WO2010137525A1 - 繊維束の開繊方法及び開繊糸シート並びに繊維補強シートの製造方法 - Google Patents
繊維束の開繊方法及び開繊糸シート並びに繊維補強シートの製造方法 Download PDFInfo
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- WO2010137525A1 WO2010137525A1 PCT/JP2010/058602 JP2010058602W WO2010137525A1 WO 2010137525 A1 WO2010137525 A1 WO 2010137525A1 JP 2010058602 W JP2010058602 W JP 2010058602W WO 2010137525 A1 WO2010137525 A1 WO 2010137525A1
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- Prior art keywords
- fiber bundle
- fiber
- opening
- spread
- width
- Prior art date
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Classifications
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D11/00—Other features of manufacture
- D01D11/02—Opening bundles to space the threads or filaments from one another
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
- C08J5/043—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
- D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
- D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
- D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
- D02J1/18—Separating or spreading
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4242—Carbon fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/002—Inorganic yarns or filaments
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T428/268—Monolayer with structurally defined element
Definitions
- the present invention is a fiber bundle opening method for conveying a fiber bundle consisting of a large number of fibers in the fiber length direction and opening the fiber bundle by moving it in the width direction while allowing the fluid to pass through the fiber bundle, Further, the present invention relates to a spread yarn sheet obtained by opening a fiber bundle, and a method for producing a fiber reinforced sheet in which a resin material is adhered or impregnated to the spread yarn sheet.
- fiber-reinforced composite materials that combine carbon fiber, glass fiber, aramid fiber, and matrix resin such as epoxy resin is underway. These reinforcing fibers are made of thin spread yarn sheets that are aligned in one direction. A reliable high-strength composite material molded product can be obtained by stacking in multiple directions. Also, composite materials using thermoplastic resin such as polyamide 6 resin, polyetherimide resin, polyetheretherketone resin as matrix resin due to advantages such as recyclability, short-time moldability, and improved impact resistance of molded products. Molded products are expected to increase in the future.
- carbon fiber composite materials have attracted much attention as materials for aircraft and automobiles.
- carbon fibers There are various types of carbon fibers, but the main ones are those with a tensile modulus of about 24 ton / mm 2 and a single yarn diameter of about 7 ⁇ m.
- Carbon fibers are bundled and marketed as carbon fiber bundles, but the number of bundles is also various. In terms of price, product quality (fiber straightness, fiber alignment, etc.) and ease of handling, general-purpose carbon fiber bundles have 12,000 bundles and 15000 bundles (fineness of about 800-1100g / 1000m). As the high-strength medium elastic carbon fiber bundles, those having a bundling number of 12,000 and 24000 (fineness of about 400 to 1000 g / 1000 m) are mainly used.
- the fiber opening process is important for fiber bundles with a large number of bundles.
- the opening technique for example, in Patent Document 1, the multifilament is conveyed from the yarn supplying unit to the winding unit, and the multifilament is allowed to bow in the leeward direction by allowing the airflow to pass through the multifilament a plurality of times.
- a method for producing a multifilament spread sheet is disclosed in which the filaments constituting the multifilament are separated in the width direction and opened.
- the unwinding part which flows the fluid in the direction orthogonal to the moving direction of an aggregate fiber with respect to the draw
- a fiber opening device that includes a winding roll that winds a fiber sheet that has been opened at the fiber opening part
- the fiber opening part is arranged in a plurality of stages along the moving direction.
- fiber bundles are pulled out and supplied from a plurality of yarn feeders, respectively, and the supplied fiber bundles are run in an air stream at a plurality of fluid flow portions to bend the fiber bundles by the action of the air stream.
- a fiber-spreading device that opens in the width direction is described.
- the above-described patent document describes a fiber opening technique for expanding a fiber bundle to a predetermined width by allowing a fluid to pass through the conveyed fiber bundle.
- a fiber spreading technique it is necessary to widen the spread width as much as possible while uniformly dispersing the fibers constituting the fiber bundle, and to form the spread fiber bundle as uniform and thin as possible.
- fiber bundles with increased number of fibers that is, thick fiber bundles
- the production cost can be lowered.
- a wider spread yarn sheet can be obtained by a single fiber opening step, so that the production efficiency can be significantly increased.
- Patent Document 1 in order to widen the spread width of the fiber bundle, the fiber bundle is subjected to a fiber opening action over a plurality (in the embodiment, twice), but the front feeder, the back feeder, and the deflection measurement sensor. It is necessary to install equipment for adjusting the amount of bending of the fibers, etc. at a plurality of places (two places in the embodiment), which makes it impossible to increase the size of the apparatus and increases the equipment cost burden. Furthermore, it is difficult to line up the facilities in the width direction, and it is difficult to obtain a sheet-like spread yarn sheet in which a plurality of fiber bundles are simultaneously opened.
- Patent Documents 2 and 3 a plurality of opening portions are continuously provided, and the opening width is continuously increased each time the fiber bundle passes through each opening portion.
- the spread width is continuously expanded in this way, the fibers constituting the fiber bundle are not uniformly dispersed, and the density of the opened fibers becomes coarse and in some cases gaps are generated. It becomes like this.
- the general-purpose carbon fiber bundles having 12,000 or 15,000 converging fibers, or high-strength medium elastic carbon having 12000 or 24000 converging fibers When a fiber bundle is used, carbon fibers are dispersed almost uniformly and spread with a uniform thickness up to a width of about 20 to 25 mm (weight is about 40 g / m 2 ). Although the yarn sheet can be formed continuously, cracks are generated in the spread yarn sheet when the wide spread with a spread width of 25 mm or more (a basis weight of about 30 g / m 2 or less) is continuously performed. A part can be made.
- the carbon fiber bundle when using a carbon fiber bundle with a large fineness of 24,000, the carbon fiber bundle is almost uniformly carbonized until the opening width of one carbon fiber bundle is about 30 to 35 mm (the basis weight is about 50 g / m 2 ).
- a spread yarn sheet with a uniform thickness can be continuously formed by dispersing fibers, but a wide spread with a spread width of about 40 mm or more (a basis weight of about 40 g / m 2 or less) is continued. As a result, the spread yarn sheet can be broken, converged due to fiber entanglement, and has a part that causes partial twist.
- the fibers move in the width direction in a state where the fibers are gathered, or the fiber entanglement is increased to deteriorate the dispersibility of the fibers. Or a portion that easily causes an unstable state of the gap and the opening width in the opened state of the fiber bundle. That is, it has been found that it becomes difficult to continuously open the fibers constituting the fiber bundle in a uniformly dispersed state.
- a wider opening (12000 bundling, 15000 general-purpose carbon fiber bundles and 12000 bundling high-strength medium elastic carbon fiber bundles in the case of 14,000 carbon fibers are used.
- the present invention can also be applied to a fiber bundle having an increased number of bundles, and the fibers are uniformly dispersed to continuously form a thin spread yarn sheet having a wide spread width and a uniform thickness.
- the object is to provide a manufacturing method.
- a fiber bundle composed of a large number of fibers is conveyed in the fiber length direction, and the fluid passes through the fiber bundle in a movable region set so that the fibers can move in the width direction.
- the fiber bundle is opened by moving the fiber bundle in the width direction while bending the fiber, and the width direction while bending the fiber by passing a fluid through the fiber bundle to the movable region.
- Expansion region B i (i 1,..., Which is set on the upstream side in the conveying direction and expands the width of the fiber bundle toward the end as the fiber opening region A i moves in the fiber width direction.
- area group of pairs consisting of n) S i (i 1 , ⁇ , n) wherein n (n ⁇ 2 in the conveying direction of the fiber bundle) into individual sequences, sequentially to pass through the region group S i Is conveyed to the fiber bundle so as characterized by opening in.
- the fibers are moved in the width direction while being bent by allowing fluid to pass through the fiber bundle in a plurality of sections.
- at least one contact roll arranged in the width direction and in contact with the fiber bundle is disposed so that the fiber bundle contacts the contact roll. It is characterized by being conveyed.
- the contact roll reciprocates along the width direction of the fiber bundle.
- the fiber bundle is heated in at least a part of the expansion region and / or the spread region.
- the amount of bending of the fiber bundle is changed with time.
- the opening region is opened while securing a predetermined amount of bending of the fiber bundle by a bending securing roll.
- the fiber bundle is vibrated in a direction perpendicular to the conveying direction by at least one of the bending securing rolls.
- the fiber bundle is conveyed on the upstream side of the movable region while preventing the fiber bundle from being pulled back.
- a vibration is imparted to the spread yarn sheet obtained by opening the fiber bundle in the width direction.
- the fiber bundles are simultaneously opened while being conveyed.
- the present invention is characterized in that a plurality of spread fiber sheets that are opened and paralleled are imparted with vibration in the width direction to form a uniform sheet as a whole.
- a carbon fiber bundle having a fiber bundle number of 12,000 to 24000 and a fineness of 400 g / 1000 m to 1100 g / 1000 m is opened, and the carbon fiber bundle has a width of 25 mm or more and a thickness. It is characterized by being 0.04 mm or less. Furthermore, a carbon fiber bundle having a fiber bundle number of 24,000 or more and a fineness of 1600 g / 1000 m or more is opened to make the carbon fiber bundle 40 mm or more in width and 0.2 mm or less in thickness.
- the method for producing a fiber reinforced sheet according to the present invention is to produce a fiber reinforced sheet by forming a resin layer on one side or both sides of a spread yarn sheet obtained by any one of the fiber bundle opening methods. It is characterized by. Furthermore, the resin layer is formed using a resin sheet. Furthermore, the fiber reinforced sheet is produced by attaching the spread yarn sheet obtained by any one of the fiber bundle opening methods to both surfaces of the resin sheet. Furthermore, the fiber-reinforced sheet is produced by impregnating a spread yarn sheet obtained by any of the fiber bundle opening methods with a resin material.
- the present invention has the above-described configuration, so that the fibers in the fiber bundle are movable in the width direction so that the fibers can move in the width direction.
- Expansion region B i (i 1,..., which is set on the upstream side in the conveying direction and expands the width of the fiber bundle toward the end as the fiber opening region A i moves in the fiber width direction.
- the movement phenomenon in the width direction due to the fiber dispersion of the fiber bundles generated in the opening region A i is upstream.
- the fiber is uniformly dispersed in the opening area A i by performing pre-opening in which each fiber is gradually moved in the width direction by exerting on the expansion area B i , thereby increasing the opening width to a predetermined width and increasing the thickness. Equalization Thus, the fiber bundle can be widened with a good fiber dispersibility.
- each fiber of the fiber bundle becomes a region that can move in the width direction.
- the fibers By arranging a plurality of extended regions B i and spread regions A i in this region as a pair, the fibers gradually move in the width direction even when there is uneven sizing agent adhesion or fiber entanglement in the fiber bundle.
- the fiber opening can proceed as the fiber bundle is unraveled.
- the fiber bundle in the movable region, can be sequentially expanded in the spread width while being uniformly dispersed in a state of excellent straightness without meandering the fibers.
- the opening width of one carbon fiber bundle is 25 mm or more (the basis weight is about 30 g / second).
- m 2 or less) carbon fibers can be uniformly dispersed to form a thin spread fiber sheet having a uniform thickness. Further, even if the focused number was used large fineness carbon fiber bundle described above present 24000, a thin opened yarn sheet Open ⁇ is a wide uniform thickness by increasing the sequence number of the area group S i stably It becomes possible to open the fiber.
- each fiber is not affected by uneven sizing agent adhesion or fiber entanglement.
- the fiber bundle can be opened so as not to crack while unraveling the partial twists of the fiber bundle.
- the remaining group of regions S j (j 2, ⁇ , n) in the open ⁇ W j-1 of the open ⁇ area A j-1, open ⁇ area A j open ⁇ W j and expansion
- the length L j in the conveyance direction of the fiber bundle in the region B j is 0 ⁇ (W j ⁇ W j ⁇ 1 ) / 2L j ⁇ tan 30 °.
- the uneven adhesion of the sizing agent and the entanglement of the fibers that are partially generated in the fiber bundle are gradually unraveled by the preliminary opening in the expansion region B j , and the opening region A j
- the spread yarn sheet obtained by the present spread method becomes a spread yarn sheet with a small number of fibers in the thickness direction, which is excellent in fiber straightness and fiber dispersibility, easily impregnated with a matrix material such as a resin, and fibers.
- the sheet can sufficiently exhibit the original mechanical properties (tensile properties).
- the original mechanical properties of fibers (for example, tensile properties, compression, etc.) can be obtained by a production method in which a resin material is adhered or impregnated on a spread yarn sheet excellent in fiber straightness and fiber dispersibility obtained by the present spread method. It is possible to obtain a fiber reinforced sheet that is sufficiently expressed in the width direction and the thickness direction and exhibits sufficient characteristics and the like, and has few defects that cause stress concentration.
- a fiber reinforced sheet excellent in moldability that is, draping property, by a manufacturing method in which a resin material is adhered or impregnated into a thin open fiber yarn sheet having a small number of fibers in the thickness direction obtained by the present fiber opening method. Can be obtained.
- FIG. It is explanatory drawing regarding area group Sj-1 and area group Sj . It is an explanatory diagram relating to open ⁇ W j in the open ⁇ area A j. It is another explanatory diagram relating to open ⁇ W j in the open ⁇ area A j. It is a schematic plan view regarding another example of apparatus which implements the fiber-spreading method which concerns on this invention.
- FIG. It is a schematic side view regarding the example of an apparatus shown in FIG. It is a schematic plan view regarding another example of apparatus which implements the fiber-spreading method which concerns on this invention. It is a schematic side view regarding the example of an apparatus shown in FIG. It is a schematic plan view regarding another example of apparatus which implements the fiber-spreading method which concerns on this invention. It is a schematic side view regarding the example of an apparatus shown in FIG. It is a schematic side view regarding the example of another apparatus which implements the fiber-spreading method which concerns on this invention. It is a schematic side view regarding the example of another apparatus which implements the fiber-spreading method which concerns on this invention.
- FIG. 1 and FIG. 2 are a schematic plan view and a schematic side view relating to an apparatus example for carrying out the fiber opening method according to the present invention.
- a fiber bundle Tm in which a plurality of long fibers are bundled is wound around a bobbin type yarn supplying body 11, and the fiber bundle Tm is fed out by rotating the yarn supplying body 11 by a yarn supplying motor 12. ing.
- fiber material used for the fiber bundle Tm carbon fiber bundles, glass fiber bundles, aramid fiber bundles, reinforcing fiber bundles made of high strength fibers such as ceramic fiber bundles, polyethylene, polypropylene, nylon 6, nylon 66, nylon 12,
- thermoplastic resin fiber bundles obtained by arranging thermoplastic synthetic fiber fibers such as polyethylene terephthalate, polyphenylene sulfide, and polyether ether ketone.
- carbon fiber bundles many 12,000 to 24000 bundles of fiber bundles are distributed in the market. In the present invention, however, bundles of bundles exceeding 24,000 (for example, 48000, 60000, etc.) It can also be used.
- the form of the fiber bundle Tm it is desirable that a plurality of fibers are aligned and converged so as not to be separated by a sizing agent or the like. Due to the adhesion of the sizing agent, the shape of the opened yarn sheet is stabilized. A fiber bundle in a form in which twisting is forcibly twisted is difficult to obtain a continuous opening state, and it is not desirable to use it in the opening method of the present invention.
- the fiber bundle Tm fed out from the yarn supplying body 11 is drawn out in a predetermined pulling direction by a guide roll 21 supported rotatably at a predetermined position.
- the drawn fiber bundle Tm is sandwiched between the feed roll 22 and the support roll 23 and fed at a predetermined feed amount.
- the feed amount of the fiber bundle Tm is adjusted by controlling the rotation operation of the feed motor 24 that rotates the feed roll 22.
- the fiber bundle Tm fed by the feed roll 22 is supported and transported by a pair of support rolls 25 arranged at a predetermined interval in the transport direction of the fiber bundle Tm.
- a tension applying roll 26 is provided between the support rolls 25 so as to be movable up and down, and the fiber bundle Tm is set so as to go around from the upper side of the support roll 25 to the lower side of the tension applying roll 26.
- the fiber bundle Tm passing between the support rolls 25 is given a predetermined range of tension by the tension applying roll 26.
- tensile_strength provision roll 26 comes to raise / lower with the feed amount of the fiber bundle Tm sent by the feed roll 22.
- the lifting operation of the tension applying roll 26 is detected by an upper limit position detection sensor 27 and a lower limit position detection sensor 28.
- the tension applying roll 26 operates so as to rise when the feed amount decreases with respect to the amount (transport amount) of the fiber bundle Tm that is opened and transported, and to descend when the feed amount increases with respect to the transport amount of the fiber bundle Tm. . Therefore, when the tension applying roll 26 rises and the upper limit position detection sensor 27 detects the tension applying roll 26, the rotation of the feed roll 22 is accelerated and the feed amount of the fiber bundle Tm is increased. Further, when the tension applying roll 26 descends and the lower limit position detection sensor 28 detects the tension applying roll 26, the rotation of the feed roll 22 is delayed to reduce the feed amount of the fiber bundle Tm.
- the feed amount of the fiber bundle Tm is adjusted based on the detection signals from the upper limit position detection sensor 27 and the lower limit position detection sensor 28 so that the tension applying roll 26 is positioned within the predetermined range, and the tension of the fiber bundle Tm is set within the predetermined range. To stabilize.
- any method other than this mechanism may be used as long as it is a mechanism that draws the fiber bundle from the bobbin and stabilizes the tension of the fiber bundle continuously within a certain range.
- a nip roll 29 is provided on the downstream side of the support roll 25, and the fiber bundle Tm is nipped by the nip roll 29 and conveyed to the fiber opening section.
- a one-way clutch (not shown) is attached to the nip roll 29, and the nip roll 29 rotates only in the direction of feeding the fiber bundle Tm and does not rotate in the direction of pulling back.
- the fiber bundle Tm that passes through the nip roll 29 and is set to a predetermined range of tension passes through a plurality of spread parts arranged in the transport direction.
- Each fiber opening portion supports the fiber bundle Tm by a pair of guide rolls 31 arranged in the transport direction.
- a wind tunnel 32 is provided between the guide rolls 31, and an upper opening of the wind tunnel 32 is formed between the guide rolls 31 with a predetermined width.
- a flow rate adjustment valve 33 and an intake pump 34 are attached to the lower side of the wind tunnel pipe 32, and the upper opening between the guide rolls 31 is sucked by operating the intake pump 34 to suck air in the wind tunnel pipe 32.
- the air flow is generated by suction.
- the fiber bundle Tm When the suction airflow passes through the fiber bundle Tm being conveyed between the guide rolls 31, the fiber bundle Tm is bent due to the relationship between the tension of the fiber bundle Tm and the flow velocity of the airflow. In such a state, when the airflow passes between the fibers of the fiber bundle Tm, a force that moves the fibers in the width direction of the fiber bundle Tm works, and the fiber bundle Tm is opened by the effect that the fibers are bent. become so. Such opening action is known.
- the amount of the bend can be expressed by the bend amount t.
- the amount of bending t can be represented by the distance from the upper surface of the guide roll 31 to the lowest position when the fiber bundle is bent.
- the fiber bundle Tm is not pulled back in the direction opposite to the conveying direction, and it is easy to form a deflection in the wind tunnel.
- a pair of guide members 35 are attached along the conveying direction on both sides of the upper opening of the wind tunnel 32, and the opening is opened by the suction airflow passing through the fiber bundle Tm being conveyed between the guide rolls 31.
- the spread width is defined by the guide member 35.
- the guide member 35 may form the upper opening of the wind tunnel 32 in a rectangular shape and use the side wall of the opening as it is. Further, a plurality of wires or the like can be erected inside the wind tunnel tube 32 and used as a guide member.
- the fiber bundle Tm is formed in a thin spread yarn sheet Ts having a thin thickness in which the fibers are uniformly dispersed by being opened multiple times by the opening portion.
- the spread yarn sheet Ts is nipped by the take-up roll 41 and conveyed.
- the take-up roll 41 is rotationally driven by the take-up motor 42 to draw in the spread yarn sheet Ts and convey the spread yarn sheet Ts. Therefore, the conveyance speed of the fiber bundle Tm can be adjusted by the rotational speed of the take-up motor 42.
- the spread yarn sheet Ts carried out by the take-up roll 41 is wound up by a winding device (not shown). Or it is continuously conveyed to the apparatus etc. which adhere or impregnate a resin material.
- the fiber bundle Tm is sandwiched between the nip rolls 29, the spread yarn sheet Ts is sandwiched between the take-up rolls 41, and the fiber bundle Tm is sandwiched between these roller pairs. Absent. Therefore, between the two roller pairs, there is a movable region M in which the fibers of the fiber bundle Tm are conveyed in a state in which they can move in the width direction.
- the fiber bundle Tm is adjusted so that the tension is in a predetermined range by the tension applying roll 26 while being transported by the take-up roll 41 at a predetermined transport speed. Therefore, the fiber bundle Tm is conveyed in a state where it is bent by the suction airflow at a plurality of opening portions arranged in the movable region M.
- the space between the guide rolls 31 of the opening portion is set to the opening regions A 1 to A 3 , respectively.
- the spread widths W 1 to W 3 of each spread area are set by the distance between the pair of guide members of each spread section.
- the width before the fiber bundle Tm enters the movable region M is the original width W 0 .
- each spread region is set to expansion regions B 1 to B 3 where the fiber bundle Tm spreads toward the end.
- the expansion region B 1 is set from the nip roll 29 to the guide roll on the upstream side of the spread region A 1
- the expansion regions B 2 to B 3 are on the downstream side of the guide member 35. It is set between the end portion and the guide roll on the upstream side of the opening area.
- the length L 2 and L 3 in the conveying direction of the fiber bundle Tm in the extended area set on the upstream side of each opening ⁇ zone, the length of the region where the fiber bundle Tm is actually spread flared, its starting position This is the length from the downstream end of the guide member 35 to the upstream guide roll in the opening area.
- an interval is formed between the opening position of the guide member 35 and the opening area on the upstream side of the expansion area. It is also possible to set the extended area to be continuous.
- each spread region is set to expansion regions B 1 to B 3 where the fiber bundle Tm spreads toward the end.
- the lengths L 2 and L 3 in the conveying direction of the fiber bundle Tm in the expansion region between the opening regions are set as an interval between the guide rolls in the adjacent opening regions.
- the expansion area B 1 is set from the nip roll 29 to the fiber opening area A 1 .
- a group of regions S 1 to S 3 paired with the spread region and the expansion region are arranged in the movable region M in the conveying direction of the fiber bundle Tm.
- each region group is continuously arranged.
- the region groups may be arranged so as to be spaced from each other.
- Area group S i, open ⁇ area A i is opened to open ⁇ W i is moved in the widthwise direction while bending the fiber by passing the suction airflow as a fluid in the fiber bundle and the open ⁇ area A i
- an extension region B i that is set on the upstream side in the transport direction and expands the width of the fiber bundle to the end as the fiber width of the opening region A i moves in the width direction.
- the phenomenon in which each fiber of the fiber bundle generated in the opening area A i moves in the width direction is exerted on the upstream expansion area B i to spread the fiber in a divergent manner.
- the entanglement is gradually released and the fibers are opened so as to unravel the fibers. That is, the fiber can be opened while suppressing the influence of uneven adhesion of the sizing agent and the entanglement of the fibers.
- sequence of each area group is continuous, and there is a space
- the fiber bundle is opened to a predetermined spread width, and the spread width is increased as the fiber bundle is conveyed downstream, so the thickness of the fiber bundle to be opened gradually decreases. . If the fiber bundle is thick, sizing agent adhesion unevenness and entanglement between fibers are in a built-in state, but each fiber gradually moves in the width direction, and the sizing agent adhesion unevenness built-in as the thickness gradually decreases. and entanglement of fibers is gradually eliminated in the expansion region B i.
- the adhesion unevenness of the sizing agent of the fiber bundle and the entanglement of the fibers have the most influence when the fiber is first opened.
- the entire fiber bundle may be twisted, and when the fiber bundle is opened, a continuous and stable opening width cannot be obtained. Causes cracks between the fiber bundles.
- the fibers can be uniformly dispersed while suppressing the influence of the entanglement between the fibers in the fiber bundle and the twist of the entire fiber bundle, and the initial opening can be performed stably.
- the spread width W 1 is expanded more than 5 times the original width W 0 , the entanglement between the fibers in the fiber bundle and the twist of the entire fiber bundle become stronger on the contrary, and it is continuously stabilized under the influence. The spread width cannot be obtained, or cracks are easily generated between the fiber bundles.
- FIG. 4 is an explanatory diagram regarding the region group S j-1 and the region group S j .
- the region group S j-1 includes a spread region A j-1 and an expansion region B j-1.
- the spread region A j-1 is set to the spread width W j-1 and the expansion region B j-1 Is set to a length L j-1 in the conveying direction of the fiber bundle.
- the region group S j includes a spread region A j and an expansion region B j , the spread region A j is set to the spread width W j , and the expansion region B j is the length in the fiber bundle conveyance direction. Set to L j .
- the expansion region B j is widened toward the downstream side, and the spread width W j is wider than the spread width W j ⁇ 1 .
- the extension region B j is set so as to extend by an equal distance on both sides. If setting is made in which the spread method is biased, the movement in the width direction of each fiber due to the spread is biased, and it is difficult to perform the spread with uniform fiber dispersion.
- the fibers can be uniformly dispersed in the opening area A j and opened to the opening width W j .
- the angle ⁇ is larger than 30 °, the sizing agent adhesion unevenness and the fiber entanglement are not sufficiently eliminated in the expansion region B j , and the gap is formed between the fibers, or the density of the fibers is increased or decreased. This makes it difficult to perform uniform dispersion continuously.
- open ⁇ area A j-1 of the open ⁇ W j-1, open ⁇ area A j of an open ⁇ W j and the length L j of the conveying direction of the fiber bundle in the expansion region B j is 0 ⁇ (W j ⁇ W j ⁇ 1 ) / 2L j ⁇ tan 30 °
- the angle ⁇ is more preferably 5 ° ⁇ ⁇ ⁇ 20 °.
- the fibers are evenly dispersed in the opening area A i by unwinding the fibers and performing preliminary opening while eliminating the uneven adhesion of the sizing agent and the entanglement of the fibers in the expansion area B i .
- the spread width can be expanded to a predetermined width to make the thickness uniform. Then, by setting a plurality of region groups S i composed of the opening region A i and the expansion region B i , it is possible to finish the spread yarn sheet with a wider opening width than the conventional one.
- the spread width is about 27 mm (weight per unit area is about 30 g / m 2 ), and further the spread width is about 40 mm (per unit weight is about 20 g / m 2 ). Even if the opening is performed, a spread yarn sheet in which the fibers are uniformly dispersed can be formed.
- the present invention it is possible to open a spread yarn sheet that is much thinner than in the case of continuous opening as in the prior art, and it is difficult to open a wide opening with the conventional technology.
- a wide fiber opening with excellent fiber dispersibility can be performed even for a fiber bundle having a large number of bundles.
- Open ⁇ W j in the open ⁇ area A j for example, from schematic illustration of FIG. 1, fitted with a pair of guide members 35 along the conveying direction of the fiber bundle on both sides of the upper opening of the air channel tube 32, the guide Defined by member 35.
- the guide member 35 When the shape of the upper opening of the wind tunnel 32 is rectangular as shown in FIG. 1, that is, FIG. 5, the guide member 35 is attached in parallel to the transport direction. Then, the length (wind tunnel width) on the upstream side and the downstream side in the fiber bundle conveyance direction in the wind tunnel pipe 32, that is, the spread width W j is the same length.
- the shape of the wind tunnel 32 may be a shape in which the downstream length is longer than the upstream length in the fiber bundle conveyance direction. That is, a shape that expands in the transport direction may be used.
- a pair of guide members 35 are attached to both sides of the wind tunnel opening so as to expand along the transport direction.
- the width WB j on the downstream side in the transport direction of the fiber bundle can be set as the spread width W j in the spread region A j .
- FIG. 7 and 8 are a schematic plan view and a schematic side view regarding another example of apparatus for carrying out the fiber-spreading method according to the present invention.
- symbol is attached
- a longitudinal vibration imparting mechanism is provided on the downstream side of the opening portion.
- pressing rolls 53 are arranged between a pair of support rolls 51.
- the pressing roll 53 is attached to the lower end of the lifting rod 52, and the upper end of the lifting rod 52 is connected to one end of the crank arm 54.
- the other end of the crank arm 54 is connected to the output shaft of the crank motor 55.
- the crank motor 55 When the crank motor 55 is rotationally driven, the lifting rod 52 repeats the lifting and lowering operation. Therefore, the pressing roll 53 comes to abut on the upper surface of the opened spread yarn sheet Ts that moves up and down and passes through the upper side of the support roll 51 at a predetermined cycle.
- the repetition of the tensioned state and the relaxed state of the spread yarn sheet Ts propagates to the fiber bundle Tm in the spread portion, and the amount of deflection of the fiber bundle Tm changes with time in the spread portion. That is, in the opening portion, when the fiber bundle Tm is tensioned, the deflection amount of the fiber bundle Tm decreases, and when the fiber bundle Tm relaxes, the deflection amount of the fiber bundle Tm changes.
- the fiber opening operation when the fluid action is periodically repeated in the direction in which the amount of bending of the fiber bundle increases and decreases, each fiber becomes more straight and gradually moves in the width direction. Therefore, it is easier to open the fiber with a wider width and good fiber dispersibility. That is, it becomes possible to increase the opening efficiency.
- the fiber bundle is tensioned and the fiber bundle Tm is no longer bent at each opening portion, the fiber bundle is easily converged, and the opening width becomes unstable. Therefore, by adjusting the vertical movement speed of the pressing roll 53 according to the conveyance speed of the fiber bundle and adjusting the tension state and the relaxed state of the spread yarn sheet Ts, the bending of the fiber bundle is ensured in each spread portion. It is important to stabilize the spread width.
- the vibration imparted to the spread yarn sheet Ts propagates to the upstream side of the nip roll 29.
- a mechanism for removing the transmitted vibration is provided between the support roll 25 and the nip roll 29.
- a mechanism example a pair of support rolls 201 and a tension roll 202 are provided.
- the tension roll 202 is arranged between the pair of support rolls 201, and the fiber bundle Tm passing below the support roll 201 is a tension roll 202. It is set to pass through the upper side of.
- the tension roll 202 is attached to the spring member 203, and the tension roll 202 also vibrates up and down in accordance with the vibration of the fiber bundle to remove the vibration of the fiber bundle.
- the fiber bundle reversal due to the influence of the vibration of the tension roll 202 does not affect the opening portion, and the bending of the fiber bundle is stably formed in each wind tunnel tube. It has become.
- the region from the nip roll 29 to the take-up roll 41 is set as the movable region M.
- the space between the guide rolls 31 of the opening portion is set to the opening regions A 1 to A 3 , respectively.
- the upstream side of each spread region is set to expansion regions B 1 to B 3 where the fiber bundle Tm spreads toward the end.
- the expansion area B 1 is set from the nip roll 29 to the fiber opening area A 1 .
- a group of regions S 1 to S 3 paired with the spread region and the expansion region are arranged in the movable region M in the conveying direction of the fiber bundle Tm.
- the longitudinal vibration applying mechanism may be disposed at any location within the range of the movable region M. For example, it may be arranged in any one of the expansion regions B 1 to B 3 or the spread regions A 1 to A 3 .
- the amount of bending of the fiber bundle is temporally changed in the fiber opening region by the longitudinal vibration applying mechanism.
- the amount of bending can be changed periodically.
- the control of changing the rotation of the crank motor 55 with time is performed, the amount of deflection can be changed irregularly.
- an elliptical rotating body is brought into contact with the fiber bundle Tm or the opened yarn sheet Ts, and the elliptical rotating body is rotated. By doing so, the amount of bending of the fiber bundle in the fiber opening region can be temporally changed.
- the opening / closing amount of each flow rate adjusting valve 33 in time, the size of the fluid flowing through each opening portion is changed in time, and the deflection amount of the fiber bundle in the opening region is changed in time. It is also possible to use a method of making it.
- each region group as described above, the spread width of each spread region and the length in the transport direction of each expansion region are set, thereby eliminating sizing agent adhesion unevenness and fiber entanglement in the expanded region.
- the fiber can be unwound and pre-opened, and the fiber can be uniformly dispersed in the open region to increase the open width to a predetermined width and make the thickness uniform. Then, by arranging a plurality of region groups composed of the spread region and the expansion region, it is possible to finish the spread yarn sheet with a wider spread width than before.
- FIG. 9 and FIG. 10 are a schematic plan view and a schematic side view relating to another device example for carrying out the fiber-spreading method according to the present invention.
- symbol is attached
- a deflection securing roll 36 is provided in the upper opening of the wind tunnel 32 in the opening portion.
- the fiber bundle Tm passing through the upper side of the guide roll 31 is conveyed so as to pass through the lower side of the bending securing roll 36. Even if the amount of bending of the fiber bundle Tm is reduced by the longitudinal vibration applying mechanism, the fiber bundle Tm is set in a curved state having a predetermined size by the bending securing roll 36. Therefore, the fiber bundle Tm is not linear at each spread part, and the spread width of the fiber bundle is prevented from shrinking.
- the longitudinal vibration applying mechanism reduces the amount of bending of the fiber bundle Tm and instantaneously contacts the bending securing roll 36, the dispersibility and straightness of each fiber in the fiber bundle are improved, and a high-quality opened state is obtained. It becomes possible. That is, when the fiber bundle Tm is in a relaxed state, it forms a bend away from the bend securing roll 36, and when it is in a tension state, it forms a bend that momentarily contacts the bend securing roll 36, and repeats these two states. Thus, fiber bundles are widely opened and excellent in fiber dispersibility.
- the longitudinal vibration imparting mechanism is disposed on the downstream side of the opening portion A 3 , but the longitudinal vibration imparting mechanism may be disposed in any one of the expansion regions B 1 to B 3 .
- the area groups S 1 to S 3 paired with the spread area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- each area group the opening width of each opening area and the length in the transport direction of each extension area are set as described above, so that the fibers are unraveled in the extension area and preliminary opening is performed. It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- FIG.11 and FIG.12 is the schematic plan view and schematic side view regarding another example of an apparatus which implements the fiber-spreading method which concerns on this invention.
- symbol is attached
- a longitudinal vibration imparting mechanism is arranged at the most downstream side opening portion, and the pressing roll 53 is installed as the bending securing roll 36. That is, the bending securing roll 36 is vibrated in a direction orthogonal to the fiber bundle conveyance direction, preferably in the fiber bundle bending direction. Thereby, a tension
- the pressing roll 53 of the longitudinal vibration imparting mechanism is arranged in the most downstream opening section, but the pressing roll 53 of the longitudinal vibration imparting mechanism may be disposed in any other opening section. Good. Moreover, you may arrange
- the area groups S 1 to S 3 having a pair of the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- each area group the opening width of each opening area and the length in the transport direction of each extension area are set as described above, so that the fibers are unraveled in the extension area and preliminary opening is performed. It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- FIG. 13 is a schematic side view relating to another device example for carrying out the fiber-spreading method according to the present invention.
- symbol is attached
- the fiber bundle Tm is formed in a bent state in the two sections at the opening portion, and the opening is performed.
- a space between the uppermost stream side and the most downstream side guide rolls 31 is set as a fiber opening area, and the group of areas S 1 to S 1 that are paired with the fiber opening area and the expansion area, as in the apparatus example shown in FIG. S 3 is arranged in the movable region M in the conveying direction of the fiber bundle Tm.
- each area group the opening width of each opening area and the length in the transport direction of each extension area are set as described above, so that the fibers are unraveled in the extension area and preliminary opening is performed. It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- the longitudinal vibration imparting mechanism is disposed on the downstream side of the opening portion A 3 , but the longitudinal vibration imparting mechanism may be disposed in any one of the expansion regions B 1 to B 3 . 12, at least one of the bending securing rolls 36 in the opening portion is moved up and down by a longitudinal vibration applying mechanism, and tension and relaxation are repeatedly applied to the fiber bundle Tm to open the fibers. The amount of deflection of the fiber bundle in the region may be changed with time.
- FIG. 14 is a schematic side view relating to another example of apparatus for carrying out the fiber-spreading method according to the present invention.
- symbol is attached
- a heating mechanism 61 is provided for heating the fiber bundle Tm by blowing hot air corresponding to the opening portion.
- the sizing agent attached to the fiber bundle Tm can be softened. Therefore, the fibers are easily unwound in the expansion region, and the fibers are uniformly dispersed in the spread region.
- area groups S 1 to S 3 having a pair of the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- each area group the opening width of each opening area and the length in the transport direction of each extension area are set as described above, so that the fibers are unraveled in the extension area and preliminary opening is performed. It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- FIG. 15 is a schematic side view relating to another device example for carrying out the fiber-spreading method according to the present invention. Note that the same parts as those in the example of the apparatus shown in FIG. 14 are denoted by the same reference numerals, and description thereof is omitted.
- a pair of contact rolls 71 are arranged along the width direction of the fiber bundle Tm on the upper side of the fiber bundle Tm in the expansion region, and a support roll 72 is arranged between the contact rolls 71 on the lower side.
- the contact roll 71 and the support roll 71 may be rotatable or may be fixed.
- the fiber bundle Tm is conveyed in contact with each roll, the fiber bundle is crushed in the width direction, and at the same time, each fiber is separated from fixing by the sizing agent and easily moved in the width direction. As a result, the fibers are dispersed. Pre-opened with good quality.
- the contact roll 71 may reciprocate along the width direction of the fiber bundle Tm by a crank mechanism (not shown).
- the fibers of the fiber bundle Tm move in the width direction by the reciprocating movement of the contact roll 71, and the fibers are more efficiently conveyed. It acts to disperse uniformly.
- area groups S 1 to S 3 having a pair of the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- each area group the opening width of each opening area and the length in the transport direction of each extension area are set as described above, so that the fibers are unraveled in the extension area and preliminary opening is performed. It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- FIG. 16 and FIG. 17 are a schematic plan view and a schematic side view regarding another example of apparatus for carrying out the fiber-spreading method according to the present invention.
- a plurality of apparatus examples shown in FIGS. 9 and 10 are arranged in parallel, and a plurality of spread fiber sheets Ts can be simultaneously formed by opening a plurality of fiber bundles Tm in parallel.
- symbol is attached
- the fiber bundles Tm fed from the yarn feeders 11 are respectively fed through the nip rollers 29 and conveyed toward the alignment roll 205 by the guide roll 204.
- the alignment roll 205 collectively holds the conveyed plurality of fiber bundles Tm, aligns them so as to be arranged at equal intervals on the same plane, and carries out the plurality of fiber bundles Tm.
- the plurality of unloaded fiber bundles Tm are opened at the three opening portions as in the device examples shown in FIGS. 9 and 10, but the most downstream opening portion bundles the plurality of fiber bundles Tm. Thus, an upper opening is formed over the entire width so that the fiber is opened.
- the spread yarn sheets Ts formed by being collectively opened are given vibrations by the pressing roll 53 of the longitudinal vibration applying mechanism and are carried out by the take-up roll 41.
- the area from the alignment roll 205 to the take-up roll 41 is set as the movable area M.
- the space between the guide rolls 31 of the opening portion is set to the opening regions A 1 to A 3 , respectively.
- the upstream side of each spread region is set to expansion regions B 1 to B 3 where the fiber bundle Tm spreads toward the end.
- the expansion area B 1 is set from the alignment roll 205 to the fiber opening area A 1 .
- the opening ⁇ W 3 in the open ⁇ area A 3 of each fiber bundle Tm in the most downstream side of the opening section is a length in the width direction of the opening section, a fiber bundle number that passes through the opening section Divide value.
- a group of regions S 1 to S 3 paired with the spread region and the expansion region are arranged in the movable region M in the conveying direction of the fiber bundle Tm.
- each region group the spread width of each spread region and the length in the transport direction of each expansion region are set as described above, while eliminating uneven sizing agent adhesion and fiber entanglement in the expansion region.
- the fibers can be unwound and pre-opened, and the fibers can be uniformly dispersed in the opening region to increase the opening width to a predetermined width and make the thickness uniform. Then, by arranging a plurality of region groups composed of the spread region and the expansion region, it is possible to finish the spread yarn sheet with a wider spread width than before.
- FIG. 18 and FIG. 19 are a schematic plan view and a schematic side view regarding another example of apparatus for carrying out the fiber-spreading method according to the present invention.
- symbol is attached
- a width direction vibration imparting mechanism is provided on the downstream side of the longitudinal vibration imparting mechanism in sliding contact with the fibers of the spread yarn sheet Ts in the width direction.
- the width direction vibration imparting mechanism has a pair of bow bars 81 arranged over the entire width above the spread yarn sheet Ts, and a support roll 82 is arranged below the spread yarn sheet Ts.
- the bow bar 81 is connected to a crank mechanism 84, and the crank mechanism 84 is driven by a crank motor 83 to move the bow bar 81 forward and backward in the width direction of the spread yarn sheet Ts.
- the bow bar 81 is moved forward and backward to come into sliding contact with the fibers of the spread yarn sheet Ts, so that the portion where the fibers adhere is softly unwound and the entire spread yarn sheet Ts is finished in a single sheet state in which the fibers are uniformly dispersed. be able to.
- the area groups S 1 to S 3 having a pair of the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- the opening width of each opening area and the length in the transport direction of each extending area are set as described above, and the pre-opening is performed by unraveling the fibers in the expanding area, It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- a plurality of area groups each consisting of an opening area and an expansion area, it is possible to finish the opening yarn sheet with a wider opening width than before.
- the width direction vibration applying mechanism is applied to a plurality of spread yarn sheets Ts to obtain one wide spread yarn sheet Ts.
- the width direction vibration imparting mechanism may be applied to one spread yarn sheet Ts to obtain a spread yarn sheet Ts with good fiber dispersibility.
- FIG. 20 is a schematic side view relating to another device example for carrying out the fiber-spreading method according to the present invention.
- symbol is attached
- a heating mechanism 61 is provided for heating the fiber bundle Tm by blowing hot air corresponding to the opening portion.
- the sizing agent attached to the fiber bundle Tm can be softened. Therefore, the fibers are easily unwound in the expansion region, and the fibers are uniformly dispersed in the spread region.
- the area groups S 1 to S 3 having a pair of the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- each area group the opening width of each opening area and the length in the transport direction of each extension area are set as described above, so that the fibers are unraveled in the extension area and preliminary opening is performed. It is possible to uniformly disperse the fibers in the opening region, thereby expanding the opening width to a predetermined width and making the thickness uniform.
- a spread fiber having good fiber dispersibility in which a carbon fiber bundle having a bundling number of 12,000 to 24000 and a fineness of 400 g / 1000 m to 1100 g / 1000 m is set to a width of 25 mm or more and a thickness of 0.04 mm or less.
- the basis weight of the spread yarn sheet can be about 30 g / m 2 or less.
- a spread fiber sheet having a good fiber dispersibility in which a bundle of thick fine fibers having a bundling number of 24,000 or more and a fineness of 1600 g / 1000 m or more is 40 mm or more and 0.2 mm or less in thickness.
- a bundle of thick fine fibers having a bundling number of 24,000 or more and a fineness of 1600 g / 1000 m or more is 40 mm or more and 0.2 mm or less in thickness.
- the basis weight of the obtained spread yarn sheet is about 80 g / m 2 .
- the basis weight of the obtained spread yarn sheet is about 100 g / m 2 .
- the maximum width and the minimum thickness of the spread yarn sheet obtained by opening are the cases where the bundled fibers are arranged in a line in the width direction. Since this fiber opening method gradually opens the fiber bundle in the width direction, each fiber that forms the fiber bundle is in a well-aligned state, and if the fiber bundle has no entanglement of each fiber, each bundle is concentrated. It is also possible to open a fiber bundle in which fibers are arranged in a line in the width direction.
- This fiber opening method can also be applied to fiber bundles with a larger number of bundles, so even when there are thick fiber fibers bundles with more than 60000 bundles, fiber bundles with a width of 40 mm or more can be opened. It is also possible to obtain a spread yarn sheet having a basis weight of 120 to 160 g / m 2 produced using 12,000 to 24000 carbon fiber bundles.
- the width and thickness of the opened fiber bundle are measured with the opened fiber bundle in a natural state.
- the spread width is measured using a length meter that can measure a minimum of 1 mm, and the thickness is measured by an outer micrometer with a minimum display amount of 0.001 mm specified in JIS B 7502 (corresponding to international standard ISO 3611).
- the measurement is performed at 10 places every 10 cm, 10 places every 1 m, or 10 places every 10 m in the length direction.
- an outer micrometer measures, and the dispersion
- the variation in thickness in the width direction becomes small.
- a spread fiber sheet excellent in fiber dispersibility having a width of 25 mm or more and a thickness of 0.04 mm or less of a carbon fiber bundle having a bundled number of 12,000 to 24000 and a fineness of 400 g / 1000 m to 1100 g / 1000 m.
- the average thickness varies within ⁇ 0.01 mm. Since the single yarn diameter of the carbon fiber is 0.005 to 0.007 mm, the variation is about 1 to 2 carbon fibers.
- the average thickness is ⁇ 0.
- the variation is 0.02 mm or less. Since the single yarn diameter of the carbon fiber is 0.005 to 0.007 mm, the variation is about 3 to 4 pieces.
- a spread fiber sheet excellent in fiber dispersibility having a width of 25 mm or more and a thickness of 0.04 mm or less of a carbon fiber bundle having a bundled number of 12,000 to 24000 and a fineness of 400 g / 1000 m to 1100 g / 1000 m.
- the width is within ⁇ 10% of the average spread width
- the thickness is ⁇ 0.01 mm or less of the average thickness.
- the width is an average spread. Within ⁇ 10% of the width, the thickness is ⁇ 0.02 mm or less of the average thickness.
- FIG. 21 is a schematic side view regarding the manufacturing process of the fiber reinforced sheet Ps according to the present invention. Description on the process of manufacturing the fiber-reinforced sheet Ps by continuously bonding the resin-attached release sheet JRs to one side of the wide spread yarn sheet Ts obtained by the apparatus example of FIG. FIG.
- the resin-attached release sheet JRs is continuously supplied to one side of the spread yarn sheet Ts from the resin-attached release sheet supply mechanism 902 so that the resin surface adheres to the spread yarn sheet Ts.
- a release sheet Rs is continuously supplied from a release sheet supply mechanism 901, and a heating and pressing roll 905, a heating flat plate 907, a heating and pressing roll 905, a cooling flat plate 908, and a cooling roll 906 are provided.
- a fiber reinforced sheet Ps in which the spread yarn sheet Ts and the resin are adhered, or the fiber bundle of the spread yarn sheet Ts is impregnated with the resin is obtained.
- the release sheets Rs bonded to the upper and lower surfaces of the fiber reinforced sheet Ps are each wound up by the release sheet winding mechanism 903, and the fiber reinforced sheet Ps is renewed as a new release sheet.
- the product is taken up by the product take-up mechanism 904 after being bonded to the release sheet Rs supplied from the supply mechanism 902.
- the resin-attached release sheet JRs is a sheet having a resin attached to one side of the release sheet Rs, and the attached resin is a thermosetting resin or a thermoplastic resin.
- a thermoplastic resin a resin obtained by mixing two or more of these thermoplastic resins into a polymer alloy may be used.
- a release-treated paper that is, a release paper, a fluororesin sheet, a thermosetting polyimide resin sheet, or the like is used.
- the resin As the state of the resin adhering to the release sheet Rs, the resin is applied to one side of the release sheet Rs and attached in a sheet form, or the powdered resin is dispersed and attached to one side of the release sheet Rs, etc. There is.
- the resin is attached to one side of the opened yarn sheet Ts, or in the opened yarn sheet Ts. Can be impregnated with resin.
- the adhesion of the resin to the spread yarn sheet Ts means that the resin is thermally fused to the entire surface or a plurality of portions of one side or both sides of the spread yarn sheet, or mechanical characteristics when the molded product is formed.
- the spread yarn sheet and the resin are bonded and integrated by, for example, thinly applying and bonding an adhesive that does not affect the fiber.
- the surface layer portion of the spread yarn sheet may be slightly impregnated with the resin, but it can be said that the resin is still attached.
- the impregnation of the spread yarn sheet Ts with the resin means that the resin enters the space between the fibers constituting the spread yarn sheet, and the fibers and the resin are integrated.
- the state in which the resin has entered almost the entire space of the spread yarn sheet is often referred to as impregnation, but in the present invention, it can be handled as impregnation even in a semi-impregnated state where the space remains.
- the number of the heating and pressing roll 905, the cooling roll 906, the heating flat plate 907, and the cooling flat plate 908 is arbitrarily determined according to the processing speed and the like.
- the resin-attached release sheet JRs is supplied only on one side of the spread yarn sheet Ts.
- the resin-attached release sheet JRs is supplied on both the upper and lower sides, and the resin is applied to the upper and lower sides of the spread yarn sheet Ts. You may obtain the fiber reinforced sheet Ps which impregnated resin from the upper and lower sides of the adhered fiber reinforced sheet Ps, and also the open yarn sheet
- the region from the alignment roll 205 to the first heating and pressing roll 905 is set as the movable region M. Then, similarly to the example of the apparatus shown in FIG. 20, the area groups S 1 to S 3 paired with the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- a resin By adhering or impregnating a resin to a thin spread yarn sheet Ts having a wide spread width and excellent in fiber dispersibility obtained by the present spread method in which a plurality of region groups each composed of an expanded region and a spread region are arranged.
- the fiber reinforced sheet Ps that fully expresses the original mechanical properties of the fiber and is homogenized in the width direction and the thickness direction with few defects causing stress concentration and the like, and further excellent in formability, that is, draping property It becomes.
- FIG. 22 is another schematic side view regarding the manufacturing process of the fiber reinforced sheet Ps according to the present invention. Explanatory drawing regarding the process of manufacturing the fiber reinforced sheet
- the spread yarn sheet Ts obtained by the present spreader travels on the reverse roll 909 and is then supplied to the heating and pressurizing roll 905 so as to overlap with the resin sheet Js supplied from the resin extrusion mechanism 910.
- the release sheet Rs is continuously supplied from the release sheet supply mechanism 901 from both sides of the first heating and pressing roll 905, and after the last cooling roll 906 travels, it is bonded to both surfaces of the fiber reinforced sheet Ps.
- the release sheet Rs is wound up by the release sheet winding mechanism 903, and the fiber reinforced sheet Ps is wound up by the product winding mechanism 904.
- the resin sheet Js is a sheet-like resin extruded from the resin extrusion mechanism 910, and a thermoplastic resin or the like is used.
- the resin to be extruded may be a single thermoplastic resin, or may be a resin that has been polymerized by adding two or more kinds of resins.
- a release-treated paper that is, a release paper, a fluororesin sheet, a thermosetting polyimide resin sheet, or the like is used as in FIG.
- the fiber reinforced sheet Ps can be manufactured without supplying the release sheet Rs and without the release sheet.
- the resin sheet Js is attached to one side of the spread yarn sheet Ts, that is, stuck together, or the spread yarn sheet Ts is impregnated with resin or half-finished. It can be in an impregnated state.
- the number of the heating and pressing rolls 905 and the cooling rolls 906 can be arbitrarily determined according to the processing speed.
- Another set of the fiber opening device is installed on the opposite side of the heat and pressure roll 905 to obtain the fiber reinforced sheet Ps with the fiber yarn sheet Ts attached or impregnated on both sides of the resin sheet Js. You can also.
- the area from the alignment roll 205 to the reverse roll 909 is set as the movable area M. Then, similarly to the example of the apparatus shown in FIG. 20, the area groups S 1 to S 3 paired with the opening area and the expansion area are arranged in the movable area M in the conveying direction of the fiber bundle Tm.
- the movable region is set by holding the fiber bundle or the spread yarn sheet with a pair of rolls.
- it is movable with a nip roll (a pair of rolls) and a reverse roll.
- An area is set.
- the fiber reinforced sheet Ps is homogenized in the width direction and the thickness direction with few defects causing stress concentration and the like, and further has excellent formability, that is, draping property.
- Example 1 In the apparatus shown in FIGS. 11 and 12, two opening portions were arranged, a longitudinal vibration applying mechanism was installed in the downstream opening portion, and a heating mechanism 61 shown in FIG. 14 was provided.
- the fiber bundle carbon fiber (Toray Industries, Inc., TORAYCA T700SC-12K; fiber diameter of about 7 ⁇ m, number of bundling 12000) was used.
- the original width W 0 of the fiber bundle was about 7 mm.
- Open ⁇ zone Open ⁇ W 1 of A 1 is 16 mm
- open ⁇ W 2 of the opening ⁇ area A 2 is 27 mm
- the length L 2 in the conveying direction of the expansion region B 2 is 30 mm
- spread angle ⁇ is about 10 ° Set to.
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 6 mm
- the surface was textured.
- the diameter of the deflection ensuring roll was 10 mm, and the surface was textured.
- the deflection securing roll was positioned and set 5 mm below the guide roll.
- the initial tension applied to the fiber bundle was set to 150 g, and the fiber bundle was transported at a transport speed of 5 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the number of vibrations was 600 rpm and the stroke amount of the pressing roll was set to 10 mm.
- the pressure roll was 10 mm in diameter and the surface was textured.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 30 g / m 2 .
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 25 to 27 mm, and the average spread width was about 26.5 mm.
- the variation was ⁇ 5.7% to 1.9% with respect to the average spread width.
- the thickness was in the range of 0.028 to 0.038 mm, and the average thickness was 0.034 mm.
- the variation was ⁇ 0.006 to 0.004 mm with respect to the average thickness.
- Example 2 In the apparatus shown in FIGS. 11 and 12, two opening portions were arranged, a longitudinal vibration applying mechanism was installed in the downstream opening portion, and a heating mechanism 61 shown in FIG. 14 was provided.
- the fiber bundle carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; fiber diameter of about 7 ⁇ m, number of bundling 15000) was used.
- the original width W 0 of the fiber bundle was about 6 mm.
- Open Open ⁇ W 1 of ⁇ zone A 1 is 25 mm
- open ⁇ W 2 of the opening ⁇ area A 2 is 48 mm
- the length L 2 in the conveying direction of the expansion region B 2 is 30 mm
- spread angle ⁇ is about 21 ° Set to.
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 6 mm
- the surface was textured.
- the diameter of the deflection ensuring roll was 10 mm, and the surface was textured.
- the deflection securing roll was positioned and set 5 mm below the guide roll.
- the initial tension applied to the fiber bundle was set to 150 g, and the fiber bundle was transported at a transport speed of 5 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the number of vibrations was 600 rpm and the stroke amount of the pressing roll was set to 10 mm.
- the pressure roll was 10 mm in diameter and the surface was textured.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 21 g / m 2 .
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 44 to 48 mm, and the average spread width was about 46.6 mm.
- the variation was ⁇ 5.6% to 3.0% with respect to the average spread width.
- the thickness was in the range of 0.020 to 0.028 mm, and the average thickness was 0.023 mm.
- the variation was ⁇ 0.003 to 0.005 mm with respect to the average thickness.
- Example 3 The same apparatus configuration as in Example 2 and the same carbon fiber bundle were used.
- Open Open ⁇ W 2 of ⁇ area A 1 of the opening ⁇ W 1 and open ⁇ zone A 2 were the same as in Example 2.
- the length L 2 in the conveyance direction of the expansion region B 2 was set to 20 mm, and the expansion angle ⁇ was set to about 30 °.
- the length between guide rolls in each spread area, guide roll diameter and surface treatment, deflection securing roll diameter and surface treatment, and the position of the deflection securing roll were the same as in Example 2.
- the initial tension applied to the fiber bundle, the transport speed of the fiber bundle, the flow velocity of the suction air flow at the opening part, the hot air temperature from the heating mechanism, the number of vibrations of the longitudinal vibration applying mechanism, the diameter of the pressing roll, the surface treatment and the stroke amount are Same as Example 2.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 21 g / m 2 . Even when the spread angle ⁇ was 30 °, a spread yarn sheet having excellent fiber dispersibility could be obtained.
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 42 to 48 mm, and the average spread width was about 45.7 mm.
- the variation was ⁇ 8.1% to 5.0% with respect to the average spread width.
- the thickness was in the range of 0.019 to 0.029 mm, and the average thickness was 0.024 mm.
- the variation was ⁇ 0.005 to 0.005 mm with respect to the average thickness.
- Example 4 In the apparatus shown in FIG. 1, two opening portions were arranged, and the apparatus was provided with the heating mechanism 61 shown in FIG. 14.
- the fiber bundle carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; fiber diameter of about 7 ⁇ m, number of bundling 15000) was used.
- the original width W 0 of the fiber bundle was about 6 mm.
- Open ⁇ W 1 of the opening ⁇ area A 1 is 20 mm
- open ⁇ area A 2 of the open ⁇ W 2 is 40 mm
- the length L 2 in the conveying direction of the expansion region B 2 is 50 mm
- spread angle ⁇ is about 11 ° Set to.
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 6 mm
- the surface was textured.
- the initial tension applied to the fiber bundle was set to 100 g, and the fiber bundle was transported at a transport speed of 3 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 30 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 26 g / m 2 .
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 36 to 40 mm, and the average spread width was about 37.8 mm.
- the variation was ⁇ 4.8% to 5.8% with respect to the average spread width.
- the thickness was in the range of 0.024 to 0.031 mm, and the average thickness was 0.028 mm.
- the variation was ⁇ 0.004 to 0.003 mm with respect to the average thickness.
- Example 5 In the apparatus shown in FIGS. 9 and 10, two opening portions were arranged, a longitudinal vibration applying mechanism was installed in the downstream opening portion, and a heating mechanism 61 shown in FIG. 14 was provided.
- the fiber bundle carbon fiber (Toray Industries, Inc., TORAYCA T700SC-24K; fiber diameter of about 7 ⁇ m, number of bundling 24000) was used.
- the original width W 0 of the fiber bundle was about 12 mm.
- Open ⁇ W 1 of the opening ⁇ area A 1 is 25 mm
- open ⁇ area A 2 of the open ⁇ W 2 is 45 mm
- the length L 2 in the conveying direction of the expansion region B 2 is 50 mm
- spread angle ⁇ is about 11 ° Set to.
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 6 mm
- the surface was textured.
- the diameter of the deflection ensuring roll was 10 mm, and the surface was textured.
- the deflection securing roll was positioned and set 5 mm below the guide roll.
- the initial tension applied to the fiber bundle was set to 200 g, and the fiber bundle was transported at a transport speed of 5 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the number of vibrations was 600 rpm and the stroke amount of the pressing roll was set to 10 mm.
- the pressing roll had a diameter of 10 mm and the surface was textured.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 37 g / m 2 .
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 40 to 45 mm, and the average spread width was about 42.9 mm.
- the variation was ⁇ 6.8% to 4.9% with respect to the average spread width.
- the thickness was in the range of 0.034 to 0.046 mm, and the average thickness was 0.041 mm.
- the variation was ⁇ 0.007 to 0.005 mm with respect to the average thickness.
- Example 6 In the apparatus shown in FIGS. 11 and 12, three opening portions were arranged, a longitudinal vibration applying mechanism was installed in the most downstream opening portion, and a heating mechanism 61 shown in FIG. 14 was provided.
- the fiber bundle carbon fiber (Toray Industries, Inc., TORAYCA T700SC-24K; fiber diameter of about 7 ⁇ m, number of bundling 24000) was used.
- the original width W 0 of the fiber bundle was about 12 mm.
- Open ⁇ W 1 of the opening ⁇ area A 1 is 25 mm
- Open Open ⁇ W 2 of ⁇ zone A 2 is 45 mm
- open ⁇ region Open ⁇ W 3 of A 3 is 65 mm
- the expansion region B 2 in the transport direction The length L 2 was set to 50 mm (expansion angle ⁇ is about 11 °)
- the length L 3 in the transport direction of the expansion region B 3 was set to 50 mm (expansion angle ⁇ was about 11 °).
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 6 mm
- the surface was textured.
- the diameter of the deflection ensuring roll was 10 mm, and the surface was textured.
- the deflection securing roll was positioned and set 5 mm below the guide roll.
- the initial tension applied to the fiber bundle was set to 200 g, and the fiber bundle was transported at a transport speed of 7 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the number of vibrations was 800 rpm and the stroke amount of the pressing roll was set to 10 mm.
- the pressure roll was 10 mm in diameter and the surface was textured.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 25 g / m 2 .
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 58 to 65 mm, and the average spread width was about 62.3 mm.
- the variation was ⁇ 6.9% to 4.3% with respect to the average spread width.
- the thickness was in the range of 0.023 to 0.034 mm, and the average thickness was 0.027 mm.
- the variation was ⁇ 0.004 to 0.006 mm with respect to the average thickness.
- Example 7 In the apparatus shown in FIGS. 11 and 12, two opening portions were arranged, a longitudinal vibration applying mechanism was installed in the downstream opening portion, and a heating mechanism 61 shown in FIG. 14 was provided.
- a fiber bundle carbon fiber (manufactured by Graphile Co., Ltd., type 50-60K; fiber diameter of about 7 ⁇ m, number of bundled 60000) was used.
- the original width W 0 of the fiber bundle was about 14 mm.
- Open ⁇ W 1 of the opening ⁇ area A 1 is 30 mm
- open ⁇ area A 2 of the open ⁇ W 2 is 50 mm
- the length L 2 in the conveying direction of the expansion region B 2 is 50 mm
- spread angle ⁇ is about 11 ° Set to.
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 6 mm
- the surface was textured.
- the diameter of the deflection ensuring roll was 10 mm, and the surface was textured.
- the deflection securing roll was positioned and set 5 mm below the guide roll.
- the initial tension applied to the fiber bundle was set to 400 g, and the fiber bundle was transported at a transport speed of 5 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the number of vibrations was 600 rpm and the stroke amount of the pressing roll was set to 10 mm.
- the pressure roll was 10 mm in diameter and the surface was textured.
- the fiber bundle was conveyed and the spread yarn sheet was continuously formed by setting as described above.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 83 g / m 2 .
- the spread width and thickness were measured at 10 locations per 1 m.
- the spread width was in the range of 44-50 mm, and the average spread width was about 47.8 mm.
- the variation was ⁇ 7.9% to 4.6% with respect to the average spread width.
- the thickness was in the range of 0.081 to 0.102 mm, and the average thickness was 0.089 mm.
- the variation was ⁇ 0.009 to 0.013 mm with respect to the average thickness.
- Example 8 In the apparatus shown in FIG. 20, two opening parts were arranged, and the apparatus structure was implemented by installing a longitudinal vibration imparting mechanism in the downstream opening part.
- the fiber bundle carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; fiber diameter of about 7 ⁇ m, number of bundling 15000) was used.
- the original width W 0 of the fiber bundle was about 6 mm.
- the number of fiber bundles was 7, and the interval between fiber bundles was set to 48 mm.
- Open ⁇ W 1 of the opening ⁇ area A 1 is 24 mm
- open ⁇ area A 2 of the open ⁇ W 2 is 48 mm
- the length L 2 in the conveying direction of the expansion region B 2 is 50 mm
- spread angle ⁇ is about 13 ° Set to.
- the length between the guide rolls in each spread area was 20 mm
- the diameter of the guide rolls was 10 mm
- the surface was textured.
- the diameter of the deflection ensuring roll was 10 mm, and the surface was textured.
- the deflection securing roll was positioned and set 5 mm below the guide roll.
- the initial tension applied to the fiber bundle was set to 150 g, and the fiber bundle was transported at a transport speed of 10 m / min.
- the flow velocity of the suction air flow in the opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 100 ° C.
- the longitudinal vibration applying mechanism the number of vibrations was 950 rpm and the stroke amount of the pressing roll was set to 10 mm.
- the stroke amount of the bow bar was set to 5 mm.
- the diameter of a press roll is 10 mm
- the diameter of a bow bar is 25 mm
- each surface has given a satin finish.
- the fiber bundle was conveyed as described above, and a spread yarn sheet having a sheet width of about 340 mm was continuously formed.
- the fibers were uniformly dispersed and no gap was formed, and the basis weight was about 21 g / m 2 .
- the spread width and thickness were measured at 10 places per 1 m.
- the spread width was in the range of 46 to 50 mm, and the average spread width was about 48.3 mm.
- the variation was ⁇ 4.8% to 3.5% with respect to the average spread width.
- the thickness was in the range of 0.018 to 0.027 mm, and the average thickness was 0.023 mm.
- the variation was ⁇ 0.005 to 0.004 mm with respect to the average thickness.
- Example 9 In the apparatus shown in FIG. 21, two opening parts were arranged, and it implemented by the apparatus structure which installed the longitudinal vibration provision mechanism in the downstream opening part.
- the fiber bundle carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; fiber diameter of about 7 ⁇ m, number of bundling 15000) was used.
- the original width W 0 of the fiber bundle was about 6 mm.
- the number of fiber bundles was 7, and the interval between fiber bundles was set to 48 mm.
- the resin-attached release sheet a sheet obtained by applying an epoxy resin having a coating weight of 20 g / m 2 on a release paper (manufactured by Lintec Corporation) having a weight of 120 g / m 2 and a width of 400 mm to a width of 350 mm was used.
- the setting of the opening area, the expansion area, each guide roll, and each deflection securing roll was the same as in Example 8.
- the conveyance speed of the fiber bundle was set to 5 m / min
- the number of vibrations of the longitudinal vibration applying mechanism was set to 550 rpm
- the number of vibrations of the width direction vibration applying mechanism was set to 300 rpm.
- Example 8 Seven fiber bundles were opened under the same conditions as in Example 8 to form a spread yarn sheet having a width of about 340 mm and excellent fiber dispersibility, and the spread fiber sheet was continuously released from the resin. It was sandwiched and conveyed between the sheet and the release sheet.
- the temperature of the heating and pressing roll and the heating plate was set to 120 ° C.
- the cooling roll and the cooling plate were set to water cooling
- the linear pressure of the heating and pressing roll was set to 15 kgf / cm
- the linear pressure of the cooling roll was set to 5 kgf / cm.
- a fiber reinforced sheet called a prepreg sheet impregnated with an epoxy resin was continuously formed.
- the fiber reinforced sheet was formed in a state where the sheet width was 340 mm, the fibers were uniformly dispersed, and the thickness was almost uniform.
- Example 10 In the apparatus shown in FIG. 22, two opening portions are arranged, a mechanism for continuously supplying a longitudinal vibration to the downstream opening portion, and a mechanism for continuously supplying a thermoplastic resin film instead of the resin extrusion mechanism,
- the press roll was implemented in a series and an apparatus configuration in which a pair of cooling rolls were installed in series.
- As the fiber bundle carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; fiber diameter of about 7 ⁇ m, number of bundling 15000) was used.
- the original width W 0 of the fiber bundle was about 6 mm.
- the number of fiber bundles was 7, and the interval between fiber bundles was set to 48 mm.
- thermosetting polyimide resin film (product name: Upilex S, thickness: 25 ⁇ m, manufactured by Ube Industries, Ltd.) having a width of 400 mm was supplied as a release sheet.
- the setting of the opening area, the expansion area, each guide roll, and each deflection securing roll was the same as in Example 9.
- the conveyance speed of the fiber bundle was set to 10 m / min
- the number of vibrations of the longitudinal vibration applying mechanism was set to 950 rpm
- the number of vibrations of the width direction vibration applying mechanism was set to 450 rpm.
- Example 9 Seven fiber bundles were opened under the same conditions as in Example 9 to form a spread yarn sheet having a width of about 340 mm and excellent fiber dispersibility, and the spread yarn sheet was continuously formed into a thermoplastic resin film. And was sandwiched between release sheets and supplied to a heating and pressing roll.
- the temperature of the heating and pressing roll was set to 340 ° C.
- the cooling roll was set to water cooling
- the linear pressure of the heating and pressing roll was set to 5 kgf / cm. After discharging from the cooling roll, the release sheets on both sides were taken up, and the product fiber reinforced sheet was taken up.
- the fiber reinforced sheet was formed with a sheet width of 340 mm and fibers uniformly dispersed.
- Open ⁇ W 2 of the opening of the open ⁇ area A 1 ⁇ W 1 and open ⁇ area A 2 is the same as in Example 2, open ⁇ W 1 of the opening ⁇ area A 1 is 25 mm, open ⁇ area A 2
- the opening width W 2 was set to 48 mm.
- the length L 2 in the transport direction of the expansion region B 2 was set to 15 mm, and the expansion angle ⁇ was set to about 37 °.
- the length between guide rolls in each spread area, guide roll diameter and surface treatment, deflection securing roll diameter and surface treatment, and the position of the deflection securing roll were the same as in Example 2.
- the initial tension applied to the fiber bundle, the transport speed of the fiber bundle, the flow velocity of the suction air flow at the opening part, the hot air temperature from the heating mechanism, the number of vibrations of the longitudinal vibration applying mechanism, the diameter of the pressing roll, the surface treatment and the stroke amount are Same as Example 2.
- a fiber bundle was conveyed to form a spread yarn sheet.
- the spread yarn sheet there were portions where the dispersibility of the fibers was poor and the density of the fibers was coarse and dense, and there were also portions where gaps were formed between the fibers.
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Abstract
Description
1<(W1/W0)≦5
となるように設定し、残りの前記領域群Sj(j=2,・・・,n)では、前記開繊領域Aj-1の開繊幅Wj-1、前記開繊領域Ajの開繊幅Wj及び前記拡張領域Bjにおける前記繊維束の搬送方向の長さLjが
0<(Wj-Wj-1)/2Lj≦tan30°
を満たすように設定することを特徴とする。さらに、前記開繊領域A1の前記繊維束の開繊幅W1を
2≦(W1/W0)≦4
となるように設定することを特徴とする。
1<(W1/W0)≦5
となるように設定することで、繊維束を最初に拡げていく場合に、繊維束がボビンから解じょされるときに生じる撚り、又は繊維束を製造する過程で生じると考えられる繊維束内部の部分的な撚りを解きほぐしながら繊維束に割れが生じないように開繊することができる。
0<(Wj-Wj-1)/2Lj≦tan30°
を満たすように設定することで、繊維束に部分的に生じているサイジング剤の付着ムラや繊維の絡み合いが拡張領域Bjにおける予備開繊で徐々に解きほぐされていき、開繊領域Ajにおいて繊維の密度ムラが生じることなく均一に分散されて開繊を行うことが可能となる。
1<(W1/W0)≦5
となるように設定することで、繊維束中の繊維同士の絡み合い及び繊維束全体のねじれの影響を抑えながら繊維を均一に分散させて最初の開繊を安定して行うことができる。開繊幅W1が元幅W0の5倍より拡がると、開繊の際に繊維束中の繊維同士の絡み合い及び繊維束全体のねじれが逆に強くなり、その影響を受けて連続安定した開繊幅を得ることができなかったり、繊維束間に割れなどを生じ易くさせる。さらに好ましくは、
2≦(W1/W0)≦4
に設定するとよい。開繊幅W1を元幅W0の2倍以上にすれば、開繊効率を高めることができる。また、開繊幅W1を元幅W0の4倍以内とすることで、繊維束中の繊維同士の絡み合い及び繊維束全体のねじれの影響をより抑えた繊維分散性の良い開繊が行われる。
ΔW=(Wj-Wj-1)/2
となる。そして、拡張領域Bjの両側において搬送方向に対して拡がる角度をθとすると、
tanθ=ΔW/Lj=(Wj-Wj-1)/2Lj
となる。
0<(Wj-Wj-1)/2Lj≦tan30°
を満たすように設定することで、繊維束の繊維が均一に分散した開繊を連続して行うことが可能となる。
tanθ=ΔW/Lj=(Wj-Wj-1)/2Lj
においては、幅Wjに開繊領域Ajの繊維束搬送方向上流側の幅WPjを、幅Wj-1に開繊領域Aj-1の繊維束搬送方向下流側の幅WBj-1を適用する。
図11、図12に示す装置において開繊部を2つ配列して下流側の開繊部に縦振動付与機構を設置し、図14に示す加熱機構61を設けた装置構成で実施した。繊維束として、炭素繊維(東レ株式会社製、トレカT700SC―12K;繊維直径約7μm、集束本数12000本)を使用した。繊維束の元幅W0は約7mmであった。
図11、図12に示す装置において開繊部を2つ配列して下流側の開繊部に縦振動付与機構を設置し、図14に示す加熱機構61を設けた装置構成で実施した。繊維束として、炭素繊維(三菱レイヨン株式会社製、パイロフィルTR50S―15K;繊維直径約7μm、集束本数15000本)を使用した。繊維束の元幅W0は約6mmであった。
実施例2と同様の装置構成、および同様の炭素繊維束を用いた。
図1に示す装置において開繊部を2つ配列して、図14に示す加熱機構61を設けた装置構成で実施した。繊維束として、炭素繊維(三菱レイヨン株式会社製、パイロフィルTR50S―15K;繊維直径約7μm、集束本数15000本)を使用した。繊維束の元幅W0は約6mmであった。
図9、図10に示す装置において開繊部を2つ配列して下流側の開繊部に縦振動付与機構を設置し、図14に示す加熱機構61を設けた装置構成で実施した。繊維束として、炭素繊維(東レ株式会社製、トレカT700SC―24K;繊維直径約7μm、集束本数24000本)を使用した。繊維束の元幅W0は約12mmであった。
図11、図12に示す装置において開繊部を3つ配列して最下流側の開繊部に縦振動付与機構を設置し、図14に示す加熱機構61を設けた装置構成で実施した。繊維束として、炭素繊維(東レ株式会社製、トレカT700SC―24K;繊維直径約7μm、集束本数24000本)を使用した。繊維束の元幅W0は約12mmであった。
図11、図12に示す装置において開繊部を2つ配列して下流側の開繊部に縦振動付与機構を設置し、図14に示す加熱機構61を設けた装置構成で実施した。繊維束として、炭素繊維(グラフィル社製、タイプ50―60K;繊維直径約7μm、集束本数60000本)を使用した。繊維束の元幅W0は約14mmであった。
図20に示す装置において開繊部を2つ配列し、下流側の開繊部に縦振動付与機構を設置した装置構成で実施した。繊維束として、炭素繊維(三菱レイヨン株式会社製、パイロフィルTR50S―15K;繊維直径約7μm、集束本数15000本)を使用した。繊維束の元幅W0は約6mmであった。繊維束の本数は7本で、繊維束の間隔を48mmに設定した。
図21に示す装置において開繊部を2つ配列し、下流側の開繊部に縦振動付与機構を設置した装置構成にて実施した。繊維束として、炭素繊維(三菱レイヨン株式会社製、パイロフィルTR50S―15K;繊維直径約7μm、集束本数15000本)を使用した。繊維束の元幅W0は約6mmであった。繊維束の本数は7本で、繊維束の間隔を48mmに設定した。また、樹脂付着離型シートには目付け120g/m2、幅400mmの離型紙(リンテック株式会社製)上に塗布量20g/m2のエポキシ樹脂が幅350mmで塗布されたシートを用いた。離型紙シートには目付け120g/m2の離型紙(リンテック株式会社製)を用いた。
図22に示す装置において開繊部を2つ配列し、下流側の開繊部に縦振動付与機構を、樹脂押出機構の変わりに熱可塑性樹脂フィルムを連続して供給する機構を、一対の加熱加圧ロールを一連、一対の冷却ロールを一連設置した装置構成にて実施した。繊維束として、炭素繊維(三菱レイヨン株式会社製、パイロフィルTR50S―15K;繊維直径約7μm、集束本数15000本)を使用した。繊維束の元幅W0は約6mmであった。繊維束の本数は7本で、繊維束の間隔を48mmに設定した。また、熱可塑性樹脂フィルムには厚さ15μm、幅350mmのポリエーテルイミド樹脂フィルム(三菱樹脂株式会社製)を使用した。そして、幅400mmの熱硬化性ポリイミド樹脂フィルム(製品名;ユーピレックスS、厚み;25μm、宇部興産株式会社製)を離型シートとして供給した。
実施例2と同様の装置構成、および同様の炭素繊維束を用いた。
Claims (20)
- 多数の繊維からなる繊維束を繊維長方向に搬送し、前記繊維が幅方向に移動可能に設定された可動領域において前記繊維束中に流体を通過させることで繊維を撓ませながら幅方向に移動させて開繊する繊維束の開繊方法であって、
前記可動領域に、前記繊維束中に流体を通過させることで繊維を撓ませながら幅方向に移動させて開繊幅Wiに開繊する開繊領域Ai(i=1,・・・,n)及び前記開繊領域Aiに対応して搬送方向上流側に設定されるとともに当該開繊領域Aiの前記繊維の幅方向の移動に伴って前記繊維束の幅が末広がりに拡張する拡張領域Bi(i=1,・・・,n)からなる対の領域群Si(i=1,・・・,n)を前記繊維束の搬送方向にn(n≧2)個配列して、前記領域群Siを順次通過するように前記繊維束を搬送させて開繊することを特徴とする繊維束の開繊方法。 - 最初の前記領域群S1では、前記繊維束の元幅W0に対して、前記開繊領域A1の前記繊維束の開繊幅W1を
1<(W1/W0)≦5
となるように設定し、
残りの前記領域群Sj(j=2,・・・,n)では、前記開繊領域Aj-1の開繊幅Wj-1、前記開繊領域Ajの開繊幅Wj及び前記拡張領域Bjにおける前記繊維束の搬送方向の長さLjが
0<(Wj-Wj-1)/2Lj≦tan30°
を満たすように設定することを特徴とする請求項1に記載の繊維束の開繊方法。 - 前記開繊領域A1の前記繊維束の開繊幅W1を
2≦(W1/W0)≦4
となるように設定することを特徴とする請求項2に記載の繊維束の開繊方法。 - 前記開繊領域のうち少なくとも一部の領域では、複数の区画において前記繊維束中に流体を通過させることで前記繊維を撓ませながら幅方向に移動させることを特徴とする請求項1から3のいずれかに記載の繊維束の開繊方法。
- 前記拡張領域のうち少なくとも一部の領域では、前記繊維束に対して幅方向に配置されて接触する接触ロールを少なくとも1本以上配設して、前記繊維束を前記接触ロールに接触させながら搬送することを特徴とする請求項1から4のいずれかに記載の繊維束の開繊方法。
- 前記接触ロールが前記繊維束の幅方向に沿って往復移動することを特徴とする請求項5に記載の繊維束の開繊方法。
- 前記拡張領域及び/又は前記開繊領域のうち少なくとも一部の領域では、前記繊維束を加熱することを特徴とする請求項1から6のいずれかに記載の繊維束の開繊方法。
- 前記開繊領域のうち少なくとも一部の領域では、前記繊維束の撓み量を時間的に変化させることを特徴とする請求項1から7のいずれかに記載の繊維束の開繊方法。
- 前記開繊領域のうち少なくとも一部の領域では、撓み確保ロールにより前記繊維束の所定の撓み量を確保しながら開繊することを特徴とする請求項8に記載の繊維束の開繊方法。
- 前記撓み確保ロールのうち少なくとも一本のロールにより前記繊維束を搬送方向と直交する方向に振動させることを特徴とする請求項9に記載の繊維束の開繊方法。
- 前記可動領域の上流側において、前記繊維束の引き戻しを阻止しながら前記繊維束を搬送させることを特徴とする請求項1から10のいずれかに記載の繊維束の開繊方法。
- 前記繊維束を開繊した開繊糸シートに対して幅方向に振動を付与することを特徴とする請求項1から11のいずれかに記載の繊維束の開繊方法。
- 複数本の前記繊維束を搬送させながら同時に開繊することを特徴とする請求項1から12のいずれかに記載の繊維束の開繊方法。
- 複数本の前記繊維束を開繊して並列した複数の開繊糸シートに対して幅方向に振動を付与して全体が一様なシート状態に形成することを特徴とする請求項13記載の繊維束の開繊方法。
- 繊維集束本数12000本から24000本、繊度400g/1000mから1100g/1000mの範囲にある炭素繊維束を開繊させて、前記炭素繊維束を幅25mm以上、厚み0.04mm以下にしたことを特徴とする開繊糸シート。
- 繊維集束本数24000本以上、繊度1600g/1000m以上の炭素繊維束を開繊させて、前記炭素繊維束を幅40mm以上、厚み0.2mm以下にしたことを特徴とする開繊糸シート。
- 請求項1から14のいずれかに記載の開繊方法により得られた開繊糸シートの片面又は両面に樹脂層を形成して繊維補強シートを製造することを特徴とする繊維補強シートの製造方法。
- 前記樹脂層は、樹脂シートを用いて形成することを特徴とする請求項17記載の繊維補強シートの製造方法。
- 請求項1から14のいずれかに記載の開繊方法により得られた開繊糸シートを樹脂シートの両面に付着させて繊維補強シートを製造することを特徴とする繊維補強シートの製造方法。
- 請求項1から14のいずれかに記載の開繊方法により得られた開繊糸シートに樹脂材料を含浸させて繊維補強シートを製造することを特徴とする繊維補強シートの製造方法。
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JP7363091B2 (ja) | 2018-06-01 | 2023-10-18 | 東レ株式会社 | サイジング剤塗布炭素繊維束およびその製造方法、熱可塑性樹脂組成物、成形体 |
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EP4342661A1 (en) | 2022-09-26 | 2024-03-27 | Subaru Corporation | Roller unit for feeding tapes, fiber placement apparatus and method of molding composite material |
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Also Published As
Publication number | Publication date |
---|---|
EP2436809A4 (en) | 2012-11-28 |
US20120135227A1 (en) | 2012-05-31 |
CN102439206B (zh) | 2014-08-13 |
JP5326170B2 (ja) | 2013-10-30 |
CN102439206A (zh) | 2012-05-02 |
HK1168394A1 (en) | 2012-12-28 |
US9003619B2 (en) | 2015-04-14 |
EP2436809B1 (en) | 2014-01-22 |
EP2436809A1 (en) | 2012-04-04 |
JP2010270420A (ja) | 2010-12-02 |
KR20120031476A (ko) | 2012-04-03 |
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