the first resin layer 3 or the second resin layer 4 has the above characteristics, the metal layer 12 can be held with high adhesion, and the metal layer 12 can be formed as a wiring portion with high processing precision.

The peeling strength between the metal layer 12 and the first resin layer 3 or the second resin layer 4 is preferably 0.3 kN/m or more, more preferably 0.6 kN/m or more. Thereby, the metal layer 12 is processed into a wiring portion, and the electrical connection reliability with, for example, a semiconductor device can be further improved.

Further, the metal layer 12 may be omitted in the laminated sheet 40.

Further, the first resin composition and the second resin composition are preferably made into the following compositions.

Each resin composition contains, for example, a curable resin, and if necessary, contains a hardening aid. It is composed of at least one of a solvent (for example, a curing agent, a curing accelerator, and the like) and an inorganic filler.

Examples of the curable resin include urea (urea) resin, melamine resin, maleic imine compound, polyurethane resin, unsaturated polyester resin, and benzoic acid. a thermosetting resin such as a ring resin, a bisallyl nalenimine compound, a vinyl benzyl resin, a vinyl benzyl ether resin, a benzocyclobutene resin, a cyanate resin, or an epoxy resin; An ultraviolet curable resin, an anaerobic resin, or the like. Among these, the curable resin is preferably a combination in which the glass transition temperature is 200 ° C or higher. For example, it is preferred to use an epoxy resin or a cyanate resin containing a spiro ring, a heterocyclic formula, a trimethylol type, a biphenyl type, a naphthyl group, a fluorene type, a novolac type, or a cyanate resin (including Prepolymer of cyanate resin), maleic imine compound, benzocyclobutene resin, with benzoic acid Ring resin.

In the curable resin, by using a thermosetting resin, after the substrate to be described later is produced, and the crosslinking density is increased in the resin layers 3 and 4 after curing, the cured resin layers 3 and 4 can be obtained. The heat resistance of the substrate) is improved.

By using the thermosetting resin and the filler in combination, the thermal expansion coefficient of the prepreg 1 (hereinafter also referred to as "low thermal expansion") can be reduced. Furthermore, the electrical characteristics (low dielectric constant, low dielectric loss tangent) of the prepreg 1 can be improved.

Examples of the epoxy resin include a phenol novolak type epoxy resin, a bisphenol type epoxy resin, a naphthalene type epoxy resin, a fluorene type epoxy resin, and an aryl alkylene group. Type epoxy resin, etc.

Among these, the epoxy resin is preferably a naphthalene type or arylalkylene type epoxy resin. By using a naphthyl group or an arylalkylene type epoxy resin, the heat-resistant solder heat resistance (solder heat resistance after moisture absorption) and flame retardancy can be improved in the cured resin layers 3 and 4 (the obtained substrate). . Examples of the naphthalene type epoxy resin include HP-4700, HP-4770, HP-4032D, HP-5000, HP-6000, and Nippon Chemical Co., Ltd., NC-7300L, manufactured by DIC Co., Ltd. ESN-375, etc., which is an aryl alkylene-based epoxy resin, such as NC-3000, NC-3000L, NC-3000-FH, and Nippon Chemical Co., Ltd., manufactured by Nippon Kayaku Co., Ltd. (Stock) system NC-7300L, Nippon Steel Chemical Co., Ltd. ESN-375. The term "aryl extended alkyl type epoxy resin" refers to an epoxy resin which contains a combination of one or more aromatic groups and an alkylene group such as a methylene group in a repeating monomer, and has heat resistance, flame retardancy and mechanical strength. superior. Further, in terms of a halogen-free wiring board, it is preferred to use an epoxy resin which does not substantially contain a halogen.

The cyanate resin can be obtained, for example, by reacting a halogenated cyanide compound with a phenol or a naphthol, and if necessary, prepolymerizing by a method such as heating. Further, a commercially available product thus prepared can also be used.

The cyanate resin may, for example, be a bisphenol type such as a novolak type cyanate resin, a bisphenol A type cyanate resin, a bisphenol E type cyanate resin, or a tetramethyl bisphenol F type cyanate resin. Cyanate resin, naphthol aralkyl type cyanate resin, and the like.

Further, the cyanate resin preferably has two or more cyanic acids in the molecule. Ester group (-O-CN). For example, 2,2-bis(4-cyanooxyphenyl)isopropylidene, 1,1-bis(4-cyanooxyphenyl)ethane, bis(4-cyanooxy-3,5) -Dimethylphenyl)methane, 1,3-bis(4-cyanooxyphenyl-1-(1-methylethylidene))benzene, bis(4-cyanooxyphenyl) sulfide, Bis(4-cyanooxyphenyl)ether, 1,1,1-gin(4-cyanooxyphenyl)ethane, ginseng (4-cyanooxyphenyl)phosphoric acid, bis(4-cyanate) Phenyl, hydrazine, 2,2-bis(4-cyanooxyphenyl)propane, 1,3-, 1,4-, 1,6-, 1,8-, 2,6- or 2,7 - dicyanoxynaphthalene, 1,3,6-tricyanooxynaphthalene, 4,4-dicyanooxybiphenyl, and phenol novolac type, cresol novolac type, dicyclopentadiene type, etc. A cyanate resin obtained by a reaction between a polyhydric phenol and a cyanogen halide, a cyanate resin obtained by a reaction between a naphthol aralkyl type polyheptanol and a cyanogen halide. Among these, the phenol novolac type cyanate resin is excellent in flame retardancy and low thermal expansion property, and 2,2-bis(4-cyanooxyphenyl)isopropylidene and dicyclopentadiene type cyanic acid. The ester resin is excellent in control of crosslinking density and moisture resistance reliability. In particular, the phenol novolac type cyanate resin is preferred from the viewpoint of low thermal expansion. Further, one or two or more kinds of other cyanate resins may be further used in combination, and are not particularly limited.

The cyanate resin may be used singly or as a cyanate resin having a different weight average molecular weight, or the above cyanate resin and its prepolymer may be used in combination.

By using such cyanate resins, heat resistance and flame retardancy can be effectively exhibited.

Further, the curable resin may be used in combination of two or more kinds. For example, when the epoxy resin is used as the curable resin, the cyanate resin can be used in combination for further improving the flame retardancy, and the maleidene compound can be used in combination for further improving the heat resistance. Furthermore, the use of the above cyanate tree When the grease is used as a curable resin, the above epoxy resin can be used in combination for further improving heat resistance, flame retardancy, and the like.

The content of the curable resin is not particularly limited, but is preferably 5 to 70% by mass, more preferably 10 to 50% by mass based on the entire resin composition. When the content of the curable resin is less than the above-described lower limit, the varnish viscosity of the first resin composition is too low, and it is difficult to form the prepreg 1 depending on the type of the curable resin. On the other hand, when the content of the curable resin is more than the above-described upper limit, the amount of the other components is too small, and the mechanical strength of the prepreg 1 may be lowered depending on the type of the curable resin or the like.

Further, the resin composition preferably contains an inorganic filler. Thereby, even if the prepreg is made thin (for example, the thickness is 35 μm or less), a substrate excellent in mechanical strength can be obtained. Furthermore, the low thermal expansion of the substrate can also be improved.

Examples of the inorganic filler include cerium oxide such as talc, alumina, glass, and molten cerium oxide, mica, aluminum hydroxide, and magnesium hydroxide. Further, in accordance with the purpose of use of the inorganic filler, a crushed or spherical shape is appropriately selected. Among these, the inorganic filler is preferably cerium oxide, and more preferably molten cerium oxide (especially spherical molten cerium oxide) from the viewpoint of superior low thermal expansion property.

Further, in addition to the components described above, the resin composition may be blended with other components as needed within the range not inhibiting the effects of the present invention. The other component may, for example, be a tackifier such as ORBEN or BENTONE, a polyoxymethylene-based, a fluorine-based or a polymer-based antifoaming agent or a leveling agent, or a coupling agent. Agent, flame retardant, phthalocyanine/blue, phthalocyanine/green, iodine/green, disazo yellow, carbon black, enamel, etc.

<First embodiment of a laminated sheet manufacturing apparatus (manufacturing method of laminated sheets)>

Next, the laminated sheet manufacturing apparatus 30 used in the production of the laminated sheet 40, that is, the laminated sheet manufacturing apparatus 30 used in the embodiment of the laminated sheet manufacturing method of the present invention, will be described with reference to FIGS. 1 to 6 and 10 . Figure 11 is explained.

In the laminated sheet manufacturing apparatus 30, the first sheet material 5A disposed on one surface (upper surface side) of the fiber base material 2 is adhered to the fiber base material 2, and is placed on the other surface (lower side) of the fiber base material 2. The second sheet 5B is a device that is pressed against the fiber base material 2.

In the present embodiment, the first sheet 5A is composed of a plurality of first sheet portions 5a disposed apart from each other, and the plurality of second sheets 5B are composed of a plurality of second sheet portions 5b disposed apart from each other.

Here, the upper side portion of the fiber base material 2 is joined to the first resin layer 3 of the first sheet portion (support portion) 5a, and the lower surface portion of the fiber base material 2 and the second sheet portion (support) are bonded. The second resin layer 4 of 5b is joined to produce a laminated sheet 40.

In addition, in the case of the finished product, even if the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b are joined, the unfinished product, that is, the fiber base material 2 and The first sheet portion 5a and the second sheet portion 5b are not easily joined, and the unfinished product is in a state in which the fibrous base material 2 and the first sheet portion 5a and the second sheet portion 5b are separated from each other. In fact, as shown in Figure 11 As shown in the schematic view, in the unfinished product, the fiber base material 2 is in contact with the first sheet portion 5a, and the second sheet portion 5b is in contact with the fiber base material 2. Further, in the chamber 7, the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b are conveyed, and at this time, the end surface in the conveying direction of the fiber base material 2 (the end surface of the end portion in the TD direction) It is not covered by the first sheet portion 5a or the second sheet portion 5b, and is exposed (see Fig. 10). The width of the first sheet portion 5a and the second sheet portion 5b (the length in the direction orthogonal to the conveying direction) is preferably equal to or shorter than the width of the fibrous base material 2.

The laminated sheet manufacturing apparatus 30 includes a conveying means 6, a chamber 7, a pressure reducing means 8, a pressurizing means 9, and a heating means 95. The configuration of each unit will be described below.

The conveying means 6 is constituted by a belt conveyor which is disposed on each of the two sides via, for example, the chamber 7. The conveying means 6 can convey the fiber base material 2, the first sheet portion 5a and the second sheet portion 5b in a horizontal direction from the left side in the drawing to the right side (in the longitudinal direction), that is, in the horizontal direction. . In other words, the conveying means 6 supplies the fiber base material 2, the first sheet portion 5a and the second sheet portion 5b into the chamber 7, and the fiber substrate 2 and the first sheet portion 5a are sent out from the chamber 7. And the second sheet portion 5b.

Further, the conveying means 6 may be conveyed by another pressure roller or a take-up roller.

In addition, when the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are transported by the transport means 6, the first resin layer 3 of the first sheet portion 5a and the fibrous base material 2 are obtained. The second resin layer 4 of the second sheet portion 5b is opposed to the lower surface of the fiber base material 2 in the opposing direction. This state is called below It is a "relative state".

In the chamber 7, the fiber base material 2 conveyed by the transport means 6 and the first sheet portion 5a and the second sheet portion 5b are kept in a state of being opposed to each other, and at this time, they are joined.

The chamber 7 is formed by the upper side structure (first structure) 71 and the lower structure (second structure) 72 which are close to each other in the vertical direction.

The upper structure 71 has a top plate 711 and a side wall 712 formed on the edge of the top plate 711 including the entire circumference thereof. The side wall 712 protrudes downward from the edge of the top plate 711. The lower structure 72 has a bottom plate 721 and a side wall 722 formed on the edge of the bottom plate 721 including the entire circumference thereof. The side wall 722 protrudes upward from the edge of the bottom plate 721.

When the upper structure 71 and the lower structure 72 are separated by a predetermined distance or more (hereinafter referred to as "open state"), the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b can be sent. The inside of the structures 71 and 72 can be fed to the outside of the structures 71 and 72 (see Fig. 6). In the chamber 7, a portion on the left side in the drawing between the upper structure 71 and the lower structure 72 serves as an inlet 73, and a portion on the right side serves as an outlet 74. More specifically, the side wall 712 is disposed on the side wall 712 on the upstream side in the transport direction, and on the fiber substrate 2, in the side wall 712, which is perpendicular to the transport direction of the fiber base material 2 or the like. The conveyance direction is such that the side wall 722 of one of the orthogonal lower side structures 72 is disposed on the side wall 722A on the upstream side in the conveyance direction, and the entrance is partitioned. Moreover, by transporting with the fiber substrate 2 or the like The direction is one of the pair of side walls 712 of the pair of orthogonal upper side structures 71, and is disposed on the side wall 712B on the downstream side in the transport direction and on the side opposite to the transport direction of the fiber base material 2 and the like. The side wall 722 is disposed on the side wall 722B on the downstream side in the conveying direction to partition the outlet. The opposing end faces of the side walls 712A and 722A serve as an inlet, and the opposing end faces of the side walls 712B and 722B serve as an outlet.

The constituent material of the upper structure 71 and the lower structure 72 is not particularly limited, and examples thereof include various metals such as iron, stainless steel, and aluminum, or alloys containing the same.

A portion of the upper structure 71 that partitions the inlet 73 (i.e., the end surface of the side wall 712A) and a portion that partitions the outlet 74 (i.e., the end surface of the side wall 712B) are respectively provided with a sealing member 75 made of an elastic material. Further, a portion of the upper structure 72 which partitions the inlet 73 (i.e., the end surface of the side wall 722A) and a portion of the partition outlet 74 (i.e., the end surface of the side wall 722B) are also provided with sealing members 76 each made of an elastic material. . The sealing members 75 and 76 are members each having a circular cross-sectional shape. The sealing member 75 is fixed to the lower portion of the side walls 712A and 712B of the upper structure 71, and the sealing member 76 is fixed to the upper portions of the side walls 722A and 722B of the lower structure 72.

In addition, as shown in FIG. 2 to FIG. 4, the sealing member 75 and the sealing member 76 sandwich the fiber base in a state in which the upper structure 71 and the lower structure 72 are close to each other (hereinafter referred to as "closed state"). The material 2 and the first sheet portion 5a and the second sheet portion 5b, that is, the sealing member 75 is adhered to the first sheet portion 5a The metal layer 12 adheres the sealing member 76 to the metal layer 12 of the second sheet portion 5b. Thereby, the airtightness in the space 77 which is partitioned by the upper side structure 71 and the lower side structure body 72, that is, the inside of the chamber 7 is maintained. At this time, the inside of the space 77 can be decompressed by the operation of the decompression means 8.

Further, although not shown here, in the four side walls of the upper structure 71, a sealing member is also disposed at the lower end portions of the side walls other than the side walls 712A and 712B. Similarly, in the four side walls of the lower structure 72, a sealing member is also disposed at the upper end portions of the side walls other than the side walls 722A and 722B. Thereby, the airtightness in the chamber 7 can be maintained.

Further, in the configuration shown in FIGS. 2 to 4, the sealing members 75 and 76 are adhered to the metal layer 12 of the first sheet portion 5a, and are adhered to the metal layer 12 of the second sheet portion 5b, but The present invention is not limited thereto, and may be adhered to the upper surface and the lower surface of the fibrous base material 2, for example.

The constituent materials of the sealing members 75 and 76 are not particularly limited, and examples thereof include natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, nitrile rubber, chloroprene rubber, and butyl rubber. Acrylic rubber, ethylene-propylene rubber, epichlorohydrin rubber, urethane rubber, polyoxyethylene rubber, fluororubber-like rubber materials (especially those treated with sulfur), or styrene, poly Olefin, polyvinyl chloride, polyurethane, polyester, polyamine, polybutadiene, trans-polyisoprene, fluororubber, chlorinated polyethylene, etc. Each of the thermoplastic elastomers may be used alone or in combination of two or more.

Further, a heater 78 composed of, for example, a heating wire is housed in each of the sealing member 75 and the sealing member 76. Thereby, the first sheet portion 5a or the second sheet portion 5b can be heated in the state shown in FIGS. 2 to 4. Thereby, since the resin layer of each sheet part can be pressure-bonded, the decompression state of the fiber base material 2 can be maintained. In other words, when the end portion on the downstream side in the conveying direction of the first sheet portion 5a or the second sheet portion 5b and the upstream end portion are heated by the sealing member 75 and the sealing member 76, each sheet portion is heated. The resin layers of 5a and 5b are melted and impregnated into the inside of the fibrous base material 2. Thereby, the region on the downstream side in the conveying direction of the fiber base material 2 in the structure 7 and the region on the upstream side are sealed by the resin layer. When the pressure reducing means to be described later is driven, the gas inside the fiber base material 2 is sucked by the pressure reducing means described later, and the reduced pressure state of the fiber base material 2 can be maintained.

Further, in the laminated sheet manufacturing apparatus 30, the sealing members 75 and 76 also have a function as a part of a pressurizing means or a heating means.

In addition, when only one of the sheet portions 5a and 5b is provided on the fiber base material 2, the sealing member may be abutted on the surface of the fiber base material 2 opposite to the sheet portion. At this time, the sheet portion is indirectly abutted against the sealing member via the fiber base material 2, and the resin layer is heated. Then, the heated resin layer is impregnated into the interior of the fibrous substrate.

The decompression means 8 has a pressure reduction of the inside of the chamber 7 to a negative pressure, and has two sets of pumps 81 and connecting pipes (tubes) 82.

A set (the upper side in the figure) of the connecting pipe 82 is connected to the top plate 711 of the upper side structure 71, and is opened at 711. Thereby, the connecting pipe 82 is connected to the inside of the chamber 7. A group of pumps 81 is connected to the upper side structure 71 via the connecting pipe 82.

The other set (the lower side in the figure) of the connecting pipe 82 is connected to the bottom plate 721 of the lower side structure 72, and is opened at 721. Thereby, the connecting pipe 82 is connected to the inside of the chamber 7. The pump 81 of the other group is connected to the lower structure 72 via the connecting pipe 82.

Each of the pumps 81 is disposed outside the chamber 7, and for example, a vacuum pump can be applied. Each of the connecting pipes 82 is a rigid pipe made of a metal material such as stainless steel.

Then, as shown in FIGS. 3 and 4, the respective pumps 81 are actuated in the closed state of the chamber 7, and the air G in the space 77 can be sucked through the respective connecting pipes 82, whereby the space 77 can be surely reduced. Pressure.

The pressurizing means 9 is placed in the chamber 7 in the closed state, and the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b in the opposing state are pressed in the thickness direction (see Figure 4).

The pressurizing means 9 includes an upper pressing member (first pressing member) 91, a cylinder 92 coupled to the upper pressing member, a lower pressing member (second pressing member) 93, and a cylinder 94 connected to the lower pressing member 93. .

In the present embodiment, both the upper pressing member 91 and the lower pressing member 93 are driven, but only one of them may be driven, and the upper pressing member 91 and the lower pressing member 93 may be relatively approached and separated from each other.

The upper pressing member 91 is a member that is placed in the chamber 7 and that presses the first sheet portion 5a from the upper side thereof. The upper pressing member 91 is a flat rectangular plate The total length (the length of the fiber base material 2 or the like along the conveying direction) is almost the same as or shorter than the total length of the prepreg 1 (or the first sheet portion 5a) obtained by cutting the laminated sheet 40. short. Further, the width of the upper pressing member 91 (the length in the inner direction of the paper surface of FIGS. 1 to 6) is wider than the width of the prepreg 1.

The upper surface of the upper pressing member 91 is connected to the cylinder 92. The cylinder 92 is a driving means for causing the upper pressing member 91 to approach and disengage the lower pressing member 93. The cylinder 92 has a rod 921 that is freely detached, and the upper pressing member 91 can be moved in the vertical direction by the presence or absence of the rod 921. Further, when the upper pressing member 91 moves downward, the first sheet portion 5a can be pressed by the upper side. Further, the rod 921 of the cylinder 92 penetrates the top plate 711 of the upper structure 71, and most of it is located outside the chamber 7.

The lower pressing member 93 is a member that is located in the chamber 7 and that presses the second sheet portion 5b from the lower side thereof. Similarly to the upper pressing member 91, the lower pressing member 93 has a flat rectangular plate shape, and the total length thereof is almost the same as the total length of the prepreg 1 (or the second sheet portion 5b) obtained by cutting the laminated sheet 40. Or a little shorter. Further, the width of the lower pressing member 93 is wider than the width of the prepreg 1.

The lower surface of the lower pressing member 93 is connected to the cylinder 94. The cylinder 94 is a driving means for causing the lower pressing member 93 to approach and disengage the upper pressing member 91. The cylinder 94 has a rod 941 that is freely detached, and the lower pressing member 93 is moved in the vertical direction by the presence of the rod 941. Further, when the lower pressing member 93 moves downward, the second sheet portion 5b can be pressed by the lower side. Further, the rod 941 of the cylinder 94 penetrates the bottom plate of the lower structure 72 721, mostly located outside the chamber 7.

Further, as shown in FIG. 12, a convex portion 90 that protrudes toward the upper pressing member 91 may be provided on the side of the inlet 73 of the lower pressing member 93, specifically, the side surface on the side of the inlet 73 of the lower pressing member 93. Similarly, a convex portion 90 that protrudes toward the upper side pressing member 91 side may be provided on the side of the outlet 74 of the lower pressing member 93, specifically, the side surface on the outlet 74 side of the lower pressing member 93. The convex portion 90 is heated by a heater 95 to be described later via the lower pressing member 93.

The convex portion 90 is formed at a position facing the upper pressing member 91. An elastic member E is provided on the opposite side of the convex portion 90 from the upper pressing member 91. When the first sheet portion 5a, the fiber base material 2, and the second sheet portion 5b are pressed against the lower side pressing member 93 and the upper side pressing member 91, the convex portion 90 passes through the first sheet portion 5a and the fiber base material 2. The second sheet portion 5b is in contact with the upper pressing member 91. Among these, since the elastic member E is provided, the convex portion 90 does not protrude further toward the upper side pressing member 91 than the upper surface of the lower pressing member 93. When the convex portion 90 is brought into contact with the second sheet portion 5b, the second sheet portion 5b is pressed against the fiber base material 2 side. That is, the elastic member E serves as a pressure adjusting mechanism that adjusts the pressing force of the convex portion 90 against the second sheet portion 5b. Then, the second sheet portion 5b is heated by the convex portion 90, and the resin layer 4 can be impregnated into the fibrous base material 2, and one portion of the fibrous base material 2 can be sealed.

The cylinder 92 is configured to adjust the amount of protrusion of the rod 921, that is, the magnitude of the pressure, and the cylinder 94 is also configured to adjust the amount of protrusion of the rod 941, that is, the pressure. size. Thereby, the degree of impregnation of the first resin layer 3 of the first sheet portion 5a with respect to the fiber base material 2 (the average thickness ta1 of the first impregnation portion 31) and the second resin layer 4 of the second sheet portion 5b can be obtained. The degree of impregnation of the fibrous base material 2 (the average thickness ta2 of the second impregnation portion 41) is adjusted to a desired size.

The constituent material of the upper pressing member 91 and the lower pressing member 93 is not particularly limited, and a metal material such as stainless steel can be used. Further, in the metal material, a rubber, a glass plate, and particularly a member having a high surface smoothness may be attached to the opposite surface. Thereby, the laminated sheet 40 which is more excellent in smoothness can be obtained.

The cylinders 92 and 94 are not particularly limited, and for example, a hydraulic cylinder or an air cylinder can be used.

Further, a heater 95 (heating means) composed of, for example, a heating wire is housed in the upper pressing member 91 and the lower pressing member 93, respectively. Thereby, the first sheet portion 5a can be surely heated by the upper pressing member 91, and the second sheet portion 5b can be surely heated via the lower pressing member 93.

In the present embodiment, the heater 95 is incorporated in both the upper pressing member 91 and the lower pressing member 93. However, the present invention is not limited thereto. For example, the heater 95 may be incorporated only in the upper pressing member 91 and the side pressing member 93. One of them.

Further, as shown in FIG. 1, the laminated sheet manufacturing apparatus 30 includes a detecting means 96, a determining means 97, and a control means 98.

The detecting means 96 detects the gap between the adjacent first sheet portions 5a (the exposed portion 21 of the fiber base material 2) or the gap between the adjacent second sheet portions 5b. (The exposed portion 21 of the fibrous base material 2).

In the present embodiment, the position of the exposed portion 21 on the inlet side of the chamber 7 is detected. As the detecting means 96, for example, a CCD camera or the like can be mentioned.

The discrimination means 97 determines whether or not one of the fiber base materials 2 and the respective sheet portions 5a and 5b are conveyed to a predetermined position in the chamber 7. Specifically, the determination means 97 determines whether or not the gap between the first sheet portions 5a detected by the detecting means or the gap between the second sheet portions 5b is located at a predetermined position. Here, the predetermined position means a position at which the exposed portion 21 does not enter the chamber 7, and the sheet portions 5a, 5b are not extruded by the chamber 7.

The control means 98 determines when one of the fibrous base material 2 and the sheet portions 5a, 5b are transported to a predetermined position in the chamber 7 by the determining means 97, that is, when the exposed portion 21 is positioned at the predetermined position, it is stopped. The drive of the transport means 6. On the other hand, when the determination means 97 does not determine that one of the fibrous base material 2 and the sheet portions 5a, 5b are conveyed to a predetermined position in the chamber 7, the control means 98 determines that the exposed portion 21 is not When it is located at the predetermined position described above, it is controlled so as not to stop the driving of the conveying means 6.

Further, in the present embodiment, the position of the exposed portion 21 on the inlet side of the chamber 7 is detected by the detecting means 96. However, the present invention is not limited thereto, and the position of the exposed portion 21 on the outlet side of the chamber 7 may be detected. At this time, the determination means 97 determines whether or not the exposed portion 21 is located at a predetermined position.

Further, by the detecting means 96, both the position of the exposed portion 21 on the inlet side of the chamber 7 and the position of the exposed portion 21 on the outlet side of the chamber 7 can be detected.

Next, a state (process) in which the laminated sheet manufacturing apparatus 30 is operated, that is, a state in which the laminated sheet manufacturing apparatus 30 manufactures the laminated sheet 40, will be described with reference to FIGS. 1 to 6 .

In the laminated sheet manufacturing apparatus 30, the fiber base material 2 is continuously supplied into the chamber 7. Then, as shown in FIG. 11, the fiber base material 2 which is continuously supplied here has a plurality of first sheet portions 5a disposed adjacent to each other via the gap 51 along the longitudinal direction on the upper surface side thereof, and plural numbers on the lower surface side. The second sheet portion 5b is disposed adjacent to each other via the gap 52. With this arrangement, the first sheet portion 5a and the second sheet portion 5b are intermittently supplied into the chamber 7.

Here, the first sheet portion 5a includes the first resin layer 3 and the metal layer 12 that supports the support of the first resin layer 3. The second sheet portion 5b includes a second resin layer 4 and a metal layer 12 that supports the support of the second resin layer 4. The first resin layer 3 and the second resin layer 4 are composed of a solid or semi-solid resin composition and are in a B-stage state.

Further, the first resin layer 3 and the second resin layer 4 may be a liquid resin composition.

The fiber base material 2 is wound around a supply roller (not shown), and the fiber base material 2 is conveyed to the chamber 7 by the supply roller. In the middle of transporting the fiber base material 2 toward the chamber 7, a plurality of sheet portions 5a and a plurality of sheet portions 5b are disposed on the fiber base material 2.

In the case of the conveyance, it is preferable that the fiber base material 2 is fixed in a state in which one portion of each of the sheet portions 5a is fixed and the other portion is not fixed, so that the fiber base material 2 is not displaced in position. . Specifically, preferred examples The end portion on the downstream side in the conveying direction of each sheet portion 5a is pressure-fixed to the fiber base material 2.

Similarly, it is preferable that the fiber base material 2 is previously formed in a state in which one portion of the sheet 5b is fixed and the other portion is not fixed. Specifically, for example, it is preferable to press-fix and fix the end portion of the sheet portion 5 b on the downstream side in the conveying direction to the fiber base material 2 .

As a method of partially pressing and fixing one of the sheet portions 5a and 5b to the fiber base material 2, for example, a part of each of the sheet portions 5a and 5b is heated by a heating means such as a sealing rod to form the resin layer 3. 4, a method of melting and impregnating the fibrous substrate 2.

Further, in the fibrous base material 2, a part of the upper surface thereof is exposed through the gap 51, and a part of the lower surface is also exposed through the gap 52. In the laminated sheet 40, the exposed portion 21 of the fiber base material 2, that is, the portion corresponding to the gaps 51 and 52 of the fiber base material 2, is used as the cut portion when the prepreg 1 is obtained by cutting the laminated sheet 40. .

In addition, as described above, the end surface (the end surface of the end portion in the TD direction) of the fiber base material 2 in the transport direction is not covered by the first sheet portion 5a or the second sheet portion 5b, but is exposed. .

The fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are conveyed in the chamber 7 by the conveying means 6. At this time, the chamber 7 is in an open state. In the detecting means 96, the gap between the adjacent first sheet portions 5a (the exposed portion 21 of the fibrous base material 2) or the gap between the adjacent second sheet portions 5b (fiber substrate) is detected. The position of the exposed portion 21) of 2. Then, the discriminating means 97 determines whether or not the gap between the first sheet portions 5a detected by the detecting means or the gap between the second sheet portions 5b is located at a predetermined position. In the discriminating means 97, when it is determined that one of the fibrous base material 2 and the sheet portions 5a, 5b are conveyed to a predetermined position in the chamber 7, the driving of the conveying means 6 is stopped. This stopped state is maintained until the fiber base material 2 in the chamber 7 is joined to the first sheet portion 5a and the second sheet portion 5b.

As shown in Fig. 1, the chamber 7 is opened, and the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b in the opposing state are inserted through the inlet 73. Further, although one portion of the fibrous base material 2 is located in the chamber 7, the other portion of the fibrous base material 2 is located on the downstream side and the upstream side in the transport direction of the chamber, and is exposed by the chamber 7.

Further, the other sheet portions 5a, 5b located outside the sheet portions 5a, 5b of the chamber 7 are located outside the chamber 7.

At this time, the heaters 95 respectively housed in the upper pressing member 91 and the lower pressing member 93 are operated in advance. Thereby, the upper side pressing member 91 and the lower side pressing member 93 are each in a heated state.

Further, the sealing member 75 provided in the upper side structure 71 of the chamber 7 and the heaters 78 respectively provided in the sealing member 76 provided in the lower structure 72 are also actuated in advance. Thereby, the sealing members 75 and 76 are respectively in a heated state.

Next, as shown in FIG. 2, the upper side structure 71 and the lower side structure body 72 are brought close, and the chamber is in a closed state. At this time, as described above, by the chamber 7 The sealing member 75 of the side structure 71 and the sealing member 76 of the lower structure 72 collectively hold the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b. Thereby, the airtightness of the chamber 7 is maintained.

Further, the sealing members 75 and 76 are respectively in a heated state. In the first sheet portion 5a, both end portions (end portions on the downstream side and the upstream side in the transport direction) of the first resin layer 3 are heated via the metal layer 12. By heating, both end portions of the first resin layer 3 are melted and pressed (fused) to the fiber base material 2. Further, in the second sheet portion 5b, both end portions of the second resin layer 4 are heated via the metal layer 12. By heating, both end portions of the second resin layer 4 are melted and pressed against the fiber base material 2. The molten resin layers 3 and 4 are impregnated into the inside of the fiber base material 2, and the region on the downstream side and the upstream side in the conveying direction of the fiber base material 2 in the chamber 7 is sealed. In this way, it is possible to suppress the gas inside the chamber 7 from leaking to the outside of the chamber 7 through the fibrous base material 2. Therefore, the inside of the chamber 7 can be easily decompressed, and a high vacuum can be created.

Next, as shown in FIG. 3, the decompression means 8 is actuated, and the pressure reduction of the chamber 7 is started. In the decompression, the upper pressing member 91 is moved downward by the operation of the cylinder 92, and the lower pressing member 93 is moved upward by the operation of the cylinder 94, and the fiber base material 2 and the first sheet portion 5a and the first portion are integrally formed. The 2 sheet portion 5b is carried out before pressurization.

Thereby, the space 77 is in a reduced pressure state, and the pressure between the auxiliary fiber base material 2 and the first resin layer 3 and the fiber base material 2 and the second resin are caused by the pressure (negative pressure) generated by the space 77. The pressure between layers 4 is sticky.

In the present embodiment, as described above, one of the sheet portions 5a is partially fixed to the fiber base material 2, and the other portion is not fixed to the fiber base material 2. Similarly, in order to fix one part of the sheet portion 5b to the fiber base material 2, the other portion is not fixed to the fiber base material 2.

Therefore, by depressurizing the chamber 7, the regions of the sheet portions 5a, 5b which are not fixed to the fibrous base material 2 are brought into contact with the fibrous base material 2.

Further, by operating the decompression means 8, the gas (air) inside the fiber base material 2 is sucked, and the inside of the fiber base material 2 is also depressurized. As shown in FIG. 10, the end surface of the fiber base material 2 located in the chamber in the transport direction is not covered by the sheet portions 5a and 5b, and is exposed. Therefore, the end surface of the fibrous base material 2 along the transport direction is The gas inside the fiber base material 2 is sucked by the decompression means 8.

Further, the gas in the fiber base material 2 is also sucked by the pressure reducing means 8 from the gap between the fiber base material 2 and the sheet portion 5a and the gap between the fiber base material 2 and the sheet portion 5b.

In addition, as described above, the regions on the downstream side and the upstream side in the transport direction of the fiber base material 2 located in the chamber 7 are impregnated into the resin layers 3 and 4, and are sealed by the resin layers 3 and 4, so that they can be sealed. The gas inside the fiber base material 2 located in the chamber 7 is surely attracted, and the inside of the fiber base material 2 is decompressed.

Further, the end portion of the fibrous base material 2 along the conveying direction is located inside the chamber 7, and is not exposed by the chamber 7.

Next, as shown in FIG. 4, under the reduced pressure state in which the operation of the decompression means 8 is maintained, the lower pressing member 93 is moved upward, and the upper side is pressed. The pressing member 91 is moved to the lower side. Thereby, the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b are pressurized.

Further, as described above, the upper pressing member 91 and the lower pressing member 93 are each in a heated state. Thereby, the intermediate portion of the first resin layer 3 is heated in the first sheet portion 5a via the metal layer 12. By this heating, the intermediate portion of the first resin layer 3 is melted, pressure-bonded (fused) to the fiber base material 2, and the resin layer 3 is further impregnated into the fiber base material 2. Further, in the second sheet portion 5b, the intermediate portion of the second resin layer 4 is also heated via the metal layer 12. By heating, the intermediate portion of the second resin layer 4 is melted, and the fiber substrate 2 is pressure-bonded, and the resin layer 4 is further impregnated into the fiber base material 2.

In the laminated sheet manufacturing apparatus 30, the pressure bonding by the action of the pressing means 9 and the pressure bonding by the operation of the decompressing means 8 are performed, and the reinforcing fiber substrate 2 and the first resin layer 3 are bonded. Bonding and joining of the fibrous base material 2 and the second resin layer 4. Thereby, for example, regardless of the thickness or composition of the first resin layer 3 or the second resin layer 4, the laminated sheet 40 in which the respective resin layers are reliably and firmly bonded to the fiber base material 2 can be produced. Further, the laminated sheet 40 to be produced is one in which the fiber base material 2 is impregnated with one of the resin layers, as shown in Fig. 8 .

In the present embodiment, the resin layers 3 and 4 are impregnated into the fibrous base material 2 in a state where the chamber 7 is depressurized by the decompression means 8. Thereby, when the impregnation is performed, the gas inside the fiber base material 2 is sucked by the decompression means 8. Therefore, it is possible to suppress the gas remaining in the fiber base material 2 from becoming a bubble. Thereby, a prepreg with reduced voids can be produced.

Further, the resin layers 3 and 4 are impregnated into the fibrous base material 2 by decompressing the chamber 7 by the decompression means 8. In other words, since the resin layer is impregnated in a state where the gas inside the fiber base material 2 is sucked by the decompression means, the impregnation property of the resin layer to the fiber base material 2 can be improved.

In addition, the operating conditions of the pressurizing means 9 and the heating means 95, that is, the pressurizing time, the heating time, and the heating temperature are respectively considered as constituent materials of the fiber base material 2, the first resin layer 3, and the second resin layer 4, or The thickness is different, and as the pressurizing time, it is preferably, for example, 5 to 180 seconds, more preferably 10 to 120 seconds. Further, the heating time is preferably, for example, 5 to 180 seconds, more preferably 10 to 120 seconds. Further, the heating temperature is preferably, for example, 60 to 150 degrees, more preferably 80 to 130 degrees.

Further, the pressure is preferably, for example, 0.1 to 3.0 MPa, more preferably 0.5 to 1.5 MPa.

Next, as shown in FIG. 5, after the operation of the decompression means 8 is stopped and the atmosphere is released, the upper pressing member 91 is moved upward, and the lower pressing member 93 is moved downward. The upper side structure 71 and the lower side structure body 72 are separated, and the chamber 7 is opened.

Next, as shown in FIG. 6, the conveying means 6 is actuated, and the laminated sheet 40 is sent out from the outlet 74 of the chamber 7. In conjunction with this, the fiber base material 2 which has not been joined, and the first sheet portion 5a and the second sheet portion 5b are inserted into the chamber 7.

Here, the fiber substrate 2 and the laminate of the first sheet portion 5a and the second sheet portion 5b are sequentially fed from the outlet 74 of the chamber 7 under atmospheric pressure. At this time, the exposed portion 21 is flexed, and the laminated sheet 40 is folded and recovered.

Then, the laminated sheet 40 sent out from the outlet 74 of the chamber 7 is cut at the exposed portion 21 of the fibrous base material 2 by a step (not shown). Thereby, the prepreg 1 was obtained.

Further, the laminated sheet 40 sent out from the outlet 74 of the chamber 7 is not folded, and the exposed portion 21 can be immediately cut.

Further, in the laminated sheet manufacturing apparatus 30, when the exposed portion 21 is positioned at the position where the exposed portion 21 is detected, the driving of the transporting means 6 is stopped.

The exposed portion 21 can be used for positioning the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b with respect to the chamber 7. As a result, as shown in FIG. 1, the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b constituting one prepreg 1 can be surely positioned in the chamber 7, and if the pressure is thereafter pressed If it is sticky, the prepreg 1 can be obtained.

Further, in the present embodiment, the long-sized fibrous base material 2 is fed into the chamber 7. By first making the fiber base material 2 into a long shape, the generation of cutting chips and the like of the fiber base material 2 can be suppressed.

Further, in the present embodiment, the sheet 5A (5B) is cut in advance to form a plurality of sheet portions 5a. Further, the sheet portion 5a (5b) is disposed on the fiber base material 2 with a detachment therebetween. Thus, when the prepreg 1 is obtained, it is not necessary to cut the sheet portion 5a (5b).

<Second Embodiment of a laminated sheet manufacturing apparatus (manufacturing method of laminated sheets)>

Hereinafter, a second embodiment of a laminated sheet manufacturing apparatus, a laminated sheet manufacturing method, and a laminated sheet according to the present invention will be described with reference to Fig. 7, but with the above embodiment The difference is described centering, and the description of the same matters is omitted.

This embodiment is the same as the above-described first embodiment except that the arrangement positions of the heaters included in the respective sealing members in the first embodiment are different.

As shown in FIG. 7, the inside of the upper structure 71 is supported by two heaters 78. Similarly to this, the inside of the lower structure 72 is also supported by the two heaters 78. Hereinafter, the heater 78 on the side of the side structure 71 will be described as a representative.

One of the two heaters 78 is disposed in the upper structure 71, and is disposed in front of the transport direction of the first sheet portion 5a (on the right side in FIG. 7), and the other heater 78 is disposed in the first The sheet portion 5a is disposed behind the conveyance direction (the left side in Fig. 7). Thereby, the first sheet portion 5a can be surely heated.

Hereinabove, the laminated sheet manufacturing apparatus, the laminated sheet manufacturing method, and the laminated sheet of the present invention have been described with reference to the embodiments shown in the drawings. However, the present invention is not limited thereto, and the laminated sheet manufacturing apparatus and the components constituting the laminated sheet can be utilized. Any component of the same function is replaced. Further, any constituent may be added.

In addition, the laminated sheet manufacturing apparatus, the laminated sheet manufacturing method, and the laminated sheet of the present invention may be a combination of any two or more of the above-described respective embodiments.

Further, in the configuration shown in FIG. 8, the laminated sheet is bonded to each other on both surfaces of the fibrous base material. However, the laminated layer is not limited thereto, and the resin layer may be bonded only to one surface of the fibrous base material. The laminated sheet of such a configuration can also be formed by laminating sheets Manufacturing equipment for manufacturing.

In the configuration shown in FIG. 8, the laminated sheet is impregnated with the first resin composition and the second resin composition in the fiber base material, but the present invention is not limited thereto, and may be, for example, the following. The first example is a laminated sheet in which the first resin composition is impregnated as a whole in the thickness direction of the fiber base material, and the second resin composition is not impregnated. The second example is a laminated sheet in which the second resin composition is impregnated as a whole in the thickness direction of the fiber base material, and the first resin composition is not impregnated. The third example is a laminated sheet in which a part of the thickness direction of the fiber substrate is impregnated with the first resin composition and the second resin composition is not impregnated. In the fourth example, the second resin composition is impregnated in one of the thickness directions of the fibrous base material, and the laminated sheet of the first resin composition is not impregnated. In the laminated sheets of the above four examples, the composition of the first resin composition and the second resin composition may be different from each other, or the compositions may be identical to each other. Further, the laminated sheet of such a configuration can also be produced by a laminated sheet manufacturing apparatus.

In the above-described embodiments, the laminated sheet of the fiber base material 2 and the resin layer is produced. However, the laminated sheet is not limited thereto. For example, another resin layer may be laminated on at least one surface of the resin layer to produce a laminated sheet. Further, a laminate sheet may be formed by laminating a resin layer or other prepreg on at least one side of the prepreg. At this time, a laminated sheet using the building material used as a circuit board can be obtained.

Further, in the above-described embodiment, the first sheet 5A is laminated on one surface side of the fiber base material 2, and the second sheet 5B is laminated on the other surface side, but only one side of the fiber base material 2 may be used. Side laminate sheet.

Further, in the above embodiment, a fibrous base material is used as the base material, and other porous base materials other than the fibrous base material may be used. It is preferable that the porous base material has a hole that communicates in a direction orthogonal to the conveyance direction and communicates with the end surface along the conveyance direction. In such a porous substrate, gas inside the substrate can be attracted in the chamber 7.

The present invention is based on the following constituents.

(1) A manufacturing apparatus for a laminated sheet, which is a resin sheet having a long-length thin plate-shaped support body having a resin layer composed of a solid or semi-solid resin composition on one side, and joined to a long-length thin plate A laminated sheet is produced on one or both sides of the substrate; and the substrate and the substrate are opposed to each other, and the support and the substrate are transported along the longitudinal direction thereof. a means for maintaining the chamber through which the support body and the base material are conveyed by the transport means while maintaining the relative state; and a pressure reducing means for decompressing the chamber; and in the chamber a pressing/heating means for pressurizing and heating the support body in the opposing state and the base material in the thickness direction thereof; and the support body by the transport means in the chamber and the above The transfer of the substrate is temporarily stopped, and in the stopped state, the chamber is depressurized by the decompression means, and the above-mentioned relative state is applied by the pressurization/heating means. Pressurizing the support and the substrate / plus Heat, and the above resin layer is pressure-bonded to the above substrate.

(2) The apparatus for manufacturing a laminated sheet according to (1), wherein the pressure reduction by the pressure reducing means is started before the pressurization by the pressurizing/heating means.

(3) The apparatus for manufacturing a laminated sheet according to (1) or (2), wherein the support system is intermittently supplied into the chamber, and the substrate is continuously supplied into the chamber.

(4) The apparatus for manufacturing a laminated sheet according to (3), wherein the plurality of support members are adjacently arranged along the longitudinal direction of the substrate, and the substrate corresponds to the gap. The portion to be used as the positioning portion when the transfer of the support body and the substrate is temporarily stopped in the chamber is used.

(5) The apparatus for manufacturing a laminated sheet according to any one of (1) to (4), wherein the pressurizing/heating means includes: the support body and the substrate on the one side of the opposing state The upper pressing member that performs pressing; and the lower pressing member that is pressed by the other surface side.

(6) The apparatus for manufacturing a laminated sheet according to (5), wherein the pressurizing/heating means is incorporated in at least one of the upper pressing member and the lower pressing member, and has a pressing force via the one of the pressing members A heater that heats the support body by the member.

(7) The manufacturing apparatus of the laminated sheet according to any one of (1) to (6) wherein the pressure/heating means is configured to adjust the pressure.

(8) The apparatus for manufacturing a laminated sheet according to any one of (1) to (7), wherein the cavity The chamber has an inlet for feeding the support and the substrate, an outlet for feeding the support fed from the inlet to the substrate, and the inlet and the outlet are respectively adhered to the support Or a sealing member that maintains the airtightness in the chamber in the above substrate.

(9) The apparatus for manufacturing a laminated sheet according to (8), wherein each of the sealing members is configured to be capable of heating the support or the substrate, and has a function as a part of the pressurizing/heating means.

(10) The manufacturing apparatus of the laminated sheet according to any one of (1) to (9) wherein the chamber is composed of two structures close to each other.

(11) The apparatus for manufacturing a laminated sheet according to any one of (1) to (10), wherein the pressure reducing means has a tube that communicates with the chamber; and is connected to the chamber via the tube. Pump.

(12) A method for producing a laminated sheet, which is produced by using the apparatus for producing a laminated sheet according to any one of the above (1) to (11).

The present application claims priority based on Japanese Patent Application No. 2011-080363, filed on March 31, 2011, and Japanese Patent Application No. 2012-065031, filed on March 22, 2012. Take this for this.

1‧‧‧Prepreg

2‧‧‧Fiber substrate

3‧‧‧1st resin layer

4‧‧‧2nd resin layer

5a‧‧‧1st sheet

5b‧‧‧2nd Sheet

5A‧‧‧1st sheet

5B‧‧‧2nd sheet

6‧‧‧Transportation means

7‧‧‧ chamber

8‧‧‧Decompression

9‧‧‧pressure means

12‧‧‧metal layer

20‧‧‧ border

21‧‧‧Exposed Department

30‧‧‧Laminated sheet manufacturing equipment

31‧‧‧1st impregnation

32‧‧‧1st Non-Immersion Department

40‧‧‧Layered film

41‧‧‧2nd Impregnation Department

42‧‧‧2nd Non-Immersion Department

51, 52‧ ‧ gap

71‧‧‧Upside structure

72‧‧‧lower structure

73‧‧‧ Entrance

74‧‧‧Export

75, 76‧‧‧ Sealing members

77‧‧‧ Space

78‧‧‧heater

81‧‧‧ pump

82‧‧‧Connecting tube

90‧‧‧ convex

91‧‧‧Upper pressing member

92, 94‧‧ ‧ cylinder

93‧‧‧Bottom pressing member

95‧‧‧heating means

96‧‧‧Detection means

97‧‧‧Discrimination means

98‧‧‧Control means

711‧‧‧ top board

712, 712A, 712B, 722, 722A, 722B‧‧‧ side walls

721‧‧‧floor

921, 941‧‧‧ pole

E‧‧‧elastic components

G‧‧‧Air

Fig. 1 is a schematic cross-sectional side view showing an operation state of the laminated sheet manufacturing apparatus (first embodiment) of the present invention in order.

Fig. 2 is a view showing the apparatus for manufacturing a laminated sheet of the present invention in order (first embodiment) A schematic cross-sectional side view of the actuation state.

Fig. 3 is a schematic cross-sectional side view showing an operation state of the laminated sheet manufacturing apparatus (first embodiment) of the present invention in order.

Fig. 4 is a schematic cross-sectional side view showing an operation state of the laminated sheet manufacturing apparatus (first embodiment) of the present invention in order.

Fig. 5 is a schematic cross-sectional side view showing an operation state of the laminated sheet manufacturing apparatus (first embodiment) of the present invention in order.

Fig. 6 is a schematic cross-sectional side view showing an operation state of the laminated sheet manufacturing apparatus (first embodiment) of the present invention in order.

Fig. 7 is a schematic cross-sectional side view showing a laminated sheet manufacturing apparatus (second embodiment) of the present invention.

Figure 8 is a cross-sectional view showing a laminated sheet.

Fig. 9 is a plan view showing a state in which a plurality of sheet portions are intermittently arranged on a substrate.

Figure 10 is a cross-sectional view taken along line X-X of Figure 4;

Fig. 11 is a cross-sectional view along the longitudinal direction of the fiber base material; and a cross-sectional view showing a state in which the sheet portions are disposed apart from each other with respect to the fiber base material.

Fig. 12 is a schematic cross-sectional side view showing a modification of the laminated sheet manufacturing apparatus of the present invention.

2‧‧‧Fiber substrate

3‧‧‧1st resin layer

4‧‧‧2nd resin layer

5a‧‧‧1st sheet

5b‧‧‧2nd Sheet

5A‧‧‧1st sheet

5B‧‧‧2nd sheet

6‧‧‧Transportation means

7‧‧‧ chamber

8‧‧‧Decompression

9‧‧‧pressure means

12‧‧‧metal layer

21‧‧‧Exposed Department

30‧‧‧Laminated sheet manufacturing equipment

51‧‧‧ gap

52‧‧‧ gap

71‧‧‧Upside structure

72‧‧‧lower structure

73‧‧‧ Entrance

74‧‧‧Export

75‧‧‧ Sealing members

76‧‧‧ Sealing members

77‧‧‧ Space

78‧‧‧heater

81‧‧‧ pump

82‧‧‧Connecting tube

91‧‧‧Upper pressing member

92‧‧‧ cylinder

93‧‧‧Bottom pressing member

94‧‧‧ cylinder

95‧‧‧heating means

711‧‧‧ top board

712‧‧‧ side wall

712A‧‧‧ sidewall

712B‧‧‧ Sidewall

722‧‧‧ side wall

722A‧‧‧ sidewall

722B‧‧‧ side wall

921‧‧‧ rod

941‧‧‧ rod

G‧‧‧Air

Claims (13)

A manufacturing apparatus for a laminated sheet, which is obtained by bonding the resin layer of a thin plate-shaped sheet having a resin layer on one side to one side or both sides of a long-length thin plate-shaped substrate to produce a laminated sheet; a conveying means for conveying the sheet and the substrate along a longitudinal direction of the substrate in a state in which the substrate and the resin layer face each other; and the sheet conveyed by the conveying means and the above a substrate through which a substrate passes under the relative orientation; a decompression means for decompressing the chamber; and a heating means for heating the substrate and the sheet in the chamber; a pressing means for pressurizing the substrate and the sheet in a relative state in a thickness direction thereof in a chamber; and the substrate and the substrate which are carried by the conveying means in the chamber The conveyance of the sheet is temporarily stopped, and in the stopped state, while the inside of the chamber is depressurized by the decompression means, the opposing direction is performed by the pressing means and the heating means The substrate and the sheet are pressed and heated to pressurize the resin layer and the substrate; the chamber has an inlet for feeding the substrate and the sheet; and The substrate and the outlet for feeding the sheet; the inlet and the outlet of the chamber are respectively abutted a sealing member of the substrate or the sheet; the device for laminating the sheet of the substrate belonging to the fiber substrate; wherein the conveying means is directed to the resin layer of the sheet facing the substrate, and along The substrate and the sheet are conveyed into the chamber in a state where the end surface of the substrate in the transport direction is exposed; the sealing member is configured to be in contact with the sheet or the substrate and the resin layer side. The sealing member has a heating portion that heats the resin layer to impregnate the resin layer with the substrate. The manufacturing apparatus of the laminated sheet according to the first aspect of the invention, wherein the manufacturing apparatus is located in a region in which the one portion of the base material is located in the chamber, and a region on the upstream side and a downstream side in a conveying direction of the portion of the base material In the state outside the chamber, the pressurization of the pressurizing means and the heating by the heating means are performed. The apparatus for manufacturing a laminated sheet according to the first aspect of the invention, wherein the pressurizing means includes: a first pressing member that presses one side of the base material and the sheet relative to each other; The first pressing member may be spaced apart from and close to the second pressing member that is pressed against the base material and the sheet by the other side. The apparatus for manufacturing a laminated sheet according to claim 1, wherein the chambers are opposed to each other, and are configured to be decompressed by the decompression means. a first structure and a second structure in the decompression chamber; the first structure and the second structure are configured to be relatively detachable and close to each other; and the first structure and the second structure are formed between the first structure and the second structure The inlet and the outlet; wherein the sealing member is provided in a portion of the structure in which at least one of the structures is separated from the inlet and at least one of the structures of the structure. The apparatus for manufacturing a laminated sheet according to the first aspect of the invention, wherein the conveying means transports a long-sized base material and the sheet having a plurality of sheet portions intermittently arranged along a longitudinal direction of the substrate And a means for determining whether a part of the base material and the sheet portion are conveyed to a predetermined position in the chamber; and determining, by the discriminating means, one of the base material and the sheet portion When being transported to a predetermined position in the chamber, the driving of the transport means is stopped, and when the discriminating means does not determine that one of the base material and the sheet portion are transported to a predetermined position in the chamber, The means for controlling the driving of the above-described transport means and controlling the control. The manufacturing apparatus of the laminated sheet of the fifth aspect of the invention, wherein the detecting means has a detecting means for detecting a position of the gap between the sheet portions; and wherein the determining means determines the position of the gap detected by the detecting means Whether it is a predetermined position, and discriminate one part of the above substrate and Whether or not the sheet portion is conveyed to a predetermined position in the chamber. A manufacturing apparatus for a laminated sheet according to the first aspect of the invention, wherein the resin layer of the sheet is composed of a solid, semi-solid or liquid resin composition. A manufacturing method of a laminated sheet is a manufacturing apparatus for a laminated sheet of the first application of the patent application. A method for producing a laminated sheet, which is obtained by bonding the resin layer of a sheet having a resin layer on one side to one side or both sides of a long-length sheet-shaped substrate to form a laminated sheet; a step of transporting the sheet and the substrate in a state in which the substrate and the resin layer face each other in a state in which the substrate and the resin layer are opposed to each other; and the sheet and an area of the substrate facing the sheet a step of stopping the transfer of the sheet and the substrate in a state in which the other portion of the substrate on the upstream side and the downstream side in the transport direction of the substrate is located outside the chamber in the chamber; Depressurizing the chamber, heating a portion of the substrate in the chamber and the sheet, and pressing a portion of the substrate and the sheet; wherein the transferring step is long The base material of the flaky fiber base material faces the resin layer of the sheet, and the base material is exposed in a state in which the end surface of the base material is exposed along the transport direction. Said sheet conveyed to the chamber; In the above step of pressurizing one of the substrate and the sheet, the chamber is decompressed by a pressure reducing means, and the end surface side of the substrate is attracted by the pressure reducing means. The gas inside the substrate; the substrate and the sheet are heated, and the substrate and the sheet are pressed to impregnate the resin layer of the sheet into the substrate. The method for producing a laminated sheet according to claim 9, wherein, after stopping the conveyance of the sheet and the substrate, the front portion of the chamber is decompressed by the pressure reducing means, including: The chamber inlet side region and the chamber outlet side region of the resin layer of the sheet in the chamber are melted, and the resin layer is impregnated with the substrate. The method for producing a laminated sheet according to claim 10, wherein the sheet is composed of a plurality of sheet portions; in the transferring step, the long-sized substrate is conveyed and has a substrate along the substrate The sheet of the plurality of sheet portions intermittently disposed in the longitudinal direction; in the step of stopping the conveyance, at least one sheet portion and a portion of the substrate facing the sheet portion The substrate and the sheet are stopped from being conveyed to the chamber, and the other portion of the substrate on the upstream side and the downstream side in the transport direction of the substrate is located outside the chamber. The manufacturing method of the laminated sheet of claim 11 of the patent application, wherein In the preceding stage of the above-described transfer step, the sheet portion is placed on the substrate so as to fix one of the sheet portions and the other portion is not fixed. The method for producing a laminated sheet according to claim 11, wherein in the step of stopping the conveyance of the sheet and the substrate, it is detected whether a gap position between the sheet portions of the sheet is conveyed to At the predetermined position, when the conveyance to the predetermined position is detected, the conveyance of the sheet and the substrate is stopped.