WO2018038205A1 - Method for manufacturing fiber reinforced resin molded body and method for manufacturing unidirectional fiber reinforced member - Google Patents
Method for manufacturing fiber reinforced resin molded body and method for manufacturing unidirectional fiber reinforced member Download PDFInfo
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- WO2018038205A1 WO2018038205A1 PCT/JP2017/030314 JP2017030314W WO2018038205A1 WO 2018038205 A1 WO2018038205 A1 WO 2018038205A1 JP 2017030314 W JP2017030314 W JP 2017030314W WO 2018038205 A1 WO2018038205 A1 WO 2018038205A1
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- resin
- thermoplastic resin
- fiber
- tape
- extrusion
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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
- B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
Definitions
- the present invention relates to a method for producing a fiber reinforced resin molded body and a method for producing a unidirectional fiber reinforced member.
- a unidirectional fiber reinforced member obtained by impregnating a fiber bundle composed of a plurality of fibers aligned in one direction with a resin is used as a reinforcing member such as a UD tape.
- a unidirectional fiber reinforced member is attached to various resin molded bodies, for example.
- the resin molded body is reinforced by attaching the unidirectional fiber reinforced member to the resin molded body.
- a resin molded body reinforced by attaching a unidirectional fiber reinforced member is referred to as a fiber reinforced resin molded body.
- Patent Document 1 discloses a method for producing a resin molded body (fiber reinforced resin molded body) reinforced with a thick film unidirectional fiber reinforced member.
- a resin molded body fiber reinforced resin molded body
- a thick film unidirectional fiber reinforced member a resin molding material reinforced with a thick film unidirectional fiber reinforced member is manufactured by stacking a resin molding material on the softened laminate and stamping molding.
- a mold for molding a laminate of unidirectional fiber reinforced members, and a laminate and a resin molding material are stacked and stamped. Therefore, the unidirectional fiber reinforced member is cooled and solidified while the laminate of unidirectional fiber reinforced members is transferred from the preform mold to the stamping mold. Therefore, before stamping molding, it is necessary to heat (preheat) the laminated body previously molded with the preform mold and soften it.
- the fiber-reinforced resin molded article described in Patent Document 1 is a stamping process in which a unidirectional fiber-reinforced member is laminated, a laminated body is heated, and the heated laminated body and a resin molding material are stacked and stamped. It is manufactured through. For this reason, there are many processes required in order to obtain a fiber reinforced resin molding. Further, when stamping the laminated body with the resin molding material, there is a high possibility that voids are generated at the joint interface between the two by entraining air from the outside. For this reason, a good bonding interface between the unidirectional fiber reinforced member and the resin molded body cannot be obtained, and as a result, the strength of the manufactured fiber reinforced resin molded body may be reduced.
- the present invention provides a method for manufacturing a fiber-reinforced resin molded body that can be manufactured with fewer steps, and a method for manufacturing a unidirectional fiber-reinforced member used for the fiber-reinforced resin molded body thus manufactured.
- the purpose is to provide
- the present invention is manufactured by a first step of manufacturing a unidirectional fiber reinforced member (100) in which a resin is impregnated into a fiber bundle composed of a plurality of fibers aligned in one direction, and the first step.
- the unidirectional fiber reinforced member is introduced into the extrusion die (8) together with the molten thermoplastic resin (S), and the thermoplastic resin is molded into a predetermined cross sectional shape in the extrusion die, and unidirectional fiber reinforced.
- the member and the thermoplastic resin are merged, and the unidirectional fiber reinforced member is joined to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape by the resin pressure of the thermoplastic resin merged with the unidirectional fiber reinforced member,
- a second step of extruding the fiber reinforced resin molded article (10) by discharging the thermoplastic resin molded into a predetermined cross-sectional shape together with the unidirectional fiber reinforced member joined to the region from the extrusion die. Provides a method for producing a fiber-reinforced resin molded body.
- a unidirectional fiber reinforced member is manufactured in the first step, and in the second step performed subsequent to the first step, the unidirectional fiber reinforced member and the molten thermoplastic resin are both extruded dies. To be introduced. And a fiber reinforced resin molded object is manufactured by extrusion molding using this extrusion die. Since the fiber reinforced resin molded product is extruded using the extrusion die in the second step, the unidirectional fiber reinforced member produced in the first step can be directly introduced into the extrusion die used in the second step. it can. That is, manufacture of a unidirectional fiber reinforced member and manufacture of a fiber reinforced resin molding using the same can be continuously performed.
- the process of heating this (preheating) is not required. Therefore, the fiber-reinforced resin molded product can be manufactured with fewer steps than conventional. Furthermore, since the unidirectional fiber reinforced member is joined to the thermoplastic resin in the extrusion die, bubbles are not easily caught from the outside when the two are joined. Further, even if bubbles are entrained, the entrained bubbles are eliminated by the resin pressure of the thermoplastic resin acting on the one-way fiber reinforced member when the unidirectional fiber reinforced member and the thermoplastic resin are joined. be able to. Therefore, it is possible to effectively suppress the generation of voids at the bonding interface between the unidirectional fiber reinforced member and the thermoplastic resin.
- the first step includes a coating step in which a thermoplastic resin is applied to the fiber bundle, a fiber bundle in which the thermoplastic resin is applied in the coating step, and a molten thermoplastic as an additional resin (R).
- a coating step in which a thermoplastic resin is applied to the fiber bundle, a fiber bundle in which the thermoplastic resin is applied in the coating step, and a molten thermoplastic as an additional resin (R).
- Extrusion that impregnates the fiber bundle with the thermoplastic resin by introducing the resin into the extrusion die (6) and pressing the additional resin against the fiber bundle coated with the thermoplastic resin at a predetermined resin pressure in the extrusion die.
- an impregnation step According to this, a thick film-like unidirectional fiber reinforced resin is manufactured by pressing an additional resin into the fiber bundle to which the thermoplastic resin is applied in an extrusion die and impregnating the fiber bundle with the thermoplastic resin.
- the extrusion impregnation step may be performed simultaneously with the second step. That is, the extrusion die used in the extrusion impregnation step and the extrusion die used in the second step may be a common extrusion die. According to this, the fiber reinforced resin molded object reinforced with the thick film-like unidirectional fiber reinforced member can be easily manufactured using one extrusion die.
- thermoplastic resin (additional resin) used in the extrusion impregnation step and the thermoplastic resin used in the second step may be the same.
- the extrusion die used in the extrusion impregnation step and the extrusion die used in the second step are common, and the thermoplastic resin (additional resin) used in the extrusion impregnation step is the same as the thermoplastic resin used in the second step.
- the second step is configured to include the extrusion impregnation step of the first step. That is, in this case, in the second step, the fiber bundle (F4) coated with the thermoplastic resin in the coating step of the first step is introduced into the extrusion die (9) together with the molten thermoplastic resin.
- the thermoplastic resin is molded into a predetermined cross-sectional shape, the fiber bundle and the thermoplastic resin are merged, and the fiber bundle is impregnated with the resin pressure of the thermoplastic resin merged with the fiber bundle.
- the unidirectional fiber reinforced member (100) is molded by joining the molded unidirectional fiber reinforced member to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape and bonded to the predetermined region.
- the fiber reinforced resin molded body is extruded by discharging the thermoplastic resin molded into a predetermined cross-sectional shape together with the member from the extrusion die.
- the present invention provides an application step of applying a thermoplastic resin to a fiber bundle composed of a plurality of fibers aligned in one direction, and a fiber bundle (F4) in which a thermoplastic resin is applied in the application step.
- the molten thermoplastic resin as the additional resin (R) is introduced into the extrusion die (6), and the additional resin is pressed against the fiber bundle to which the thermoplastic resin is applied in the extrusion die at a predetermined resin pressure.
- a thick film-shaped unidirectional fiber reinforced member can be manufactured by pressing an additional resin in an extrusion die against a fiber bundle to which a resin has been previously applied.
- a fiber reinforced resin molded body having a higher reinforcing effect can be produced by joining the thick unidirectional fiber reinforced member produced according to the present invention to a thermoplastic resin molded body as a reinforcing material by extrusion molding. Can do.
- the water-dispersible emulsion in which the thermoplastic resin particles are dispersed in water is applied to the fiber bundle (F2), and the fiber bundle to which the water-dispersible emulsion is applied is dried. And a drying step.
- the thermoplastic resin particles dispersed in water in the emulsion application step are applied to the fiber bundle, so that the thermoplastic resin particles enter the gaps between the plurality of fibers constituting the fiber bundle.
- the additional resin impregnates the fiber bundle by the resin pressure acting on the fiber bundle in the subsequent extrusion impregnation step, and the thermoplastic resin particles applied in the emulsion application step enter deep into the fiber bundle.
- thermoplastic resin can be uniformly impregnated in the thickness direction of the fiber bundle. Even when a fiber bundle having a large thickness is used, the thermoplastic resin can be uniformly impregnated in the thickness direction. That is, a thick unidirectional fiber reinforced member can be easily manufactured.
- thermoplastic resin used in the second step according to the present invention is not limited as long as it is a thermoplastic resin used for resin molding.
- PP polypropylene
- PA6 polyamide 6
- PA6,6 polyamide 6,6
- PPS polyphenylene sulfide
- PEEK polyetheretherketone
- the thermoplastic resin used in the second step according to the present invention may be a foamed resin or a multicolor molding resin. Furthermore, the thermoplastic resin used in the second step according to the present invention may contain reinforcing fibers.
- the reinforcing fiber contained in the thermoplastic resin is not particularly limited as long as it is generally used as a reinforcing fiber. Examples of the reinforcing fiber include glass fiber, carbon fiber, aramid fiber, plant-derived CNF (cellulose nanofiber) and the like.
- the unidirectional fiber reinforced member according to the present invention may be any fiber bundle formed of a plurality of fibers aligned in one direction, and the fiber bundle is impregnated with resin. But you can.
- the expression “a fiber bundle composed of a plurality of fibers aligned in one direction” has at least a fiber bundle composed of a plurality of fibers aligned in one direction. It is used in the sense of good, and it does not deny that it includes fiber bundles that are aligned in directions other than one direction.
- Examples of the unidirectional fiber reinforced member include UD (Uni Directional) tape, cloth (woven fabric), and the like.
- the predetermined cross-sectional shape of the thermoplastic resin molded in the extrusion die in the second step according to the present invention may be a circular cross section or an irregular cross section (non-circular cross section).
- the irregular cross section include a flat cross section, an L-shaped cross section, and a hollow cross section.
- the unidirectional fiber reinforced member may be bonded to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape.
- the predetermined area may be a surface area of the thermoplastic resin or an internal area.
- thermoplastic resin applied to the fiber bundle in the coating process according to the present invention and the additional resin used in the extrusion impregnation process according to the present invention may be resins having the same compatibility.
- the additional resin may be a thermoplastic resin made of the same material as the thermoplastic resin applied to the fiber bundle in the application step.
- the number of fibers constituting the fiber bundle used in the present invention is not particularly limited, but is preferably 3000 to 60000.
- the material of the fiber is not particularly limited. Examples of the fiber material include carbon fiber, glass fiber, and aramid fiber.
- FIG. 8 is a sectional view taken along line VIII-VIII in FIG. It is a figure which shows a production line in case the 1st extrusion die and the 2nd extrusion die are comprised by the same extrusion die, and the thermoplastic resin used by an additional resin and an extrusion molding process is the same. It is a figure which shows the example in which four UD tapes are introduce
- FIG. 1 is a schematic view showing a manufacturing process of a UD tape according to this embodiment together with a manufacturing line.
- the UD tape manufacturing method according to the present embodiment includes an opening process, an emulsion application process, a drying process, and an extrusion impregnation process, and these processes are executed in this order.
- the emulsion coating process and the drying process correspond to the coating process of the present invention.
- the fiber bundle F1 drawn from the uncoiler 1 is opened.
- the fiber bundle F1 is composed of a plurality of fibers aligned in one direction. If the fiber which comprises the fiber bundle F1 is a fiber generally used as a reinforced fiber, the kind will not be ask
- the fiber bundle F1 can be composed of carbon fiber, glass fiber, aramid fiber, or the like.
- the some fiber which comprises the fiber bundle F1 is couple
- the opening process is carried out in order to slightly open the gap between the fibers blocked by the sizing agent.
- the fiber bundle F1 is heated through a heated roll heated to 80 ° C. to 120 ° C., and then the heated fiber bundle F1 is paired between the pair of satin finish rolls. This can be done by passing it through.
- the fiber bundle F1 is passed between the satin rolls, the fiber bundle F1 is opened by the frictional force that the fiber bundle F1 receives from the satin roll.
- the water-dispersible emulsion is applied to the fiber bundle F2 opened in the fiber opening process.
- the water-dispersible emulsion used in the emulsion coating step includes water and thermoplastic resin particles dispersed in water.
- the thermoplastic resin particles dispersed in water include polyolefin resins such as PP (polypropylene) resin, polyamide resins, and the like, but are not limited thereto.
- the emulsion coating step is performed by passing the fiber bundle F2 through a pair of coater rolls 3 and 3 having a water-dispersible emulsion 2 coated on the surface thereof, that is, by a touch roll method.
- the coating method is not limited to the example of FIG.
- the water-dispersible emulsion can be applied to the fiber bundle F2 by spraying the water-dispersible emulsion toward the fiber bundle F2, that is, by a spray method.
- the water dispersible emulsion can be applied to the fiber bundle F2 by immersing the fiber bundle F2 in the water dispersible emulsion filling tank.
- the fiber bundle F3 coated with the water-dispersible emulsion 2 in the emulsion coating process is dried.
- the heating method is not particularly limited. For example, as shown in FIG. 1, by passing a fiber bundle F3 coated with a water-dispersible emulsion between a pair of heat rolls 4 and 4 heated to a predetermined temperature, The fiber bundle F3 can be dried.
- the heating temperature may be a temperature at which water evaporates, and is particularly preferably 80 ° C. to 130 ° C.
- the fiber bundle F4 that has undergone the drying process can also be said to be a unidirectional fiber reinforced member. Note that the amount of the thermoplastic resin (particles) applied in the emulsion application process is small, and after application and drying, there are many pores inside.
- the additional resin R is impregnated into the fiber bundle F4 that has undergone the drying process.
- the additional resin R may be the same resin as the thermoplastic resin particles constituting the water-dispersible emulsion applied to the fiber bundle F2 in the emulsion application process.
- the first extrusion device 5 and the first extrusion die 6 are used in the extrusion impregnation step.
- the first extrusion device 5 includes an extrusion cylinder and an extrusion screw arranged inside the extrusion cylinder.
- pellets of the additional resin R are supplied through, for example, a hopper.
- a heater is laid on the outer peripheral surface of the extrusion cylinder, and the pellet of the additional resin R supplied into the extrusion cylinder is heated by operating this heater. By this heating, the additional resin R in the extrusion cylinder is melted.
- the molten additional resin R in the extrusion cylinder is kneaded, and the molten additional resin R moves to the front side of the extrusion cylinder. Then, the molten additional resin R is discharged from a nozzle attached to the tip of the extrusion cylinder.
- the molten additional resin R discharged from the extrusion cylinder of the first extrusion device 5 is introduced into the first extrusion die 6.
- the fiber bundle F ⁇ b> 4 that has undergone the drying process is also introduced into the first extrusion die 6.
- the molten additional resin R is pressed against the fiber bundle F4 with a predetermined resin pressure.
- the thermoplastic resin already applied to the fiber bundle and the additional resin R are impregnated in the fiber bundle.
- the UD tape 100 unidirectional fiber reinforced member
- the UD tape 100 is discharged from the first extrusion die 6. That is, the UD tape 100 is extruded.
- the UD tape 100 is manufactured through the above steps.
- the water-dispersible emulsion 2 containing thermoplastic resin particles is applied to the fiber bundle in the emulsion application step, and the thermoplastic resin is further applied to the fiber bundle in the extrusion impregnation step. Is impregnated.
- thermoplastic resin particles in the water-dispersible emulsion applied to the fiber bundle in the emulsion application process are very small, they easily enter the gaps between the plurality of fibers constituting the fiber bundle.
- the extrusion impregnation step is executed after the emulsion coating step and the drying step.
- the additional resin R is pressed against the fiber bundle F4 with a predetermined resin pressure.
- the impregnation of the thermoplastic resin into the fiber bundle F4 proceeds.
- the thermoplastic resin already applied (impregnated) to the fiber bundle by the emulsion application step is impregnated deep into the fiber bundle by the resin pressure.
- the surface of the fiber bundle is impregnated with the additional resin.
- the process of impregnating the fiber bundle with the thermoplastic resin is divided into at least two stages.
- the first process emulsion application process
- fine thermoplastic particles are applied to the fiber bundle.
- the second step extrusion impregnation step
- the additional thermoplastic resin is pressed against the fiber bundle by its own pressure (resin pressure). Therefore, when the second process is executed, the thermoplastic resin applied in the first process can be penetrated deep into the fiber bundle by the resin pressure, and the additional resin can be applied to the surface of the fiber bundle by the own resin pressure. Can be impregnated. For this reason, even when the fiber bundle is thick, a UD tape in which the resin is uniformly impregnated in the thickness direction can be manufactured.
- thermoplastic resin particles applied to the fiber bundle in the emulsion application step are very small, even when the gaps between the opened fibers are very small, the gaps are heated.
- the plastic resin particles sufficiently enter.
- a fiber bundle having a high fiber content that is, a small gap between fibers after opening
- thermoplastic resin can be sufficiently impregnated with a thermoplastic resin. That is, it is possible to manufacture a thick UD tape with a high fiber content.
- the fiber bundle F4 after the emulsion coating process / drying process has a large number of voids.
- the additional resin R is pressed against the fiber bundle with a predetermined resin pressure in the extrusion impregnation step after the drying step.
- the amount of voids can be reduced.
- the porosity of the UD tape can be reduced. Therefore, the strength of the manufactured UD tape can be improved.
- Example 1 A long carbon fiber bundle (carbon fiber: SIGRAFIL C030 T050 EPY manufactured by SGL) having a width of 15 to 20 mm was passed through a hot roll heated to 80 ° C. to 120 ° C. to melt the sizing agent in the carbon fiber bundle. Subsequently, the carbon fiber bundle was allowed to pass through a satin roll whose surface was textured and textured. The width of the carbon fiber bundle was expanded to 28 mm to 35 mm by the frictional force that the carbon fiber bundle received from the satin roll when the carbon fiber bundle passed through the satin roll. In this way, the carbon fiber bundle was opened (opening process).
- carbon fiber SIGRAFIL C030 T050 EPY manufactured by SGL
- the carbon fiber bundle after opening was passed through a pair of coater rolls coated with a water-dispersible emulsion in which thermoplastic resin particles (polyolefin resin particles or polyamide resin particles) were dispersed in water.
- thermoplastic resin particles polyolefin resin particles or polyamide resin particles
- the carbon fiber bundle was squeezed with a pressure of 0.2 MPa, and a water-dispersible emulsion was applied to the carbon fiber bundle (emulsion application step).
- the carbon fiber bundle after the emulsion coating step was passed through a hot roll heated to 80 ° C. to 130 ° C. to dry the carbon fiber bundle. Thereafter, the carbon fiber bundle was passed through a hot roll heated to a temperature equal to or higher than the melting point of the thermoplastic resin particles contained in the water-dispersible emulsion applied to the carbon fiber bundle. At this time, by applying a pressure of 0.5 Mpa to the carbon fiber bundle, the carbon fiber bundle was impregnated with a thermoplastic resin (drying step).
- the carbon fiber bundle after the drying process was introduced into the extrusion die.
- the same thermoplastic resin as the thermoplastic resin in the water-dispersible emulsion was introduced as an additional resin into the extrusion die together with the carbon fiber bundle with a predetermined resin pressure.
- the additional resin was pressed against the carbon fiber bundle at a predetermined resin pressure in the extrusion die, and the carbon fiber bundle was impregnated with the additional resin, and the carbon fiber bundle impregnated with the additional resin was extruded ( Extrusion impregnation step).
- the UD tape according to Example 1 was manufactured.
- Comparative Example 1 A UD tape according to Comparative Example 1 was produced in the same manner as in Example 1 except that the extrusion impregnation step was omitted. That is, the UD tape according to Comparative Example 1 was manufactured through the opening process, the emulsion application process, and the drying process shown in Example 1.
- Comparative Example 2 A UD tape according to Comparative Example 2 was produced by the same method as in Example 1 except that the emulsion coating step and the drying step were omitted. That is, the UD tape according to Comparative Example 2 was manufactured through the opening process and the extrusion impregnation process shown in Example 1.
- the fiber content (wt%), thickness (mm), and porosity (%) of the unidirectional fiber reinforced members produced in Example 1, Comparative Example 1, and Comparative Example 2 were determined.
- the fiber content is a mass ratio of carbon fibers per unit mass of the manufactured UD tape.
- the mass per unit length of the carbon fiber used for the manufacture of the UD tape is 3.3 g / m
- the manufactured UD tape is 20 cm (0.2 m). Cut to length, measure the weight W of the cut UD tape, the following formula 3.3 ⁇ 0.2 / W ⁇ 100 was used to calculate the fiber content.
- the thickness is a thickness at a portion where it can be confirmed that the resin is sufficiently impregnated in the thickness of the manufactured UD tape.
- the observation surface cross section of the UD tape
- the polished observation surface was observed with a microscope.
- the observation surface was binarized by image analysis, and the porosity was calculated based on the binarized image. Table 1 shows the measurement results of the fiber content, thickness, and porosity of the UD tape according to each example.
- the fiber content of the UD tape according to Example 1 is higher than the fiber content of the UD tape according to Comparative Example 2. Further, the thickness of the UD tape according to Example 1 is thicker than the thickness of the UD tape according to Comparative Examples 1 and 2. Furthermore, the porosity of the UD tape according to Example 1 is smaller than the porosity of the UD tape according to Comparative Examples 1 and 2.
- Example 1 a UD tape having a fiber content of 70 wt% or more, a thickness of 0.7 mm or more, and a porosity of 2% or less can be produced.
- FIG. 2 is a perspective view of the fiber-reinforced resin molded body 10 manufactured by the manufacturing method according to the present embodiment.
- the fiber reinforced resin molded body 10 is formed in a long shape, and is configured such that a cross-sectional shape perpendicular to the longitudinal direction is substantially constant along the longitudinal direction.
- the cross-sectional shape of the fiber reinforced resin molded body 10 does not need to be completely constant along the longitudinal direction, and for example, the cross-sectional shape is configured to gradually change (gradual change) along the longitudinal direction. May be.
- FIG. 3 is a view showing a cross-sectional shape perpendicular to the longitudinal direction of the fiber-reinforced resin molded body 10.
- the fiber reinforced resin molded body 10 is disposed so as to face the upper and lower side wall portions 11 and 12 spaced apart in the vertical direction in FIG. 3 and separated in the left and right direction in FIG. 3. It has a left side wall part 13 and a right side wall part 14, and an intermediate wall part 15 provided between the upper side wall part 11 and the lower side wall part 12.
- the left end of the upper wall 11 in FIG. 3 is connected to the upper end of the left side wall 13, and the right end of the upper side wall 11 in FIG. 3 is connected to the upper end of the right side wall 14. Further, the left end of the lower wall portion 12 in FIG. 3 is connected to the lower end of the left side wall portion 13, and the right end of the lower wall portion 12 in FIG. 3 is connected to the lower end of the right side wall portion 14. Therefore, the upper side wall part 11, the lower side wall part 12, the left side wall part 13, and the right side wall part 14 form a rectangular cross section.
- the intermediate wall portion 15 is arranged in a space surrounded by the four side wall portions 11, 12, 13, and 14 so that one surface thereof faces the upper wall portion 11 and the other surface faces the lower wall portion 12.
- the left end of the intermediate wall 15 in FIG. 3 is connected to an intermediate position in the vertical direction of the left wall 13, and the right end of the intermediate wall 15 in FIG. Connected to an intermediate position.
- the upper side wall part 11, the lower side wall part 12, the left side wall part 13, the right side wall part 14, and the intermediate wall part 15 make the cross-sectional shape of the fiber reinforced resin molded body 10 as shown in FIG.
- the fiber reinforced resin molded body 10 includes a portion (resin molded portion) molded by a thermoplastic resin and a UD tape 100 as a reinforcing body.
- the resin molding part is reinforced by the UD tape 100.
- the upper side wall part 11, the lower side wall part 12, and the intermediate wall part 15 of the fiber reinforced resin molded body 10 are made of only a thermoplastic resin.
- the left side wall part 13 and the right side wall part 14 have a part constituted by a thermoplastic resin and a part constituted by the UD tape 100.
- the UD tape 100 is disposed along the longitudinal direction inside the left wall portion 13 and the right wall portion 14, and is joined to these wall portions inside these wall portions.
- the cross-sectional shape of the fiber reinforced resin molded body 10 is the cross-sectional shape of the part (resin molding part) comprised with a thermoplastic resin.
- the UD tape 100 is arrange
- joining does not represent an aspect in which the bolts or the like are mechanically coupled, but an aspect in which the thermoplastic resin constituting the resin molded portion and the thermoplastic resin contained in the UD tape are welded. Represents.
- FIG. 4 is a schematic view showing a manufacturing process of the fiber-reinforced resin molded body 10 together with a manufacturing line. As shown in FIG. 4, the fiber reinforced resin molded body 10 is manufactured through a UD tape manufacturing process and an extrusion molding process.
- the UD tape manufacturing process corresponds to the first process of the present invention
- the extrusion molding process corresponds to the second process of the present invention.
- UD tape 100 is manufactured in the UD tape manufacturing process.
- This UD tape manufacturing process includes each process described in the UD tape manufacturing method according to the first embodiment, specifically, a fiber opening process, an emulsion coating process, a drying process, and an extrusion impregnation process. A description of each of these steps is omitted.
- the fiber-reinforced resin molded body 10 is manufactured by extrusion.
- a second extrusion device 7 and a second extrusion die 8 are used.
- the second extrusion device 7 includes an extrusion cylinder and an extrusion screw disposed inside the extrusion cylinder.
- pellets of thermoplastic resin constituting the resin molding part are supplied through, for example, a hopper.
- a heater is laid on the outer peripheral surface of the extrusion cylinder, and when the heater is activated, the pellets of the thermoplastic resin supplied into the extrusion cylinder are heated. By this heating, the thermoplastic resin in the extrusion cylinder is melted.
- the molten thermoplastic resin in the extrusion cylinder is kneaded, and the molten thermoplastic resin moves to the front side of the extrusion cylinder. And the molten thermoplastic resin is discharged
- thermoplastic resin discharged from the second extrusion device 7 is introduced into the second extrusion die 8.
- the UD tape 100 manufactured in the UD tape manufacturing process is introduced into the second extrusion die 8 together with the thermoplastic resin S discharged from the second extrusion device 7.
- two UD tapes 100 respectively produced on two separate production lines are introduced into the second extrusion die 8.
- FIG. 5 is a perspective view showing a configuration in the vicinity of the second extrusion die 8.
- the tip of the second extrusion device 7 is connected to the second extrusion die 8.
- the heated and melted thermoplastic resin discharged from the tip of the second extrusion device 7 is introduced into the second extrusion die 8 from the material supply surface 8 a side of the second extrusion die 8.
- the two UD tapes 100 manufactured by the UD tape manufacturing process are arrange
- These UD tapes 100 are also introduced into the second extrusion die 8 from the material supply surface 8a side of the second extrusion die 8, respectively.
- the fiber reinforced resin molding 10 is discharged
- FIG. 6 is a view showing a cross section of the second extrusion die 8 shown in FIG. 5 cut along a plane P indicated by a broken line in FIG.
- the second extrusion die 8 includes a first metal plate 81, a second metal plate 82, and a third metal plate 83, and these metal plates are stacked in this order and fastened with bolts or the like. It is comprised by. Accordingly, one surface of the first metal plate 81 and one surface of the third metal plate 83 constitute two opposing surfaces of the second extrusion die 8. Of the two opposing surfaces, one surface of the first metal plate 81 forms the material supply surface 8a of the second extrusion die 8, and one surface of the third metal plate 83 is the product discharge surface of the second extrusion die 8. 8b is constituted.
- a plurality of flow paths are formed in each metal plate. Specifically, in the first metal plate 81, the resin introduction flow path 81a, the first branch resin flow path 81b, the second branch resin flow path 81c, the third branch resin flow path 81d, and the fourth branch resin flow path 81e.
- the first UD tape introduction flow path 81f and the second UD tape introduction flow path 81g are formed.
- a first connection channel 82a, a second connection channel 82b, a first merge channel 82c, and a second merge channel 82d are formed.
- a third merge channel 83a and a fourth merge channel 83b are formed in the third metal plate 83.
- Each of the resin introduction flow path 81a, the first UD tape introduction flow path 81f, and the second UD tape introduction flow path 81g formed in the first metal plate 81 is formed on the material supply surface 8a of the first metal plate 81. One end opens.
- the opening position of the first UD tape introduction flow path 81f and the opening position of the second UD tape introduction flow path 81g are positioned symmetrically across the opening position of the resin introduction flow path 81a.
- thermoplastic resin discharged from the second extrusion device 7 is introduced into the resin introduction channel 81a.
- the UD tape 100 is introduced into the first UD tape introduction flow path 81f and the second UD tape introduction flow path 81g, respectively.
- the first branch resin flow path 81b, the second branch resin flow path 81c, the third branch resin flow path 81d, and the fourth branch resin are provided at the other end of the resin introduction flow path 81a.
- One end of each of the flow paths 81e is connected.
- the other end of each branched resin flow path (81b, 81c, 81d, 81e) is a surface opposite to the material supply surface 8a of the first metal plate 81 and on the side facing the second metal plate 82. Open to the surface.
- first branch resin flow path 81b and the first UD tape introduction flow path 81f intersect, and the fourth branch resin flow path 81e and the second UD tape introduction flow path 81g intersect.
- the resin flow paths (first branch resin flow path 81b, fourth branch resin flow path 81e) are connected to the UD tape introduction flow path (first UD tape introduction flow path 81f) so that the flow paths intersecting at the respective intersection positions do not merge. , Bypasses the second UD tape introduction flow path 81g).
- One end of each of the first connection flow channel 82a, the second connection flow channel 82b, the first merge flow channel 82c, and the second merge flow channel 82d formed in the second metal plate 82 is a second metal plate.
- 82 is a surface that faces the first metal plate 81, and the other end of each is a surface of the second metal plate 82 that faces the third metal plate 83. Open to.
- the other end opening of the first branched resin flow path 81 b formed in the first metal plate 81 faces one end opening of the first connection flow path 82 a formed in the second metal plate 82. .
- the first branch resin flow path 81b communicates with the first connection flow path 82a.
- the other end opening of the second branch resin flow path 81c formed in the first metal plate 81 and the other end opening of the first UD tape introduction flow path 81f are formed in the second metal plate 82.
- the first confluence channel 82c faces one end opening. For this reason, both the 2nd branch resin flow path 81c and the 1st UD tape introduction flow path 81f are connected to the 1st confluence
- the other end opening of the third branch resin flow path 81d formed in the first metal plate 81 and the other end opening of the second UD tape introduction flow path 81g are formed in the second metal plate 82. It faces one end opening of the second merge channel 82d. For this reason, both the third branch resin flow path 81d and the second UD tape introduction flow path 81g communicate with the second merge flow path 82d.
- the other end opening of the fourth branch resin flow path 81 e formed in the first metal plate 81 faces one end opening of the second connection flow path 82 b formed in the second metal plate 82. . For this reason, the fourth branched resin flow path 81e communicates with the second connection flow path 82b.
- One end of the third merge channel 83a and one end of the fourth merge channel 83b formed in the third metal plate 83 are both the surface of the third metal plate 83 and the second metal. An opening is made on the surface facing the plate 82. Further, the other end of the third merge channel 83 a and the other end of the fourth merge channel 83 b both open to the product discharge surface 8 b of the third metal plate 83.
- the other end opening of the first connection channel 82 a formed in the second metal plate 82 and the other end opening of the first merge channel 82 c are both formed in the third metal plate 83. It faces one end opening of the three-merged flow path 83a. For this reason, the first connection channel 82a and the first junction channel 82c communicate with the third junction channel 83a. Further, the other end opening of the second connection channel 82 b formed in the second metal plate 82 and the other end opening of the second joining channel 82 d are both formed in the third metal plate 83. Furthermore, it faces one end opening of the fourth merging channel 83b. For this reason, the second connection channel 82b and the second junction channel 82d communicate with the fourth junction channel 83b.
- an air flow passage 84 is formed in the second metal plate 82 and the third metal plate 83.
- One end portion of the air flow passage 84 opens to the outer surface of the second metal plate 82, and the other end portion is an opening position of the third merge channel 83 a in the product discharge surface 8 b of the third metal plate 83. And a position between the opening position of the fourth merge channel 83b.
- the air flow passage 84 intersects the second connection flow path 82b and the second merge flow path 82d.
- the resin flow paths (the second connection flow path 82b and the second merge flow path 82d) are detoured with respect to the air flow path 84 so that the flow paths intersecting at each intersection position do not merge.
- FIG. 7 is a cross-sectional view showing a state in which the thermoplastic resin and the UD tape 100 are flowing in the second extrusion die 8 shown in FIG. 6, and FIG. 8 is a cross-sectional view taken along the line VIII-VIII in FIG.
- FIG. 8 is a cross-sectional view taken along the line VIII-VIII in FIG.
- the molten thermoplastic resin S discharged from the second extrusion device 7 is introduced into a resin introduction flow path 81a opened in the material supply surface 8a of the second extrusion die 8.
- the thermoplastic resin S introduced into the resin introduction flow path 81a is transferred from the resin introduction flow path 81a to the first branch resin flow path 81b, the second branch resin flow path 81c, the third branch resin flow path 81d, and the fourth branch. It flows through the resin flow path 81e.
- the two UD tapes 100 manufactured in the UD tape manufacturing process are provided in the first UD tape introduction flow path 81f and the second UD tape introduction flow path 81g opened in the material supply surface 8a of the second extrusion die 8. Each is introduced.
- thermoplastic resin S flowing through the first branch resin flow path 81b flows from the first branch resin flow path 81b to the first connection flow path 82a.
- the thermoplastic resin S flowing through the second branch resin flow path 81c flows from the second branch resin flow path 81c to the first merge flow path 82c.
- the thermoplastic resin S flowing through the third branch resin flow path 81d flows from the third branch resin flow path 81d to the second merge flow path 82d.
- the thermoplastic resin S flowing through the fourth branch resin flow path 81e flows from the fourth branch resin flow path 81e to the second connection flow path 82b.
- the UD tape 100 introduced into the first UD tape introduction flow path 81f flows from the first UD tape introduction flow path 81f to the first merge flow path 82c.
- the molten thermoplastic resin S from the second branch resin flow path 81c also flows through the first merge flow path 82c. Therefore, as shown in FIG. 7, the molten thermoplastic resin S from the first branch resin flow path 81b and the UD tape 100 from the first UD tape introduction flow path 81f merge in the first merge flow path 82c. .
- the UD tape 100 flows along the surface of the molten thermoplastic resin S in the first merge channel 82c.
- the UD tape 100 introduced into the second UD tape introduction flow path 81g flows from the second UD tape introduction flow path 81g to the second merge flow path 82d.
- the molten thermoplastic resin S from the third branch resin flow channel 81d also flows through the second merge flow channel 82d. Accordingly, as shown in FIG. 7, the molten thermoplastic resin S from the third branch resin flow path 81d and the UD tape 100 from the second UD tape introduction flow path 81g merge in the second merge flow path 82d. .
- the UD tape 100 flows along the surface of the molten thermoplastic resin S in the second merge channel 82d.
- thermoplastic resin S flowing through the first connection flow channel 82a flows from the first connection flow channel 82a to the third merge flow channel 83a. Further, the thermoplastic resin S and the UD tape 100 flowing through the first merge channel 82c flow from the first merge channel 82c to the third merge channel 83a. Therefore, as shown in FIG. 7, the thermoplastic resin S from the first connection flow channel 82 a, the thermoplastic resin S from the first merge flow channel 82 c, and the UD tape 100 merge in the third merge flow channel 83 a. To do. At this time, the thermoplastic resin S from the first connection channel 82a covers the surface of the UD tape 100 from the first junction channel 82c in the third junction channel 83a.
- the UD tape 100 in the third merge channel 83a is disposed inside the thermoplastic resin S. Further, the UD tape 100 receives the resin pressure of the joined thermoplastic resin S in the third merge channel 83a. The UD tape 100 is bonded to the thermoplastic resin S by this resin pressure.
- thermoplastic resin S flowing through the second connection flow path 82b flows from the second connection flow path 82b to the fourth merge flow path 83b. Further, the thermoplastic resin S and the UD tape 100 flowing through the second merge channel 82d flow from the second merge channel 82d to the fourth merge channel 83b. Accordingly, as shown in FIG. 7, the thermoplastic resin S from the second connection channel 82b and the thermoplastic resin S and the UD tape 100 from the second junction channel 82d are merged in the fourth merge channel 83b. To do. At this time, in the fourth merge channel 83b, the thermoplastic resin from the second connection channel 82b covers the surface of the UD tape 100 from the second merge channel 82d.
- the UD tape 100 in the fourth merge channel 83b is disposed inside the thermoplastic resin S. Moreover, the UD tape 100 receives the resin pressure of the joined thermoplastic resin S in the fourth merge channel 83b. The UD tape 100 is bonded to the thermoplastic resin S by this resin pressure.
- thermoplastic resin S flowing through the third merge channel 83a and the UD tape 100 joined to the thermoplastic resin S are discharged from the second extrusion die 8 through the other end opening of the third merge channel 83a.
- the left side wall 13 of the fiber reinforced resin molded body 10 is formed by the thermoplastic resin S and the UD tape 100 discharged from the second extrusion die 8 through the other end opening of the third merge channel 83a.
- thermoplastic resin S flowing through the fourth merge channel 83b and the UD tape 100 joined to the thermoplastic resin S are discharged from the second extrusion die 8 through the other end opening of the fourth merge channel 83b. Is done.
- the right side wall portion 14 of the fiber-reinforced resin molded body 10 is configured by the thermoplastic resin S and the UD tape 100 discharged from the second extrusion die 8 through the other end opening of the fourth merge channel 83b.
- the upper side wall part 11, the lower side wall part 12, and the intermediate wall part 15 of the fiber reinforced resin molded body 10 are routed through a branch channel (not shown in FIGS. 6 and 7) branched from the resin introduction channel 81a.
- the thermoplastic resin discharged from the second extrusion die 8. In this way, the thermoplastic resin S passing through the second extrusion die 8 is branched and merged, so that the thermoplastic resin S is formed into a predetermined cross-sectional shape.
- the UD tape 100 merges with the thermoplastic resin S and is joined to a predetermined region of the thermoplastic resin S molded into a predetermined cross-sectional shape by the resin pressure of the merged thermoplastic resin. Then, the thermoplastic resin S having a predetermined cross-sectional shape is discharged from the second extrusion die 8 together with the UD tape 100 bonded to the predetermined region.
- the method for manufacturing the fiber-reinforced resin molded body 10 includes the UD tape manufacturing process (first process) and the extrusion molding process (second process).
- the UD tape manufacturing process the UD tape 100 is manufactured.
- the extrusion process the UD tape 100 manufactured in the UD tape manufacturing process is introduced into the second extrusion die 8 together with the molten thermoplastic resin S discharged from the second extrusion device 7.
- thermoplastic resin S shape
- the UD tape 100 and the thermoplastic resin S merge, and the thermoplastic resin S which merged with the UD tape 100
- the UD tape 100 is joined to a predetermined region (in the present embodiment, inside the left side wall 13 and inside the right side wall 14) of the thermoplastic resin S having a predetermined cross-sectional shape.
- region is discharged
- the UD tape 100 is manufactured in the UD tape manufacturing process, and the second extrusion die together with the thermoplastic resin S in which the UD tape 100 is melted in the extrusion process performed following the UD tape manufacturing process. 8 is introduced.
- the fiber reinforced resin molding 10 is manufactured by extrusion molding using this second extrusion die 8. That is, in this embodiment, since the fiber reinforced resin molding 10 is extruded, the UD tape 100 manufactured before that is used as it is for extrusion molding (second extrusion die 8) together with the thermoplastic resin S. Can be introduced. Thereby, manufacture of the UD tape 100 and manufacture of the fiber reinforced resin molding 10 using the same can be performed continuously.
- the process of preheating this in order to soften the UD tape 100 is not required before an extrusion molding process. Therefore, there is no need to provide a dedicated process for heating (preheating) the UD tape 100 as in the prior art, and therefore the fiber reinforced resin molded body 10 can be manufactured with fewer processes than in the prior art.
- the UD tape 100 is joined to the thermoplastic resin S in the second extrusion die 8, air bubbles are hardly caught from the outside when the two are joined. Further, even if bubbles are entrained, the entrained bubbles can be eliminated by the resin pressure of the thermoplastic resin S acting on the UD tape 100 when the UD tape 100 and the thermoplastic resin S are joined. it can. Therefore, generation of voids at the bonding interface between the UD tape 100 and the thermoplastic resin S can be effectively suppressed.
- the UD tape manufacturing process in this embodiment includes an application process (emulsion application process and a drying process) for applying a thermoplastic resin to a fiber bundle, a fiber bundle to which a thermoplastic resin is applied in the application process, and an additional resin.
- an application process emulsion application process and a drying process
- the thick film-like UD tape 100 can be manufactured.
- the UD tape manufacturing process and the extrusion molding process are performed independently and continuously, but a part of the UD tape manufacturing process may be incorporated into the extrusion molding process.
- an extrusion impregnation process in the UD tape manufacturing process may be incorporated into the extrusion process. That is, the extrusion impregnation step may be performed simultaneously with the extrusion molding step.
- the first extrusion die 6 used in the extrusion impregnation step and the second extrusion die 8 used in the extrusion molding step may be one common extrusion die.
- the fiber reinforced resin molding reinforced with the thick film-like UD tape can be easily manufactured using one extrusion die. Furthermore, in this case, the thermoplastic resin (additional resin R) used in the extrusion impregnation step and the thermoplastic resin S used in the extrusion molding step may be the same.
- FIG. 9 shows a case where the first extrusion die 6 and the second extrusion die 8 are constituted by the same extrusion die 9 and the additional resin R and the thermoplastic resin S used in the extrusion molding step are the same. It is a figure which shows a line. According to the example shown in FIG. 9, the fiber bundles F4 coated with the thermoplastic resin are respectively produced through the fiber opening process and the coating process (emulsion coating process and drying process) in two separate production lines. .
- the two fiber bundles F4 coated with the thermoplastic resin in the coating process are melted thermoplastic from the extrusion apparatus 7A corresponding to the second extrusion apparatus 7 shown in the second embodiment. It is introduced into the extrusion die 9 together with the resin.
- the introduced thermoplastic resin has a cross-sectional shape formed into a predetermined cross-sectional shape, and the fiber bundle F4 and the thermoplastic resin merge.
- the fiber bundle F4 is impregnated with the thermoplastic resin by the resin pressure of the thermoplastic resin merged with the fiber bundle F4 in the extrusion die 9, and the UD tape 100 is molded, and the molded UD tape 100 has a predetermined cross section.
- the fiber reinforced resin molding 10 is extrusion-molded by discharging
- the fiber-reinforced resin molded body 10 can be more easily manufactured using one extrusion die.
- FIG. 10 is a diagram showing an example in which four UD tapes 100 are introduced into the second extrusion die 8 together with the thermoplastic resin S.
- a fiber reinforced resin molded body 10 ⁇ / b> A having a square cross section is manufactured from the second extrusion die 8.
- each of the four side walls (upper side wall part 11A, lower side wall part 12A, left side wall part 13A, right side wall part 14A) constituting the cross section of the fiber reinforced resin molded body 10A, the UD tape along the longitudinal direction. 100 is disposed, and each UD tape 100 is joined to the thermoplastic resin in each side wall portion.
- the cross-sectional shape of the fiber-reinforced resin molded body 10 is not limited to the cross-sectional shape as in the above embodiment.
- a cross-sectional shape such as a flat plate shape or an L shape may be used.
- the present invention can be modified without departing from the gist thereof.
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Abstract
A method for manufacturing a fiber reinforced resin molded body comprises a UD tape manufacturing step and an extrusion molding step. In the UD tape manufacturing step, a UD tape is manufactured. In the extrusion molding step, the UD tape manufactured in the UD tape manufacturing step is introduced into an extrusion die together with melted thermoplastic resin from an extrusion device. In the extrusion die, a cross-sectional shape of the thermoplastic resin is molded into a prescribed cross-sectional shape, while the UD tape and the thermoplastic resin merge with each other. By means of a resin pressure of the thermoplastic resin that has merged with the UD tape, the UD tape is joined to a prescribed region of the thermoplastic resin molded to have the prescribed cross-sectional shape. The thermoplastic resin molded to have the prescribed cross-sectional shape is ejected from the die together with the UD tape that has been joined to the prescribed region, thereby extrusion-molding a fiber reinforced resin molded body.
Description
本発明は、繊維強化樹脂成形体の製造方法、及び、一方向繊維強化部材の製造方法に関する。
The present invention relates to a method for producing a fiber reinforced resin molded body and a method for producing a unidirectional fiber reinforced member.
一方向に引き揃えられた複数の繊維により構成される繊維束に樹脂が含浸されてなる一方向繊維強化部材は、例えばUDテープのような補強部材として用いられる。このような一方向繊維強化部材は、例えば各種の樹脂成形体に取り付けられる。樹脂成形体に一方向繊維強化部材が取り付けられることによって、樹脂成形体が補強される。一方向繊維強化部材が取り付けられることによって補強された樹脂成形体を、本明細書では、繊維強化樹脂成形体と呼ぶ。
A unidirectional fiber reinforced member obtained by impregnating a fiber bundle composed of a plurality of fibers aligned in one direction with a resin is used as a reinforcing member such as a UD tape. Such a unidirectional fiber reinforced member is attached to various resin molded bodies, for example. The resin molded body is reinforced by attaching the unidirectional fiber reinforced member to the resin molded body. In the present specification, a resin molded body reinforced by attaching a unidirectional fiber reinforced member is referred to as a fiber reinforced resin molded body.
特許文献1は、厚膜状の一方向繊維強化部材で補強された樹脂成形体(繊維強化樹脂成形体)の製造方法を開示する。特許文献1の実施例7によれば、薄膜状の一方向繊維強化部材(薄膜A)を複数枚積層し、さらに積層体を200℃で3分間予熱して軟化させる。そして、軟化した積層体に樹脂成形材料を重ねてスタンピング成形することにより、厚膜状の一方向繊維強化部材で補強された樹脂成形体(繊維強化樹脂成形体)が製造される。
Patent Document 1 discloses a method for producing a resin molded body (fiber reinforced resin molded body) reinforced with a thick film unidirectional fiber reinforced member. According to Example 7 of Patent Document 1, a plurality of thin film unidirectional fiber reinforced members (thin film A) are laminated, and the laminated body is preheated at 200 ° C. for 3 minutes to be softened. Then, a resin molding material (fiber reinforced resin molding) reinforced with a thick film unidirectional fiber reinforced member is manufactured by stacking a resin molding material on the softened laminate and stamping molding.
(発明が解決しようとする課題)
特許文献1に記載の繊維強化樹脂成形体の製造方法によれば、一方向繊維強化部材の積層体を成形する成形型(プリフォーム成形型)と、積層体と樹脂成形材料とを重ねてスタンピングするための成形型(スタンピング成形型)が異なるため、一方向繊維強化部材の積層体をプリフォーム成形型からスタンピング成形型に移し替える間に、一方向繊維強化部材が冷却固化してしまう。そのため、スタンピング成形前に、予めプリフォーム成形型で成形された積層体を一旦加熱(予熱)して軟化させる必要がある。つまり、特許文献1に記載の繊維強化樹脂成形体は、一方向繊維強化部材の積層工程と、積層体の加熱工程と、加熱された積層体と樹脂成形材料とを重ね合わせてスタンピングするスタンピング工程を経て製造される。このため、繊維強化樹脂成形体を得るために必要な工程数が多い。また、積層体を樹脂成形材料と重ね合わせてスタンピングする際に、外部から空気を巻き込むことにより両者の接合界面にボイドが生じる可能性が高い。そのため、一方向繊維強化部材と樹脂成形体との良好な接合界面を得ることができず、その結果、製造された繊維強化樹脂成形体の強度が低下する虞がある。 (Problems to be solved by the invention)
According to the method for manufacturing a fiber reinforced resin molded article described inPatent Document 1, a mold (preform mold) for molding a laminate of unidirectional fiber reinforced members, and a laminate and a resin molding material are stacked and stamped. Therefore, the unidirectional fiber reinforced member is cooled and solidified while the laminate of unidirectional fiber reinforced members is transferred from the preform mold to the stamping mold. Therefore, before stamping molding, it is necessary to heat (preheat) the laminated body previously molded with the preform mold and soften it. That is, the fiber-reinforced resin molded article described in Patent Document 1 is a stamping process in which a unidirectional fiber-reinforced member is laminated, a laminated body is heated, and the heated laminated body and a resin molding material are stacked and stamped. It is manufactured through. For this reason, there are many processes required in order to obtain a fiber reinforced resin molding. Further, when stamping the laminated body with the resin molding material, there is a high possibility that voids are generated at the joint interface between the two by entraining air from the outside. For this reason, a good bonding interface between the unidirectional fiber reinforced member and the resin molded body cannot be obtained, and as a result, the strength of the manufactured fiber reinforced resin molded body may be reduced.
特許文献1に記載の繊維強化樹脂成形体の製造方法によれば、一方向繊維強化部材の積層体を成形する成形型(プリフォーム成形型)と、積層体と樹脂成形材料とを重ねてスタンピングするための成形型(スタンピング成形型)が異なるため、一方向繊維強化部材の積層体をプリフォーム成形型からスタンピング成形型に移し替える間に、一方向繊維強化部材が冷却固化してしまう。そのため、スタンピング成形前に、予めプリフォーム成形型で成形された積層体を一旦加熱(予熱)して軟化させる必要がある。つまり、特許文献1に記載の繊維強化樹脂成形体は、一方向繊維強化部材の積層工程と、積層体の加熱工程と、加熱された積層体と樹脂成形材料とを重ね合わせてスタンピングするスタンピング工程を経て製造される。このため、繊維強化樹脂成形体を得るために必要な工程数が多い。また、積層体を樹脂成形材料と重ね合わせてスタンピングする際に、外部から空気を巻き込むことにより両者の接合界面にボイドが生じる可能性が高い。そのため、一方向繊維強化部材と樹脂成形体との良好な接合界面を得ることができず、その結果、製造された繊維強化樹脂成形体の強度が低下する虞がある。 (Problems to be solved by the invention)
According to the method for manufacturing a fiber reinforced resin molded article described in
本発明は、より少ない工程で製造することができる繊維強化樹脂成形体の製造方法を提供すること、及び、そのように製造された繊維強化樹脂成形体に用いられる一方向繊維強化部材の製造方法を提供することを、目的とする。
The present invention provides a method for manufacturing a fiber-reinforced resin molded body that can be manufactured with fewer steps, and a method for manufacturing a unidirectional fiber-reinforced member used for the fiber-reinforced resin molded body thus manufactured. The purpose is to provide
(課題を解決するための手段)
本発明は、一方向に引き揃えられた複数の繊維により構成される繊維束に樹脂が含浸されてなる一方向繊維強化部材(100)を製造する第一工程と、第一工程にて製造された一方向繊維強化部材を溶融した熱可塑性樹脂(S)と共に押出ダイス(8)に導入し、押出ダイス内で、熱可塑性樹脂の断面形状を所定の断面形状に成形するとともに、一方向繊維強化部材と熱可塑性樹脂とを合流させ、一方向繊維強化部材と合流した熱可塑性樹脂の樹脂圧によって一方向繊維強化部材を所定の断面形状に成形された熱可塑性樹脂の所定領域に接合し、所定領域に接合された一方向繊維強化部材とともに所定の断面形状に成形された熱可塑性樹脂を押出ダイスから排出することにより、繊維強化樹脂成形体(10)を押出成形する第二工程と、を含む、繊維強化樹脂成形体の製造方法を提供する。 (Means for solving the problem)
The present invention is manufactured by a first step of manufacturing a unidirectional fiber reinforced member (100) in which a resin is impregnated into a fiber bundle composed of a plurality of fibers aligned in one direction, and the first step. The unidirectional fiber reinforced member is introduced into the extrusion die (8) together with the molten thermoplastic resin (S), and the thermoplastic resin is molded into a predetermined cross sectional shape in the extrusion die, and unidirectional fiber reinforced. The member and the thermoplastic resin are merged, and the unidirectional fiber reinforced member is joined to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape by the resin pressure of the thermoplastic resin merged with the unidirectional fiber reinforced member, A second step of extruding the fiber reinforced resin molded article (10) by discharging the thermoplastic resin molded into a predetermined cross-sectional shape together with the unidirectional fiber reinforced member joined to the region from the extrusion die. Provides a method for producing a fiber-reinforced resin molded body.
本発明は、一方向に引き揃えられた複数の繊維により構成される繊維束に樹脂が含浸されてなる一方向繊維強化部材(100)を製造する第一工程と、第一工程にて製造された一方向繊維強化部材を溶融した熱可塑性樹脂(S)と共に押出ダイス(8)に導入し、押出ダイス内で、熱可塑性樹脂の断面形状を所定の断面形状に成形するとともに、一方向繊維強化部材と熱可塑性樹脂とを合流させ、一方向繊維強化部材と合流した熱可塑性樹脂の樹脂圧によって一方向繊維強化部材を所定の断面形状に成形された熱可塑性樹脂の所定領域に接合し、所定領域に接合された一方向繊維強化部材とともに所定の断面形状に成形された熱可塑性樹脂を押出ダイスから排出することにより、繊維強化樹脂成形体(10)を押出成形する第二工程と、を含む、繊維強化樹脂成形体の製造方法を提供する。 (Means for solving the problem)
The present invention is manufactured by a first step of manufacturing a unidirectional fiber reinforced member (100) in which a resin is impregnated into a fiber bundle composed of a plurality of fibers aligned in one direction, and the first step. The unidirectional fiber reinforced member is introduced into the extrusion die (8) together with the molten thermoplastic resin (S), and the thermoplastic resin is molded into a predetermined cross sectional shape in the extrusion die, and unidirectional fiber reinforced. The member and the thermoplastic resin are merged, and the unidirectional fiber reinforced member is joined to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape by the resin pressure of the thermoplastic resin merged with the unidirectional fiber reinforced member, A second step of extruding the fiber reinforced resin molded article (10) by discharging the thermoplastic resin molded into a predetermined cross-sectional shape together with the unidirectional fiber reinforced member joined to the region from the extrusion die. Provides a method for producing a fiber-reinforced resin molded body.
本発明によれば、第一工程にて一方向繊維強化部材が製造され、第一工程に引き続いて行われる第二工程にて、一方向繊維強化部材と溶融した熱可塑性樹脂とが共に押出ダイスに導入される。そして、この押出ダイスを用いて繊維強化樹脂成形体が押出成形により製造される。第二工程にて押出ダイスを用いて繊維強化樹脂成形体が押出成形されるため、第一工程にて製造された一方向繊維強化部材をそのまま第二工程に用いられる押出ダイスに導入することができる。つまり、一方向繊維強化部材の製造とそれを用いた繊維強化樹脂成形体の製造を、連続的に実行することができる。このため、第二工程の実施前に一方向繊維強化部材を軟化させるためにこれを加熱(予熱)する工程を要しない。従って、従来に比べて少ない工程で、繊維強化樹脂成形体を製造することができる。さらに、押出ダイス内で一方向繊維強化部材が熱可塑性樹脂に接合されるため、両者の接合時に外部から気泡が巻き込まれにくい。また、仮に気泡が巻き込まれた場合であっても、一方向繊維強化部材と熱可塑性樹脂との接合時に一方向繊維強化部材に作用する熱可塑性樹脂の樹脂圧によって、巻き込まれた気泡を排除することができる。そのため、一方向繊維強化部材と熱可塑性樹脂との接合界面でのボイドの発生を効果的に抑制することができる。
According to the present invention, a unidirectional fiber reinforced member is manufactured in the first step, and in the second step performed subsequent to the first step, the unidirectional fiber reinforced member and the molten thermoplastic resin are both extruded dies. To be introduced. And a fiber reinforced resin molded object is manufactured by extrusion molding using this extrusion die. Since the fiber reinforced resin molded product is extruded using the extrusion die in the second step, the unidirectional fiber reinforced member produced in the first step can be directly introduced into the extrusion die used in the second step. it can. That is, manufacture of a unidirectional fiber reinforced member and manufacture of a fiber reinforced resin molding using the same can be continuously performed. For this reason, in order to soften a unidirectional fiber reinforcement member before implementation of a 2nd process, the process of heating this (preheating) is not required. Therefore, the fiber-reinforced resin molded product can be manufactured with fewer steps than conventional. Furthermore, since the unidirectional fiber reinforced member is joined to the thermoplastic resin in the extrusion die, bubbles are not easily caught from the outside when the two are joined. Further, even if bubbles are entrained, the entrained bubbles are eliminated by the resin pressure of the thermoplastic resin acting on the one-way fiber reinforced member when the unidirectional fiber reinforced member and the thermoplastic resin are joined. be able to. Therefore, it is possible to effectively suppress the generation of voids at the bonding interface between the unidirectional fiber reinforced member and the thermoplastic resin.
また、本発明において、第一工程は、繊維束に熱可塑性樹脂を塗布する塗布工程と、塗布工程にて熱可塑性樹脂が塗布された繊維束と、追加樹脂(R)としての溶融した熱可塑性樹脂とを共に押出ダイス(6)に導入し、押出ダイス内で熱可塑性樹脂が塗布された繊維束に追加樹脂を所定の樹脂圧で押し付けることにより、繊維束内に熱可塑性樹脂を含浸させる押出含浸工程と、を含むとよい。これによれば、熱可塑性樹脂が塗布された繊維束に追加樹脂を押出ダイス内で押し付けて熱可塑性樹脂を繊維束に含浸させることにより、厚膜状の一方向繊維強化樹脂が製造される。こうして製造された厚膜状の一方向繊維強化樹脂を用いて繊維強化樹脂成形体を製造することにより、補強効果の高い繊維強化樹脂成形体を得ることができる。
In the present invention, the first step includes a coating step in which a thermoplastic resin is applied to the fiber bundle, a fiber bundle in which the thermoplastic resin is applied in the coating step, and a molten thermoplastic as an additional resin (R). Extrusion that impregnates the fiber bundle with the thermoplastic resin by introducing the resin into the extrusion die (6) and pressing the additional resin against the fiber bundle coated with the thermoplastic resin at a predetermined resin pressure in the extrusion die. And an impregnation step. According to this, a thick film-like unidirectional fiber reinforced resin is manufactured by pressing an additional resin into the fiber bundle to which the thermoplastic resin is applied in an extrusion die and impregnating the fiber bundle with the thermoplastic resin. By producing a fiber reinforced resin molded body using the thick film-like unidirectional fiber reinforced resin thus manufactured, a fiber reinforced resin molded body having a high reinforcing effect can be obtained.
押出含浸工程は、第二工程と同時に実施されてもよい。つまり、押出含浸工程に用いられる押出ダイスと、第二工程に用いられる押出ダイスが共通の押出ダイスであってもよい。これによれば、厚膜状の一方向繊維強化部材により補強された繊維強化樹脂成形体を、一つの押出ダイスを用いて簡単に製造することができる。
The extrusion impregnation step may be performed simultaneously with the second step. That is, the extrusion die used in the extrusion impregnation step and the extrusion die used in the second step may be a common extrusion die. According to this, the fiber reinforced resin molded object reinforced with the thick film-like unidirectional fiber reinforced member can be easily manufactured using one extrusion die.
この場合、押出含浸工程で用いられる熱可塑性樹脂(追加樹脂)と、第二工程で用いられる熱可塑性樹脂が同じであってもよい。押出含浸工程に用いられる押出ダイスと第二工程に用いられる押出ダイスが共通であって、且つ、押出含浸工程で用いられる熱可塑性樹脂(追加樹脂)と第二工程で用いられる熱可塑性樹脂が同じである場合、第二工程は、第一工程の押出含浸工程を含むように構成される。つまり、この場合、第二工程では、第一工程の塗布工程にて熱可塑性樹脂が塗布された繊維束(F4)を溶融した熱可塑性樹脂と共に押出ダイス(9)に導入し、押出ダイス内で、熱可塑性樹脂の断面形状を所定の断面形状に成形するとともに、繊維束と熱可塑性樹脂とを合流させ、繊維束と合流した熱可塑性樹脂の樹脂圧によって繊維束内に熱可塑性樹脂を含浸することにより一方向繊維強化部材(100)を成形し、成形した一方向繊維強化部材を所定の断面形状に成形された熱可塑性樹脂の所定領域に接合し、所定領域に接合された一方向繊維強化部材とともに所定の断面形状に成形された熱可塑性樹脂を押出ダイスから排出することにより、繊維強化樹脂成形体を押出成形する。
In this case, the thermoplastic resin (additional resin) used in the extrusion impregnation step and the thermoplastic resin used in the second step may be the same. The extrusion die used in the extrusion impregnation step and the extrusion die used in the second step are common, and the thermoplastic resin (additional resin) used in the extrusion impregnation step is the same as the thermoplastic resin used in the second step. The second step is configured to include the extrusion impregnation step of the first step. That is, in this case, in the second step, the fiber bundle (F4) coated with the thermoplastic resin in the coating step of the first step is introduced into the extrusion die (9) together with the molten thermoplastic resin. The thermoplastic resin is molded into a predetermined cross-sectional shape, the fiber bundle and the thermoplastic resin are merged, and the fiber bundle is impregnated with the resin pressure of the thermoplastic resin merged with the fiber bundle. The unidirectional fiber reinforced member (100) is molded by joining the molded unidirectional fiber reinforced member to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape and bonded to the predetermined region. The fiber reinforced resin molded body is extruded by discharging the thermoplastic resin molded into a predetermined cross-sectional shape together with the member from the extrusion die.
また、本発明は、一方向に引き揃えられた複数の繊維により構成される繊維束に熱可塑性樹脂を塗布する塗布工程と、塗布工程にて熱可塑性樹脂が塗布された繊維束(F4)と、追加樹脂(R)としての溶融した熱可塑性樹脂とを共に押出ダイス(6)に導入し、押出ダイス内で熱可塑性樹脂が塗布された繊維束に追加樹脂を所定の樹脂圧で押し付けることにより、繊維束内に熱可塑性樹脂を含浸させる押出含浸工程と、を含む、一方向繊維強化部材(100)の製造方法を提供する。
Further, the present invention provides an application step of applying a thermoplastic resin to a fiber bundle composed of a plurality of fibers aligned in one direction, and a fiber bundle (F4) in which a thermoplastic resin is applied in the application step. The molten thermoplastic resin as the additional resin (R) is introduced into the extrusion die (6), and the additional resin is pressed against the fiber bundle to which the thermoplastic resin is applied in the extrusion die at a predetermined resin pressure. An extrusion impregnation step of impregnating a thermoplastic resin into the fiber bundle, and a method for producing the unidirectional fiber reinforced member (100).
本発明によれば、予め樹脂が塗布されている繊維束に追加樹脂を押出ダイス内で押し付けることにより、厚膜状の一方向繊維強化部材を製造することができる。また、本発明により製造された厚膜状の一方向繊維強化部材を補強材として熱可塑性樹脂の成形体に押出成形で接合することにより、より補強効果の高い繊維強化樹脂成形体を製造することができる。
According to the present invention, a thick film-shaped unidirectional fiber reinforced member can be manufactured by pressing an additional resin in an extrusion die against a fiber bundle to which a resin has been previously applied. Also, a fiber reinforced resin molded body having a higher reinforcing effect can be produced by joining the thick unidirectional fiber reinforced member produced according to the present invention to a thermoplastic resin molded body as a reinforcing material by extrusion molding. Can do.
この場合、塗布工程は、熱可塑性樹脂粒子が水に分散されてなる水分散性エマルジョンを、繊維束(F2)に塗布するエマルジョン塗布工程と、水分散性エマルジョンが塗布された繊維束を乾燥させる乾燥工程と、を含むとよい。これによれば、エマルジョン塗布工程にて水に分散された熱可塑性樹脂粒子が繊維束に塗布されることにより、繊維束を構成する複数の繊維の隙間に熱可塑性樹脂粒子が入り込む。そして、その後の押出含浸工程にて繊維束に作用する樹脂圧により、追加樹脂が繊維束に含浸するとともにエマルジョン塗布工程にて塗布された熱可塑性樹脂粒子が繊維束の奥深くまで入り込む。このため、繊維束の厚み方向に均一に熱可塑性樹脂を含浸させることができる。また、厚みの大きい繊維束を用いた場合でも、厚み方向に均一に熱可塑性樹脂を含浸させることができる。つまり、厚みの大きい一方向繊維強化部材を容易に製造することができる。
In this case, in the coating process, the water-dispersible emulsion in which the thermoplastic resin particles are dispersed in water is applied to the fiber bundle (F2), and the fiber bundle to which the water-dispersible emulsion is applied is dried. And a drying step. According to this, the thermoplastic resin particles dispersed in water in the emulsion application step are applied to the fiber bundle, so that the thermoplastic resin particles enter the gaps between the plurality of fibers constituting the fiber bundle. Then, the additional resin impregnates the fiber bundle by the resin pressure acting on the fiber bundle in the subsequent extrusion impregnation step, and the thermoplastic resin particles applied in the emulsion application step enter deep into the fiber bundle. For this reason, the thermoplastic resin can be uniformly impregnated in the thickness direction of the fiber bundle. Even when a fiber bundle having a large thickness is used, the thermoplastic resin can be uniformly impregnated in the thickness direction. That is, a thick unidirectional fiber reinforced member can be easily manufactured.
本発明に係る第二工程で用いられる熱可塑性樹脂は、樹脂成形に用いられる熱可塑性樹脂であれば、その種類を問わない。第二工程で用いられる熱可塑性樹脂として、PP(ポリプロピレン)樹脂、PA6(ポリアミド6)樹脂、PA6,6(ポリアミド6,6)樹脂、PPS(ポリフェニレンサルファイド)樹脂、PEEK(ポリエーテルエーテルケトン)樹脂、等を例示することができる。
The thermoplastic resin used in the second step according to the present invention is not limited as long as it is a thermoplastic resin used for resin molding. PP (polypropylene) resin, PA6 (polyamide 6) resin, PA6,6 (polyamide 6,6) resin, PPS (polyphenylene sulfide) resin, PEEK (polyetheretherketone) resin as the thermoplastic resin used in the second step , Etc. can be illustrated.
また、本発明に係る第二工程で用いられる熱可塑性樹脂は、発泡樹脂、或いは多色成形用樹脂であってもよい。さらに、本発明に係る第二工程で用いられる熱可塑性樹脂は、強化繊維を含有していてもよい。熱可塑性樹脂に含有される強化繊維は、一般的に強化繊維として用いられるものであれば、その種類は問わない。強化繊維として、ガラス繊維、炭素繊維、アラミド繊維、植物由来のCNF(セルロースナノファイバー)等を例示することができる。
The thermoplastic resin used in the second step according to the present invention may be a foamed resin or a multicolor molding resin. Furthermore, the thermoplastic resin used in the second step according to the present invention may contain reinforcing fibers. The reinforcing fiber contained in the thermoplastic resin is not particularly limited as long as it is generally used as a reinforcing fiber. Examples of the reinforcing fiber include glass fiber, carbon fiber, aramid fiber, plant-derived CNF (cellulose nanofiber) and the like.
また、本発明に係る一方向繊維強化部材は、一方向に引き揃えられた複数の繊維により構成された繊維束と、その繊維束に樹脂が含浸されてなる形態であれば、どのようなものでもよい。この場合において、「一方向に引き揃えられた複数の繊維により構成される繊維束」との表現は、少なくとも一方向に引き揃えられた複数の繊維により構成される繊維束を有していればよいという意味で用いられており、一方向以外の方向に引き揃えられた繊維束を含むことを否定しない。一方向繊維強化部材として、UD(Uni Directional)テープ、或いはクロス(織物)等を例示することができる。
In addition, the unidirectional fiber reinforced member according to the present invention may be any fiber bundle formed of a plurality of fibers aligned in one direction, and the fiber bundle is impregnated with resin. But you can. In this case, the expression “a fiber bundle composed of a plurality of fibers aligned in one direction” has at least a fiber bundle composed of a plurality of fibers aligned in one direction. It is used in the sense of good, and it does not deny that it includes fiber bundles that are aligned in directions other than one direction. Examples of the unidirectional fiber reinforced member include UD (Uni Directional) tape, cloth (woven fabric), and the like.
また、本発明に係る第二工程にて押出ダイス内で成形される熱可塑性樹脂の所定の断面形状は、円形断面でも良いし、異形断面(非円形断面)でも良い。異形断面として、平板状断面、L字状断面、中空断面等を例示することができる。
Further, the predetermined cross-sectional shape of the thermoplastic resin molded in the extrusion die in the second step according to the present invention may be a circular cross section or an irregular cross section (non-circular cross section). Examples of the irregular cross section include a flat cross section, an L-shaped cross section, and a hollow cross section.
また、本発明に係る第二工程にて、一方向繊維強化部材は、所定の断面形状に成形された熱可塑性樹脂の所定領域に接合されていればよい。上記所定領域は、熱可塑性樹脂の表面領域でもよいし内部領域でもよい。なお、熱可塑性樹脂の表面に、ガラス繊維に樹脂が含浸された一方向繊維強化部材を接合して繊維強化樹脂成形体を製造することにより、製造された繊維強化樹脂成形体と金属部材との締結時における電蝕を防止することができる。
Further, in the second step according to the present invention, the unidirectional fiber reinforced member may be bonded to a predetermined region of the thermoplastic resin molded into a predetermined cross-sectional shape. The predetermined area may be a surface area of the thermoplastic resin or an internal area. In addition, by joining a unidirectional fiber reinforced member in which a glass fiber is impregnated with a resin to the surface of a thermoplastic resin to manufacture a fiber reinforced resin molded body, the manufactured fiber reinforced resin molded body and the metal member It is possible to prevent electrolytic corrosion at the time of fastening.
また、本発明に係る塗布工程にて繊維束に塗布される熱可塑性樹脂と、本発明に係る押出含浸工程にて用いられる追加樹脂は、相溶性が同じ程度の樹脂であるとよい。この場合、追加樹脂は、塗布工程にて繊維束に塗布される熱可塑性樹脂と同じ材質の熱可塑性樹脂であってもよい。
Also, the thermoplastic resin applied to the fiber bundle in the coating process according to the present invention and the additional resin used in the extrusion impregnation process according to the present invention may be resins having the same compatibility. In this case, the additional resin may be a thermoplastic resin made of the same material as the thermoplastic resin applied to the fiber bundle in the application step.
また、本発明に用いられる繊維束を構成する繊維の本数は特に限定されないが、好ましくは、3000本から60000本である。繊維の材質も特に限定されない。繊維の材質として、炭素繊維、ガラス繊維、アラミド繊維等を例示することができる。
Further, the number of fibers constituting the fiber bundle used in the present invention is not particularly limited, but is preferably 3000 to 60000. The material of the fiber is not particularly limited. Examples of the fiber material include carbon fiber, glass fiber, and aramid fiber.
(第一実施形態)
<UDテープの製造方法>
まず、本発明の第一実施形態として、一方向繊維強化部材としてのUDテープの製造方法について説明する。図1は、本実施形態に係るUDテープの製造工程を製造ラインとともに示す概略図である。図1に示すように、本実施形態に係るUDテープの製造方法は、開繊工程と、エマルジョン塗布工程と、乾燥工程と、押出含浸工程と含み、これらの工程がこの順で実行される。エマルジョン塗布工程及び乾燥工程が、本発明の塗布工程に相当する。 (First embodiment)
<Method for manufacturing UD tape>
First, the manufacturing method of the UD tape as a unidirectional fiber reinforcement member is demonstrated as 1st embodiment of this invention. FIG. 1 is a schematic view showing a manufacturing process of a UD tape according to this embodiment together with a manufacturing line. As shown in FIG. 1, the UD tape manufacturing method according to the present embodiment includes an opening process, an emulsion application process, a drying process, and an extrusion impregnation process, and these processes are executed in this order. The emulsion coating process and the drying process correspond to the coating process of the present invention.
<UDテープの製造方法>
まず、本発明の第一実施形態として、一方向繊維強化部材としてのUDテープの製造方法について説明する。図1は、本実施形態に係るUDテープの製造工程を製造ラインとともに示す概略図である。図1に示すように、本実施形態に係るUDテープの製造方法は、開繊工程と、エマルジョン塗布工程と、乾燥工程と、押出含浸工程と含み、これらの工程がこの順で実行される。エマルジョン塗布工程及び乾燥工程が、本発明の塗布工程に相当する。 (First embodiment)
<Method for manufacturing UD tape>
First, the manufacturing method of the UD tape as a unidirectional fiber reinforcement member is demonstrated as 1st embodiment of this invention. FIG. 1 is a schematic view showing a manufacturing process of a UD tape according to this embodiment together with a manufacturing line. As shown in FIG. 1, the UD tape manufacturing method according to the present embodiment includes an opening process, an emulsion application process, a drying process, and an extrusion impregnation process, and these processes are executed in this order. The emulsion coating process and the drying process correspond to the coating process of the present invention.
開繊工程では、アンコイラ1から引き出された繊維束F1が開繊される。繊維束F1は、一方向に引き揃えられた複数の繊維により構成される。繊維束F1を構成する繊維は、一般的に強化繊維として用いられる繊維であれば、その種類を問わない。例えば、炭素繊維、ガラス繊維、アラミド繊維等により、繊維束F1を構成することができる。また、繊維束F1を構成する複数の繊維は、集束剤を介して結合されていて、繊維間の隙間が集束剤により塞がれている。開繊工程は、集束剤により塞がれた繊維間の隙間を僅かに開くために実施される。開繊工程は、例えば、繊維束F1を80℃~120℃に加熱された熱ロールに通して加熱した後に、表面に梨地処理が施された対の梨地ロール間に加熱された繊維束F1を通すことにより実施することができる。梨地ロール間に繊維束F1が通される際に繊維束F1が梨地ロールから受ける摩擦力により、繊維束F1が開繊される。
In the fiber opening process, the fiber bundle F1 drawn from the uncoiler 1 is opened. The fiber bundle F1 is composed of a plurality of fibers aligned in one direction. If the fiber which comprises the fiber bundle F1 is a fiber generally used as a reinforced fiber, the kind will not be ask | required. For example, the fiber bundle F1 can be composed of carbon fiber, glass fiber, aramid fiber, or the like. Moreover, the some fiber which comprises the fiber bundle F1 is couple | bonded through the bundling agent, and the clearance gap between fibers is block | closed with the bundling agent. The opening process is carried out in order to slightly open the gap between the fibers blocked by the sizing agent. In the opening process, for example, the fiber bundle F1 is heated through a heated roll heated to 80 ° C. to 120 ° C., and then the heated fiber bundle F1 is paired between the pair of satin finish rolls. This can be done by passing it through. When the fiber bundle F1 is passed between the satin rolls, the fiber bundle F1 is opened by the frictional force that the fiber bundle F1 receives from the satin roll.
エマルジョン塗布工程では、開繊工程にて開繊された繊維束F2に、水分散性エマルジョンが塗布される。エマルジョン塗布工程に用いられる水分散性エマルジョンは、水と、水に分散された熱可塑性樹脂粒子とを含む。水に分散された熱可塑性樹脂粒子として、PP(ポリプロピレン)樹脂などのポリオレフィン系樹脂、ポリアミド系樹脂等を例示することができるが、この限りではない。エマルジョン塗布工程の実施により、開繊された繊維束に熱可塑性樹脂粒子を含む水分散性エマルジョンが塗布される。このとき、水分散性エマルジョン中の熱可塑性樹脂粒子が、開繊された繊維束F2を構成する複数の繊維間の隙間内に入り込む。
In the emulsion application process, the water-dispersible emulsion is applied to the fiber bundle F2 opened in the fiber opening process. The water-dispersible emulsion used in the emulsion coating step includes water and thermoplastic resin particles dispersed in water. Examples of the thermoplastic resin particles dispersed in water include polyolefin resins such as PP (polypropylene) resin, polyamide resins, and the like, but are not limited thereto. By performing the emulsion application step, a water-dispersible emulsion containing thermoplastic resin particles is applied to the opened fiber bundle. At this time, the thermoplastic resin particles in the water-dispersible emulsion enter the gaps between the plurality of fibers constituting the opened fiber bundle F2.
図1において、エマルジョン塗布工程は、表面に水分散性エマルジョン2が塗布された対のコータロール3,3に繊維束F2を通すことによって、すなわちタッチロール方式によりなされるが、水分散性エマルジョン2の塗布方法については図1の例に限定されない。例えば、水分散性エマルジョンを繊維束F2に向かって噴霧することにより、すなわちスプレー方式により、繊維束F2に水分散性エマルジョンを塗布することができる。また、水分散性エマルジョンの充填槽に繊維束F2を浸漬することにより、繊維束F2に水分散性エマルジョンを塗布することができる。
In FIG. 1, the emulsion coating step is performed by passing the fiber bundle F2 through a pair of coater rolls 3 and 3 having a water-dispersible emulsion 2 coated on the surface thereof, that is, by a touch roll method. The coating method is not limited to the example of FIG. For example, the water-dispersible emulsion can be applied to the fiber bundle F2 by spraying the water-dispersible emulsion toward the fiber bundle F2, that is, by a spray method. Further, the water dispersible emulsion can be applied to the fiber bundle F2 by immersing the fiber bundle F2 in the water dispersible emulsion filling tank.
乾燥工程では、エマルジョン塗布工程にて水分散性エマルジョン2が塗布された繊維束F3を乾燥させる。この場合、熱により水分散性エマルジョン2中の水分を蒸発させることによって、繊維束F3を乾燥させるのがよい。加熱方法は特に限定されないが、例えば、図1に示すように、所定の温度に加熱された対の熱ロール4,4間に、水分散性エマルジョンが塗布された繊維束F3を通すことによって、繊維束F3を乾燥させることができる。加熱温度は、水が蒸発するような温度であればよく、特に、80℃~130℃であるとよい。
In the drying process, the fiber bundle F3 coated with the water-dispersible emulsion 2 in the emulsion coating process is dried. In this case, it is preferable to dry the fiber bundle F3 by evaporating the water in the water-dispersible emulsion 2 with heat. The heating method is not particularly limited. For example, as shown in FIG. 1, by passing a fiber bundle F3 coated with a water-dispersible emulsion between a pair of heat rolls 4 and 4 heated to a predetermined temperature, The fiber bundle F3 can be dried. The heating temperature may be a temperature at which water evaporates, and is particularly preferably 80 ° C. to 130 ° C.
乾燥工程を経た場合、繊維束F3から水分が除去されるので、繊維束中に熱可塑性樹脂が含浸する。従って、乾燥工程を経た繊維束F4も、一方向繊維強化部材と言える。なお、エマルジョン塗布工程で塗布される熱可塑性樹脂(粒子)の塗布量は少量であり、塗布・乾燥後は多くの気孔(ボイド)を内部に有した状態になっている。
When the drying process is performed, moisture is removed from the fiber bundle F3, so that the thermoplastic resin is impregnated in the fiber bundle. Therefore, the fiber bundle F4 that has undergone the drying process can also be said to be a unidirectional fiber reinforced member. Note that the amount of the thermoplastic resin (particles) applied in the emulsion application process is small, and after application and drying, there are many pores inside.
押出含浸工程では、乾燥工程を経た繊維束F4に追加樹脂Rが含浸される。追加樹脂Rは、エマルジョン塗布工程にて繊維束F2に塗布された水分散性エマルジョンを構成する熱可塑性樹脂粒子と同じ樹脂であるのがよい。
In the extrusion impregnation process, the additional resin R is impregnated into the fiber bundle F4 that has undergone the drying process. The additional resin R may be the same resin as the thermoplastic resin particles constituting the water-dispersible emulsion applied to the fiber bundle F2 in the emulsion application process.
本実施形態では、押出含浸工程に、第一押出装置5及び第一押出ダイス6が用いられる。第一押出装置5は、押出シリンダと、押出シリンダの内部に配された押出スクリューとを備える。押出シリンダ内には、追加樹脂Rのペレットが例えばホッパ等を介して供給される。また、押出シリンダの外側周面にヒータが敷設されており、このヒータが作動することで、押出シリンダ内に供給された追加樹脂Rのペレットが加熱される。この加熱により、押出シリンダ内の追加樹脂Rが溶融する。また、押出シリンダ内で押出スクリューが回転することにより、押出シリンダ内の溶融した追加樹脂Rが混錬されるとともに、押出シリンダの前方側に溶融した追加樹脂Rが移動する。そして、押出シリンダの先端に取り付けられているノズルから溶融した追加樹脂Rが排出される。
In the present embodiment, the first extrusion device 5 and the first extrusion die 6 are used in the extrusion impregnation step. The first extrusion device 5 includes an extrusion cylinder and an extrusion screw arranged inside the extrusion cylinder. In the extrusion cylinder, pellets of the additional resin R are supplied through, for example, a hopper. Further, a heater is laid on the outer peripheral surface of the extrusion cylinder, and the pellet of the additional resin R supplied into the extrusion cylinder is heated by operating this heater. By this heating, the additional resin R in the extrusion cylinder is melted. Further, when the extrusion screw rotates in the extrusion cylinder, the molten additional resin R in the extrusion cylinder is kneaded, and the molten additional resin R moves to the front side of the extrusion cylinder. Then, the molten additional resin R is discharged from a nozzle attached to the tip of the extrusion cylinder.
第一押出装置5の押出シリンダから排出された溶融した追加樹脂Rは、第一押出ダイス6に導入される。また、乾燥工程を経た繊維束F4も、第一押出ダイス6に導入される。そして、第一押出ダイス6内で、溶融した追加樹脂Rが繊維束F4に所定の樹脂圧で押し付けられる。これにより、繊維束に既に塗布されている熱可塑性樹脂及び追加樹脂Rが繊維束内に含浸する。そして、十分な量の熱可塑性樹脂が含浸された繊維束であるUDテープ100(一方向繊維強化部材)が、第一押出ダイス6から排出される。つまり、UDテープ100が押出成形される。以上の工程を経て、UDテープ100が製造される。
The molten additional resin R discharged from the extrusion cylinder of the first extrusion device 5 is introduced into the first extrusion die 6. In addition, the fiber bundle F <b> 4 that has undergone the drying process is also introduced into the first extrusion die 6. Then, in the first extrusion die 6, the molten additional resin R is pressed against the fiber bundle F4 with a predetermined resin pressure. Thereby, the thermoplastic resin already applied to the fiber bundle and the additional resin R are impregnated in the fiber bundle. Then, the UD tape 100 (unidirectional fiber reinforced member), which is a fiber bundle impregnated with a sufficient amount of thermoplastic resin, is discharged from the first extrusion die 6. That is, the UD tape 100 is extruded. The UD tape 100 is manufactured through the above steps.
本実施形態に係るUDテープ100の製造方法によれば、エマルジョン塗布工程にて繊維束に熱可塑性樹脂粒子を含む水分散性エマルジョン2が塗布され、押出含浸工程にて繊維束にさらに熱可塑性樹脂が含浸される。
According to the manufacturing method of the UD tape 100 according to the present embodiment, the water-dispersible emulsion 2 containing thermoplastic resin particles is applied to the fiber bundle in the emulsion application step, and the thermoplastic resin is further applied to the fiber bundle in the extrusion impregnation step. Is impregnated.
エマルジョン塗布工程にて繊維束に塗布された水分散性エマルジョン中の熱可塑性樹脂粒子は微小であるので、繊維束を構成する複数の繊維間の隙間に容易に入り込む。
Since the thermoplastic resin particles in the water-dispersible emulsion applied to the fiber bundle in the emulsion application process are very small, they easily enter the gaps between the plurality of fibers constituting the fiber bundle.
また、エマルジョン塗布工程、乾燥工程の後に、押出含浸工程が実行される。この押出含浸工程にて、追加樹脂Rが繊維束F4に所定の樹脂圧で押し付けられる。これにより、繊維束F4内への熱可塑性樹脂の含浸が進む。具体的には、押出含浸工程が実行された場合、エマルジョン塗布工程によって既に繊維束に塗布(含浸)されている熱可塑性樹脂が樹脂圧により繊維束の奥深くまで含浸する。一方、繊維束の表面には、追加樹脂が含浸する。
Also, the extrusion impregnation step is executed after the emulsion coating step and the drying step. In this extrusion impregnation step, the additional resin R is pressed against the fiber bundle F4 with a predetermined resin pressure. Thereby, the impregnation of the thermoplastic resin into the fiber bundle F4 proceeds. Specifically, when the extrusion impregnation step is executed, the thermoplastic resin already applied (impregnated) to the fiber bundle by the emulsion application step is impregnated deep into the fiber bundle by the resin pressure. On the other hand, the surface of the fiber bundle is impregnated with the additional resin.
このように、本実施形態では、繊維束に熱可塑性樹脂を含浸させる工程が少なくとも2段階に分けられており、1回目の工程(エマルジョン塗布工程)では、微小の熱可塑性粒子が繊維束に塗布され、2回目の工程(押出含浸工程)では、追加の熱可塑性樹脂が自身の圧力(樹脂圧)により繊維束に押し付けられる。従って、2回目の工程の実行時に、1回目の工程で塗布された熱可塑性樹脂を樹脂圧により繊維束の奥深くまで浸透させることができるとともに、追加樹脂を自身の樹脂圧で繊維束の表面に含浸させることができる。このため、繊維束の厚みが厚い場合であっても、厚み方向に均一に樹脂が含浸されたUDテープを製造することができる。
As described above, in this embodiment, the process of impregnating the fiber bundle with the thermoplastic resin is divided into at least two stages. In the first process (emulsion application process), fine thermoplastic particles are applied to the fiber bundle. In the second step (extrusion impregnation step), the additional thermoplastic resin is pressed against the fiber bundle by its own pressure (resin pressure). Therefore, when the second process is executed, the thermoplastic resin applied in the first process can be penetrated deep into the fiber bundle by the resin pressure, and the additional resin can be applied to the surface of the fiber bundle by the own resin pressure. Can be impregnated. For this reason, even when the fiber bundle is thick, a UD tape in which the resin is uniformly impregnated in the thickness direction can be manufactured.
また、本実施形態において、エマルジョン塗布工程にて繊維束に塗布された熱可塑性樹脂粒子は微小であるので、開繊された複数の繊維間の隙間が非常に小さい場合においても、その隙間に熱可塑性樹脂粒子が十分に入り込む。このため、繊維含有率が高い(すなわち開繊後の繊維間の隙間が小さい)繊維束に十分に熱可塑性樹脂を含浸させることができる。つまり、繊維含有率が高く、且つ、厚いUDテープを製造することができる。
In the present embodiment, since the thermoplastic resin particles applied to the fiber bundle in the emulsion application step are very small, even when the gaps between the opened fibers are very small, the gaps are heated. The plastic resin particles sufficiently enter. For this reason, a fiber bundle having a high fiber content (that is, a small gap between fibers after opening) can be sufficiently impregnated with a thermoplastic resin. That is, it is possible to manufacture a thick UD tape with a high fiber content.
また、上記したように、エマルジョン塗布工程・乾燥工程後の繊維束F4は多数のボイドを有する。この点に関し、本実施形態によれば、乾燥工程後の押出含浸工程にて、所定の樹脂圧でもって追加樹脂Rが繊維束に押し付けられる。斯かる樹脂圧によりボイドが押し潰されることにより、ボイドの量を低減することができる。これにより、UDテープの空隙率を減少させることができる。よって、製造されるUDテープの強度を向上させることができる。
Further, as described above, the fiber bundle F4 after the emulsion coating process / drying process has a large number of voids. In this regard, according to the present embodiment, the additional resin R is pressed against the fiber bundle with a predetermined resin pressure in the extrusion impregnation step after the drying step. By voiding the voids by such resin pressure, the amount of voids can be reduced. Thereby, the porosity of the UD tape can be reduced. Therefore, the strength of the manufactured UD tape can be improved.
(実施例1)
幅15~20mmの長尺状の炭素繊維束(炭素繊維:SGL製 SIGRAFIL C030 T050 EPY)を80℃~120℃に加熱された熱ロールに通して炭素繊維束内の集束剤を溶融させた。次いで、表面が凹凸状に梨地処理された梨地ロールに炭素繊維束を通過させた。梨地ロールを炭素繊維束が通過する際に炭素繊維束が梨地ロールから受ける摩擦力によって、炭素繊維束の幅が28mm~35mmにまで広げられた。このようにして、炭素繊維束を開繊させた(開繊工程)。 (Example 1)
A long carbon fiber bundle (carbon fiber: SIGRAFIL C030 T050 EPY manufactured by SGL) having a width of 15 to 20 mm was passed through a hot roll heated to 80 ° C. to 120 ° C. to melt the sizing agent in the carbon fiber bundle. Subsequently, the carbon fiber bundle was allowed to pass through a satin roll whose surface was textured and textured. The width of the carbon fiber bundle was expanded to 28 mm to 35 mm by the frictional force that the carbon fiber bundle received from the satin roll when the carbon fiber bundle passed through the satin roll. In this way, the carbon fiber bundle was opened (opening process).
幅15~20mmの長尺状の炭素繊維束(炭素繊維:SGL製 SIGRAFIL C030 T050 EPY)を80℃~120℃に加熱された熱ロールに通して炭素繊維束内の集束剤を溶融させた。次いで、表面が凹凸状に梨地処理された梨地ロールに炭素繊維束を通過させた。梨地ロールを炭素繊維束が通過する際に炭素繊維束が梨地ロールから受ける摩擦力によって、炭素繊維束の幅が28mm~35mmにまで広げられた。このようにして、炭素繊維束を開繊させた(開繊工程)。 (Example 1)
A long carbon fiber bundle (carbon fiber: SIGRAFIL C030 T050 EPY manufactured by SGL) having a width of 15 to 20 mm was passed through a hot roll heated to 80 ° C. to 120 ° C. to melt the sizing agent in the carbon fiber bundle. Subsequently, the carbon fiber bundle was allowed to pass through a satin roll whose surface was textured and textured. The width of the carbon fiber bundle was expanded to 28 mm to 35 mm by the frictional force that the carbon fiber bundle received from the satin roll when the carbon fiber bundle passed through the satin roll. In this way, the carbon fiber bundle was opened (opening process).
その後、熱可塑性樹脂粒子(ポリオレフィン系樹脂粒子或いはポリアミド系樹脂粒子)が水に分散されてなる水分散性エマルジョンが表面に塗布された対のコータロールに開繊後の炭素繊維束を通過させた。このとき0.2MPaの圧力で炭素繊維束が絞られるとともに、炭素繊維束に水分散性エマルジョンが塗布された(エマルジョン塗布工程)。
Thereafter, the carbon fiber bundle after opening was passed through a pair of coater rolls coated with a water-dispersible emulsion in which thermoplastic resin particles (polyolefin resin particles or polyamide resin particles) were dispersed in water. . At this time, the carbon fiber bundle was squeezed with a pressure of 0.2 MPa, and a water-dispersible emulsion was applied to the carbon fiber bundle (emulsion application step).
次いで、エマルジョン塗布工程後の炭素繊維束を80℃~130℃に加熱された熱ロールに通すことにより、炭素繊維束を乾燥させた。その後、炭素繊維束に塗布されている水分散性エマルジョンに含まれる熱可塑性樹脂粒子の融点以上の温度に加熱された熱ロールに炭素繊維束を通した。このとき0.5Mpaの圧力を炭素繊維束に加えることにより、炭素繊維束内に熱可塑性樹脂を含浸させた(乾燥工程)。
Next, the carbon fiber bundle after the emulsion coating step was passed through a hot roll heated to 80 ° C. to 130 ° C. to dry the carbon fiber bundle. Thereafter, the carbon fiber bundle was passed through a hot roll heated to a temperature equal to or higher than the melting point of the thermoplastic resin particles contained in the water-dispersible emulsion applied to the carbon fiber bundle. At this time, by applying a pressure of 0.5 Mpa to the carbon fiber bundle, the carbon fiber bundle was impregnated with a thermoplastic resin (drying step).
その後、押出ダイス内に乾燥工程後の炭素繊維束を導入した。このとき、水分散性エマルジョン中の熱可塑性樹脂と同一の熱可塑性樹脂を、追加樹脂として、押出装置から押出ダイス内に所定の樹脂圧でもって炭素繊維束とともに導入した。これにより、押出ダイス内で所定の樹脂圧で追加樹脂が炭素繊維束に押し付けられて、炭素繊維束に追加樹脂が含浸されるとともに、追加樹脂が含浸された炭素繊維束が押出成形された(押出含浸工程)。以上の工程を経て、実施例1に係るUDテープを製造した。
Thereafter, the carbon fiber bundle after the drying process was introduced into the extrusion die. At this time, the same thermoplastic resin as the thermoplastic resin in the water-dispersible emulsion was introduced as an additional resin into the extrusion die together with the carbon fiber bundle with a predetermined resin pressure. Thereby, the additional resin was pressed against the carbon fiber bundle at a predetermined resin pressure in the extrusion die, and the carbon fiber bundle was impregnated with the additional resin, and the carbon fiber bundle impregnated with the additional resin was extruded ( Extrusion impregnation step). Through the above steps, the UD tape according to Example 1 was manufactured.
(比較例1)
押出含浸工程を省略したことを除き、実施例1と同様な方法により、比較例1に係るUDテープを製造した。つまり、実施例1に示す開繊工程、エマルジョン塗布工程、乾燥工程を経て、比較例1に係るUDテープを製造した。 (Comparative Example 1)
A UD tape according to Comparative Example 1 was produced in the same manner as in Example 1 except that the extrusion impregnation step was omitted. That is, the UD tape according to Comparative Example 1 was manufactured through the opening process, the emulsion application process, and the drying process shown in Example 1.
押出含浸工程を省略したことを除き、実施例1と同様な方法により、比較例1に係るUDテープを製造した。つまり、実施例1に示す開繊工程、エマルジョン塗布工程、乾燥工程を経て、比較例1に係るUDテープを製造した。 (Comparative Example 1)
A UD tape according to Comparative Example 1 was produced in the same manner as in Example 1 except that the extrusion impregnation step was omitted. That is, the UD tape according to Comparative Example 1 was manufactured through the opening process, the emulsion application process, and the drying process shown in Example 1.
(比較例2)
エマルジョン塗布工程及び乾燥工程を省略したことを除き、実施例1と同様な方法により、比較例2に係るUDテープを製造した。つまり、実施例1に示す開繊工程、押出含浸工程を経て、比較例2に係るUDテープを製造した。 (Comparative Example 2)
A UD tape according to Comparative Example 2 was produced by the same method as in Example 1 except that the emulsion coating step and the drying step were omitted. That is, the UD tape according to Comparative Example 2 was manufactured through the opening process and the extrusion impregnation process shown in Example 1.
エマルジョン塗布工程及び乾燥工程を省略したことを除き、実施例1と同様な方法により、比較例2に係るUDテープを製造した。つまり、実施例1に示す開繊工程、押出含浸工程を経て、比較例2に係るUDテープを製造した。 (Comparative Example 2)
A UD tape according to Comparative Example 2 was produced by the same method as in Example 1 except that the emulsion coating step and the drying step were omitted. That is, the UD tape according to Comparative Example 2 was manufactured through the opening process and the extrusion impregnation process shown in Example 1.
実施例1、比較例1、及び比較例2にて製造した一方向繊維強化部材の繊維含有率(wt%)、厚さ(mm)、空隙率(%)を、それぞれ求めた。
The fiber content (wt%), thickness (mm), and porosity (%) of the unidirectional fiber reinforced members produced in Example 1, Comparative Example 1, and Comparative Example 2 were determined.
ここで、繊維含有率とは、製造したUDテープの単位質量当たりに占める炭素繊維の質量比である。この場合において、UDテープの製造に使用した炭素繊維の単位長さ当たりの質量は3.3g/mであるので、繊維含有率の算出においては、製造したUDテープを20cm(0.2m)の長さに切断し、切断したUDテープの重量Wを計測し、次式
3.3×0.2/W×100
を用いて繊維含有率を算出した。 Here, the fiber content is a mass ratio of carbon fibers per unit mass of the manufactured UD tape. In this case, since the mass per unit length of the carbon fiber used for the manufacture of the UD tape is 3.3 g / m, in the calculation of the fiber content, the manufactured UD tape is 20 cm (0.2 m). Cut to length, measure the weight W of the cut UD tape, the following formula 3.3 × 0.2 / W × 100
Was used to calculate the fiber content.
3.3×0.2/W×100
を用いて繊維含有率を算出した。 Here, the fiber content is a mass ratio of carbon fibers per unit mass of the manufactured UD tape. In this case, since the mass per unit length of the carbon fiber used for the manufacture of the UD tape is 3.3 g / m, in the calculation of the fiber content, the manufactured UD tape is 20 cm (0.2 m). Cut to length, measure the weight W of the cut UD tape, the following formula 3.3 × 0.2 / W × 100
Was used to calculate the fiber content.
また、厚さとは、製造したUDテープの厚さのうち、十分に樹脂が含浸していることが確認できる部分における厚さである。また、空隙率の測定に当たり、製造したUDテープをエポキシ樹脂で固定した後に、観察面(UDテープの断面)を研磨し、研磨した観察面を顕微鏡で観察した。また、観察面を画像解析で2値化し、2値化後の画像に基づいて、空隙率を算出した。各例に係るUDテープの繊維含有率、厚さ、空隙率の測定結果を表1に示す。
Further, the thickness is a thickness at a portion where it can be confirmed that the resin is sufficiently impregnated in the thickness of the manufactured UD tape. Moreover, in measuring the porosity, after fixing the manufactured UD tape with an epoxy resin, the observation surface (cross section of the UD tape) was polished, and the polished observation surface was observed with a microscope. Moreover, the observation surface was binarized by image analysis, and the porosity was calculated based on the binarized image. Table 1 shows the measurement results of the fiber content, thickness, and porosity of the UD tape according to each example.
表1からわかるように、実施例1に係るUDテープの繊維含有率は比較例2に係るUDテープの繊維含有率よりも高い。また、実施例1に係るUDテープの厚さは、比較例1及び2に係るUDテープの厚さよりも厚い。さらに、実施例1に係るUDテープの空隙率は、比較例1及び2に係るUDテープの空隙率よりも小さい。
As can be seen from Table 1, the fiber content of the UD tape according to Example 1 is higher than the fiber content of the UD tape according to Comparative Example 2. Further, the thickness of the UD tape according to Example 1 is thicker than the thickness of the UD tape according to Comparative Examples 1 and 2. Furthermore, the porosity of the UD tape according to Example 1 is smaller than the porosity of the UD tape according to Comparative Examples 1 and 2.
以上のことから、実施例1によれば、繊維含有率が70wt%以上、厚さが0.7mm以上、空隙率が2%以下のUDテープを製造できることがわかる。
From the above, it can be seen that according to Example 1, a UD tape having a fiber content of 70 wt% or more, a thickness of 0.7 mm or more, and a porosity of 2% or less can be produced.
(第二実施形態)
<繊維強化樹脂成形体の製造方法>
次に、本発明の第二実施形態として、繊維強化樹脂成形体の製造方法について説明する。図2は、本実施形態に係る製造方法により製造される繊維強化樹脂成形体10の斜視図である。図2に示すように、繊維強化樹脂成形体10は長尺状に形成されており、長手方向に垂直な断面形状が、長手方向に沿ってほぼ一定であるように構成される。なお、繊維強化樹脂成形体10の断面形状は、長手方向に沿って完全に一定である必要はなく、例えば、長手方向に沿って断面形状が徐々に変化(徐変)するように構成されていてもよい。 (Second embodiment)
<Method for producing fiber-reinforced resin molded article>
Next, as a second embodiment of the present invention, a method for producing a fiber-reinforced resin molded body will be described. FIG. 2 is a perspective view of the fiber-reinforced resin moldedbody 10 manufactured by the manufacturing method according to the present embodiment. As shown in FIG. 2, the fiber reinforced resin molded body 10 is formed in a long shape, and is configured such that a cross-sectional shape perpendicular to the longitudinal direction is substantially constant along the longitudinal direction. In addition, the cross-sectional shape of the fiber reinforced resin molded body 10 does not need to be completely constant along the longitudinal direction, and for example, the cross-sectional shape is configured to gradually change (gradual change) along the longitudinal direction. May be.
<繊維強化樹脂成形体の製造方法>
次に、本発明の第二実施形態として、繊維強化樹脂成形体の製造方法について説明する。図2は、本実施形態に係る製造方法により製造される繊維強化樹脂成形体10の斜視図である。図2に示すように、繊維強化樹脂成形体10は長尺状に形成されており、長手方向に垂直な断面形状が、長手方向に沿ってほぼ一定であるように構成される。なお、繊維強化樹脂成形体10の断面形状は、長手方向に沿って完全に一定である必要はなく、例えば、長手方向に沿って断面形状が徐々に変化(徐変)するように構成されていてもよい。 (Second embodiment)
<Method for producing fiber-reinforced resin molded article>
Next, as a second embodiment of the present invention, a method for producing a fiber-reinforced resin molded body will be described. FIG. 2 is a perspective view of the fiber-reinforced resin molded
図3は、繊維強化樹脂成形体10の長手方向に垂直な断面形状を示す図である。図3に示すように、繊維強化樹脂成形体10は、図3の上下方向に離間して対面配置した上側壁部11及び下側壁部12と、図3の左右方向に離間して対面配置した左側壁部13及び右側壁部14と、上側壁部11と下側壁部12との間に設けられた中間壁部15とを有する。
FIG. 3 is a view showing a cross-sectional shape perpendicular to the longitudinal direction of the fiber-reinforced resin molded body 10. As shown in FIG. 3, the fiber reinforced resin molded body 10 is disposed so as to face the upper and lower side wall portions 11 and 12 spaced apart in the vertical direction in FIG. 3 and separated in the left and right direction in FIG. 3. It has a left side wall part 13 and a right side wall part 14, and an intermediate wall part 15 provided between the upper side wall part 11 and the lower side wall part 12.
上側壁部11の図3において左方端が左側壁部13の上方端に接続され、上側壁部11の図3において右方端が右側壁部14の上方端に接続される。また、下側壁部12の図3において左方端が左側壁部13の下方端に接続され、下側壁部12の図3において右方端が右側壁部14の下方端に接続される。従って、上側壁部11、下側壁部12、左側壁部13及び右側壁部14によって、四角形状の断面が形成される。
The left end of the upper wall 11 in FIG. 3 is connected to the upper end of the left side wall 13, and the right end of the upper side wall 11 in FIG. 3 is connected to the upper end of the right side wall 14. Further, the left end of the lower wall portion 12 in FIG. 3 is connected to the lower end of the left side wall portion 13, and the right end of the lower wall portion 12 in FIG. 3 is connected to the lower end of the right side wall portion 14. Therefore, the upper side wall part 11, the lower side wall part 12, the left side wall part 13, and the right side wall part 14 form a rectangular cross section.
中間壁部15は、その一方面が上側壁部11に対面し、その他方面が下側壁部12に対面するように、4つの側壁部11,12,13,14に囲まれた空間内に配設される。また、中間壁部15の図3における左方端が、左側壁部13の上下方向における中間位置に接続され、中間壁部15の図3における右方端が、右側壁部14の上下方向における中間位置に接続される。上側壁部11、下側壁部12、左側壁部13、右側壁部14、及び中間壁部15により、繊維強化樹脂成形体10の断面形状が図3に示すような形状にされる。
The intermediate wall portion 15 is arranged in a space surrounded by the four side wall portions 11, 12, 13, and 14 so that one surface thereof faces the upper wall portion 11 and the other surface faces the lower wall portion 12. Established. Further, the left end of the intermediate wall 15 in FIG. 3 is connected to an intermediate position in the vertical direction of the left wall 13, and the right end of the intermediate wall 15 in FIG. Connected to an intermediate position. The upper side wall part 11, the lower side wall part 12, the left side wall part 13, the right side wall part 14, and the intermediate wall part 15 make the cross-sectional shape of the fiber reinforced resin molded body 10 as shown in FIG.
繊維強化樹脂成形体10は、熱可塑性樹脂により成形される部分(樹脂成形部)と、補強体としてのUDテープ100とを備える。UDテープ100により樹脂成形部が補強される。繊維強化樹脂成形体10の上側壁部11、下側壁部12、及び中間壁部15は、熱可塑性樹脂のみにより構成される。一方、左側壁部13及び右側壁部14は、熱可塑性樹脂により構成される部分と、UDテープ100により構成される部分とを有する。
The fiber reinforced resin molded body 10 includes a portion (resin molded portion) molded by a thermoplastic resin and a UD tape 100 as a reinforcing body. The resin molding part is reinforced by the UD tape 100. The upper side wall part 11, the lower side wall part 12, and the intermediate wall part 15 of the fiber reinforced resin molded body 10 are made of only a thermoplastic resin. On the other hand, the left side wall part 13 and the right side wall part 14 have a part constituted by a thermoplastic resin and a part constituted by the UD tape 100.
UDテープ100は、図3に示すように、左側壁部13及び右側壁部14の内部に長手方向に沿って配設され、これらの壁部の内部でこれらの壁部に接合される。このようにUDテープ100は樹脂成形部に埋設されているので、繊維強化樹脂成形体10の断面形状は、熱可塑性樹脂により構成される部分(樹脂成形部)の断面形状と言える。そして、そのような断面形状を有する樹脂成形部の内部にUDテープ100が樹脂成形部と接合された状態で配設される。なお、ここでいう「接合」とは、ボルト等によって機械的に結合されている態様を表すのではなく、樹脂成形部を構成する熱可塑性樹脂とUDテープに含まれる熱可塑性樹脂が溶着する態様を表す。
As shown in FIG. 3, the UD tape 100 is disposed along the longitudinal direction inside the left wall portion 13 and the right wall portion 14, and is joined to these wall portions inside these wall portions. Thus, since the UD tape 100 is embedded in the resin molding part, it can be said that the cross-sectional shape of the fiber reinforced resin molded body 10 is the cross-sectional shape of the part (resin molding part) comprised with a thermoplastic resin. And the UD tape 100 is arrange | positioned in the state joined to the resin molding part inside the resin molding part which has such a cross-sectional shape. The term “joining” as used herein does not represent an aspect in which the bolts or the like are mechanically coupled, but an aspect in which the thermoplastic resin constituting the resin molded portion and the thermoplastic resin contained in the UD tape are welded. Represents.
図4は、繊維強化樹脂成形体10の製造工程を製造ラインとともに示す概略図である。図4に示すように、繊維強化樹脂成形体10は、UDテープ製造工程と、押出成形工程を経て製造される。UDテープ製造工程が本発明の第一工程に相当し、押出成形工程が本発明の第二工程に相当する。
FIG. 4 is a schematic view showing a manufacturing process of the fiber-reinforced resin molded body 10 together with a manufacturing line. As shown in FIG. 4, the fiber reinforced resin molded body 10 is manufactured through a UD tape manufacturing process and an extrusion molding process. The UD tape manufacturing process corresponds to the first process of the present invention, and the extrusion molding process corresponds to the second process of the present invention.
UDテープ製造工程では、UDテープ100が製造される。このUDテープ製造工程は、上記第一実施形態に係るUDテープの製造方法で説明した各工程、具体的には、開繊工程、エマルジョン塗布工程、乾燥工程、及び押出含浸工程を含む。これらの各工程についての説明は省略する。
UD tape 100 is manufactured in the UD tape manufacturing process. This UD tape manufacturing process includes each process described in the UD tape manufacturing method according to the first embodiment, specifically, a fiber opening process, an emulsion coating process, a drying process, and an extrusion impregnation process. A description of each of these steps is omitted.
押出成形工程では、繊維強化樹脂成形体10が押出成形により製造される。この押出成形工程では、図4に示すように、第二押出装置7と、第二押出ダイス8が用いられる。第二押出装置7は、押出シリンダ及び押出シリンダの内部に配設された押出スクリューを備える。押出シリンダ内には、樹脂成形部を構成する熱可塑性樹脂のペレットが例えばホッパ等を介して供給される。また、押出シリンダの外側周面にヒータが敷設されており、このヒータが作動することで、押出シリンダ内に供給された熱可塑性樹脂のペレットが加熱される。この加熱により、押出シリンダ内の熱可塑性樹脂が溶融する。また、押出シリンダ内で押出スクリューが回転することにより、押出シリンダ内の溶融した熱可塑性樹脂が混錬されるとともに、押出シリンダの前方側に溶融した熱可塑性樹脂が移動する。そして、押出シリンダの先端に取り付けられているノズルから溶融した熱可塑性樹脂が排出される。
In the extrusion process, the fiber-reinforced resin molded body 10 is manufactured by extrusion. In this extrusion molding process, as shown in FIG. 4, a second extrusion device 7 and a second extrusion die 8 are used. The second extrusion device 7 includes an extrusion cylinder and an extrusion screw disposed inside the extrusion cylinder. In the extrusion cylinder, pellets of thermoplastic resin constituting the resin molding part are supplied through, for example, a hopper. Further, a heater is laid on the outer peripheral surface of the extrusion cylinder, and when the heater is activated, the pellets of the thermoplastic resin supplied into the extrusion cylinder are heated. By this heating, the thermoplastic resin in the extrusion cylinder is melted. Further, when the extrusion screw rotates in the extrusion cylinder, the molten thermoplastic resin in the extrusion cylinder is kneaded, and the molten thermoplastic resin moves to the front side of the extrusion cylinder. And the molten thermoplastic resin is discharged | emitted from the nozzle attached to the front-end | tip of an extrusion cylinder.
第二押出装置7から排出された熱可塑性樹脂は、第二押出ダイス8に導入される。また、第二押出ダイス8には、第二押出装置7から排出された熱可塑性樹脂Sとともに、UDテープ製造工程にて製造されたUDテープ100も導入される。本実施形態においては、2つの別個の製造ラインでそれぞれ製造された2本のUDテープ100が、第二押出ダイス8に導入される。
The thermoplastic resin discharged from the second extrusion device 7 is introduced into the second extrusion die 8. Further, the UD tape 100 manufactured in the UD tape manufacturing process is introduced into the second extrusion die 8 together with the thermoplastic resin S discharged from the second extrusion device 7. In the present embodiment, two UD tapes 100 respectively produced on two separate production lines are introduced into the second extrusion die 8.
図5は、第二押出ダイス8付近の構成を示す斜視図である。図4及び図5に示すように、第二押出装置7の先端部が第二押出ダイス8に連結される。第二押出装置7の先端部から排出される加熱溶融された熱可塑性樹脂は、第二押出ダイス8の材料供給面8a側から第二押出ダイス8に導入される。また、第二押出装置7を挟むように、UDテープ製造工程(UDテープ製造ライン)にて製造された2本のUDテープ100が配置している。これらのUDテープ100も第二押出ダイス8の材料供給面8a側からそれぞれ第二押出ダイス8に導入される。そして、第二押出ダイス8の材料供給面8aとは反対側の製品排出面8b側から、繊維強化樹脂成形体10が排出される。
FIG. 5 is a perspective view showing a configuration in the vicinity of the second extrusion die 8. As shown in FIGS. 4 and 5, the tip of the second extrusion device 7 is connected to the second extrusion die 8. The heated and melted thermoplastic resin discharged from the tip of the second extrusion device 7 is introduced into the second extrusion die 8 from the material supply surface 8 a side of the second extrusion die 8. Moreover, the two UD tapes 100 manufactured by the UD tape manufacturing process (UD tape manufacturing line) are arrange | positioned so that the 2nd extrusion apparatus 7 may be pinched | interposed. These UD tapes 100 are also introduced into the second extrusion die 8 from the material supply surface 8a side of the second extrusion die 8, respectively. And the fiber reinforced resin molding 10 is discharged | emitted from the product discharge | emission surface 8b side on the opposite side to the material supply surface 8a of the 2nd extrusion die 8. FIG.
図6は、図5に示す第二押出ダイス8を、図5の破線で示す平面Pで切断した断面を示す図である。図6に示すように、第二押出ダイス8は、第一金属プレート81、第二金属プレート82、第三金属プレート83を備え、これらの金属プレートをこの順に重ね合わせてボルト等により締結することにより、構成される。従って、第一金属プレート81の一表面及び第三金属プレート83の一表面が、第二押出ダイス8の対向する2つの表面を構成する。上記対向する2つの表面のうち、第一金属プレート81の一表面が第二押出ダイス8の材料供給面8aを構成し、第三金属プレート83の一表面が第二押出ダイス8の製品排出面8bを構成する。
FIG. 6 is a view showing a cross section of the second extrusion die 8 shown in FIG. 5 cut along a plane P indicated by a broken line in FIG. As shown in FIG. 6, the second extrusion die 8 includes a first metal plate 81, a second metal plate 82, and a third metal plate 83, and these metal plates are stacked in this order and fastened with bolts or the like. It is comprised by. Accordingly, one surface of the first metal plate 81 and one surface of the third metal plate 83 constitute two opposing surfaces of the second extrusion die 8. Of the two opposing surfaces, one surface of the first metal plate 81 forms the material supply surface 8a of the second extrusion die 8, and one surface of the third metal plate 83 is the product discharge surface of the second extrusion die 8. 8b is constituted.
各金属プレート内には、複数の流路が形成される。具体的には、第一金属プレート81内に、樹脂導入流路81a、第一分岐樹脂流路81b、第二分岐樹脂流路81c、第三分岐樹脂流路81d、第四分岐樹脂流路81e、第一UDテープ導入流路81f、第二UDテープ導入流路81gが形成される。第二金属プレート82内に、第一接続流路82a、第二接続流路82b、第一合流流路82c、第二合流流路82dが形成される。第三金属プレート83内に、第三合流流路83a及び第四合流流路83bが形成される。
A plurality of flow paths are formed in each metal plate. Specifically, in the first metal plate 81, the resin introduction flow path 81a, the first branch resin flow path 81b, the second branch resin flow path 81c, the third branch resin flow path 81d, and the fourth branch resin flow path 81e. The first UD tape introduction flow path 81f and the second UD tape introduction flow path 81g are formed. In the second metal plate 82, a first connection channel 82a, a second connection channel 82b, a first merge channel 82c, and a second merge channel 82d are formed. In the third metal plate 83, a third merge channel 83a and a fourth merge channel 83b are formed.
第一金属プレート81の材料供給面8aに、第一金属プレート81内に形成された樹脂導入流路81a、第一UDテープ導入流路81f、及び第二UDテープ導入流路81g、のそれぞれの一方の端部が開口する。第一UDテープ導入流路81fの開口位置と第二UDテープ導入流路81gの開口位置は、樹脂導入流路81aの開口位置を挟んで対称的に位置する。
Each of the resin introduction flow path 81a, the first UD tape introduction flow path 81f, and the second UD tape introduction flow path 81g formed in the first metal plate 81 is formed on the material supply surface 8a of the first metal plate 81. One end opens. The opening position of the first UD tape introduction flow path 81f and the opening position of the second UD tape introduction flow path 81g are positioned symmetrically across the opening position of the resin introduction flow path 81a.
樹脂導入流路81aには、第二押出装置7から排出された熱可塑性樹脂が導入される。また、第一UDテープ導入流路81f及び第二UDテープ導入流路81gには、それぞれ、UDテープ100が導入される。
The thermoplastic resin discharged from the second extrusion device 7 is introduced into the resin introduction channel 81a. The UD tape 100 is introduced into the first UD tape introduction flow path 81f and the second UD tape introduction flow path 81g, respectively.
また、第一金属プレート81内で、樹脂導入流路81aの他方の端部に、第一分岐樹脂流路81b、第二分岐樹脂流路81c、第三分岐樹脂流路81d及び第四分岐樹脂流路81eのそれぞれの一方の端部が接続される。各分岐樹脂流路(81b、81c、81d、81e)の他方の端部は、第一金属プレート81の材料供給面8aとは反対側の面であって第二金属プレート82に対面する側の面に開口する。
In the first metal plate 81, the first branch resin flow path 81b, the second branch resin flow path 81c, the third branch resin flow path 81d, and the fourth branch resin are provided at the other end of the resin introduction flow path 81a. One end of each of the flow paths 81e is connected. The other end of each branched resin flow path (81b, 81c, 81d, 81e) is a surface opposite to the material supply surface 8a of the first metal plate 81 and on the side facing the second metal plate 82. Open to the surface.
なお、図6において、第一分岐樹脂流路81bと第一UDテープ導入流路81fが交差し、第四分岐樹脂流路81eと第二UDテープ導入流路81gが交差している。それぞれの交差位置において交差する流路が合流しないように、樹脂流路(第一分岐樹脂流路81b、第四分岐樹脂流路81e)がUDテープ導入流路(第一UDテープ導入流路81f、第二UDテープ導入流路81g)に対して迂回している。
In FIG. 6, the first branch resin flow path 81b and the first UD tape introduction flow path 81f intersect, and the fourth branch resin flow path 81e and the second UD tape introduction flow path 81g intersect. The resin flow paths (first branch resin flow path 81b, fourth branch resin flow path 81e) are connected to the UD tape introduction flow path (first UD tape introduction flow path 81f) so that the flow paths intersecting at the respective intersection positions do not merge. , Bypasses the second UD tape introduction flow path 81g).
第二金属プレート82内に形成された第一接続流路82a、第二接続流路82b、第一合流流路82c、第二合流流路82dのそれぞれの一方の端部は、第二金属プレート82の表面であって第一金属プレート81に対面する側の面に開口し、それぞれの他方の端部は、第二金属プレート82の表面であって第三金属プレート83に対面する側の面に開口する。
One end of each of the first connection flow channel 82a, the second connection flow channel 82b, the first merge flow channel 82c, and the second merge flow channel 82d formed in the second metal plate 82 is a second metal plate. 82 is a surface that faces the first metal plate 81, and the other end of each is a surface of the second metal plate 82 that faces the third metal plate 83. Open to.
第一金属プレート81内に形成された第一分岐樹脂流路81bの他方の端部開口は、第二金属プレート82内に形成された第一接続流路82aの一方の端部開口に対面する。このため、第一分岐樹脂流路81bは第一接続流路82aに連通する。第一金属プレート81内に形成された第二分岐樹脂流路81cの他方の端部開口及び第一UDテープ導入流路81fの他方の端部開口は、第二金属プレート82内に形成された第一合流流路82cの一方の端部開口にそれぞれ対面する。このため、第二分岐樹脂流路81c及び第一UDテープ導入流路81fは、共に、第一合流流路82cに連通する。第一金属プレート81内に形成された第三分岐樹脂流路81dの他方の端部開口及び第二UDテープ導入流路81gの他方の端部開口は、第二金属プレート82内に形成された第二合流流路82dの一方の端部開口にそれぞれ対面する。このため、第三分岐樹脂流路81d及び第二UDテープ導入流路81gは、共に、第二合流流路82dに連通する。第一金属プレート81内に形成された第四分岐樹脂流路81eの他方の端部開口は、第二金属プレート82内に形成された第二接続流路82bの一方の端部開口に対面する。このため、第四分岐樹脂流路81eは、第二接続流路82bに連通する。
The other end opening of the first branched resin flow path 81 b formed in the first metal plate 81 faces one end opening of the first connection flow path 82 a formed in the second metal plate 82. . For this reason, the first branch resin flow path 81b communicates with the first connection flow path 82a. The other end opening of the second branch resin flow path 81c formed in the first metal plate 81 and the other end opening of the first UD tape introduction flow path 81f are formed in the second metal plate 82. The first confluence channel 82c faces one end opening. For this reason, both the 2nd branch resin flow path 81c and the 1st UD tape introduction flow path 81f are connected to the 1st confluence | merging flow path 82c. The other end opening of the third branch resin flow path 81d formed in the first metal plate 81 and the other end opening of the second UD tape introduction flow path 81g are formed in the second metal plate 82. It faces one end opening of the second merge channel 82d. For this reason, both the third branch resin flow path 81d and the second UD tape introduction flow path 81g communicate with the second merge flow path 82d. The other end opening of the fourth branch resin flow path 81 e formed in the first metal plate 81 faces one end opening of the second connection flow path 82 b formed in the second metal plate 82. . For this reason, the fourth branched resin flow path 81e communicates with the second connection flow path 82b.
第三金属プレート83内に形成された第三合流流路83aの一方の端部及び第四合流流路83bの一方の端部は、共に、第三金属プレート83の表面であって第二金属プレート82に対面する側の面に開口する。また、第三合流流路83aの他方の端部及び第四合流流路83bの他方の端部は、共に、第三金属プレート83の製品排出面8bに開口する。
One end of the third merge channel 83a and one end of the fourth merge channel 83b formed in the third metal plate 83 are both the surface of the third metal plate 83 and the second metal. An opening is made on the surface facing the plate 82. Further, the other end of the third merge channel 83 a and the other end of the fourth merge channel 83 b both open to the product discharge surface 8 b of the third metal plate 83.
第二金属プレート82内に形成された第一接続流路82aの他方の端部開口及び第一合流流路82cの他方の端部開口は、共に、第三金属プレート83内に形成された第三合流流路83aの一方の端部開口に対面する。このため、第一接続流路82a及び第一合流流路82cは、第三合流流路83aに連通する。また、第二金属プレート82内に形成された第二接続流路82bの他方の端部開口及び第二合流流路82dの他方の端部開口は、共に、第三金属プレート83内に形成された第四合流流路83bの一方の端部開口に対面する。このため、第二接続流路82b及び第二合流流路82dは、第四合流流路83bに連通する。
The other end opening of the first connection channel 82 a formed in the second metal plate 82 and the other end opening of the first merge channel 82 c are both formed in the third metal plate 83. It faces one end opening of the three-merged flow path 83a. For this reason, the first connection channel 82a and the first junction channel 82c communicate with the third junction channel 83a. Further, the other end opening of the second connection channel 82 b formed in the second metal plate 82 and the other end opening of the second joining channel 82 d are both formed in the third metal plate 83. Furthermore, it faces one end opening of the fourth merging channel 83b. For this reason, the second connection channel 82b and the second junction channel 82d communicate with the fourth junction channel 83b.
また、第二金属プレート82及び第三金属プレート83には、エアー流通路84が形成されている。エアー流通路84の一方の端部は、第二金属プレート82の外表面に開口し、他方の端部は、第三金属プレート83の製品排出面8bのうち第三合流流路83aの開口位置と第四合流流路83bの開口位置との間の位置に開口する。
Further, an air flow passage 84 is formed in the second metal plate 82 and the third metal plate 83. One end portion of the air flow passage 84 opens to the outer surface of the second metal plate 82, and the other end portion is an opening position of the third merge channel 83 a in the product discharge surface 8 b of the third metal plate 83. And a position between the opening position of the fourth merge channel 83b.
なお、図6において、エアー流通路84は、第二接続流路82b及び第二合流流路82dに交差している。それぞれの交差位置において交差する流路が合流しないように、樹脂流路(第二接続流路82b、第二合流流路82d)がエアー流通路84に対して迂回している。
In FIG. 6, the air flow passage 84 intersects the second connection flow path 82b and the second merge flow path 82d. The resin flow paths (the second connection flow path 82b and the second merge flow path 82d) are detoured with respect to the air flow path 84 so that the flow paths intersecting at each intersection position do not merge.
図7は、図6に示す第二押出ダイス8内に熱可塑性樹脂及びUDテープ100が流れている状態を示す断面図であり、図8は図7のVIII-VIII断面図である。以下、これらの図(図6、図7、図8)を参照しつつ、本実施形態に係る押出成形工程における第二押出ダイス8内での熱可塑性樹脂及びUDテープの流れについて、説明する。
7 is a cross-sectional view showing a state in which the thermoplastic resin and the UD tape 100 are flowing in the second extrusion die 8 shown in FIG. 6, and FIG. 8 is a cross-sectional view taken along the line VIII-VIII in FIG. Hereinafter, the flow of the thermoplastic resin and the UD tape in the second extrusion die 8 in the extrusion process according to this embodiment will be described with reference to these drawings (FIGS. 6, 7, and 8).
第二押出装置7から排出された溶融した熱可塑性樹脂Sは、第二押出ダイス8の材料供給面8aに開口した樹脂導入流路81aに導入される。樹脂導入流路81aに導入された熱可塑性樹脂Sは、樹脂導入流路81aから、第一分岐樹脂流路81b、第二分岐樹脂流路81c、第三分岐樹脂流路81d、及び第四分岐樹脂流路81eに、それぞれ流れる。
The molten thermoplastic resin S discharged from the second extrusion device 7 is introduced into a resin introduction flow path 81a opened in the material supply surface 8a of the second extrusion die 8. The thermoplastic resin S introduced into the resin introduction flow path 81a is transferred from the resin introduction flow path 81a to the first branch resin flow path 81b, the second branch resin flow path 81c, the third branch resin flow path 81d, and the fourth branch. It flows through the resin flow path 81e.
また、UDテープ製造工程にて製造された2本のUDテープ100は、第二押出ダイス8の材料供給面8aに開口した第一UDテープ導入流路81f及び第二UDテープ導入流路81gにそれぞれ導入される。
In addition, the two UD tapes 100 manufactured in the UD tape manufacturing process are provided in the first UD tape introduction flow path 81f and the second UD tape introduction flow path 81g opened in the material supply surface 8a of the second extrusion die 8. Each is introduced.
第一分岐樹脂流路81bを流れる熱可塑性樹脂Sは、第一分岐樹脂流路81bから第一接続流路82aに流れる。第二分岐樹脂流路81cを流れる熱可塑性樹脂Sは、第二分岐樹脂流路81cから第一合流流路82cに流れる。第三分岐樹脂流路81dを流れる熱可塑性樹脂Sは、第三分岐樹脂流路81dから第二合流流路82dに流れる。第四分岐樹脂流路81eを流れる熱可塑性樹脂Sは、第四分岐樹脂流路81eから第二接続流路82bに流れる。
The thermoplastic resin S flowing through the first branch resin flow path 81b flows from the first branch resin flow path 81b to the first connection flow path 82a. The thermoplastic resin S flowing through the second branch resin flow path 81c flows from the second branch resin flow path 81c to the first merge flow path 82c. The thermoplastic resin S flowing through the third branch resin flow path 81d flows from the third branch resin flow path 81d to the second merge flow path 82d. The thermoplastic resin S flowing through the fourth branch resin flow path 81e flows from the fourth branch resin flow path 81e to the second connection flow path 82b.
また、第一UDテープ導入流路81fに導入されたUDテープ100は、第一UDテープ導入流路81fから第一合流流路82cに流れる。第一合流流路82cには、上述したように第二分岐樹脂流路81cからの溶融した熱可塑性樹脂Sも流れる。従って、第一合流流路82cにて、図7に示すように、第一分岐樹脂流路81bからの溶融した熱可塑性樹脂Sと第一UDテープ導入流路81fからのUDテープ100が合流する。このとき、第一合流流路82c内にて、UDテープ100は溶融した熱可塑性樹脂Sの表面に沿って流れる。
Further, the UD tape 100 introduced into the first UD tape introduction flow path 81f flows from the first UD tape introduction flow path 81f to the first merge flow path 82c. As described above, the molten thermoplastic resin S from the second branch resin flow path 81c also flows through the first merge flow path 82c. Therefore, as shown in FIG. 7, the molten thermoplastic resin S from the first branch resin flow path 81b and the UD tape 100 from the first UD tape introduction flow path 81f merge in the first merge flow path 82c. . At this time, the UD tape 100 flows along the surface of the molten thermoplastic resin S in the first merge channel 82c.
また、第二UDテープ導入流路81gに導入されたUDテープ100は、第二UDテープ導入流路81gから第二合流流路82dに流れる。第二合流流路82dには、上述したように第三分岐樹脂流路81dからの溶融した熱可塑性樹脂Sも流れる。従って、第二合流流路82dにて、図7に示すように、第三分岐樹脂流路81dからの溶融した熱可塑性樹脂Sと第二UDテープ導入流路81gからのUDテープ100が合流する。このとき、第二合流流路82d内にて、UDテープ100は溶融した熱可塑性樹脂Sの表面に沿って流れる。
Also, the UD tape 100 introduced into the second UD tape introduction flow path 81g flows from the second UD tape introduction flow path 81g to the second merge flow path 82d. As described above, the molten thermoplastic resin S from the third branch resin flow channel 81d also flows through the second merge flow channel 82d. Accordingly, as shown in FIG. 7, the molten thermoplastic resin S from the third branch resin flow path 81d and the UD tape 100 from the second UD tape introduction flow path 81g merge in the second merge flow path 82d. . At this time, the UD tape 100 flows along the surface of the molten thermoplastic resin S in the second merge channel 82d.
第一接続流路82aを流れる熱可塑性樹脂Sは、第一接続流路82aから第三合流流路83aに流れる。また、第一合流流路82cを流れる熱可塑性樹脂S及びUDテープ100は、第一合流流路82cから第三合流流路83aに流れる。従って、第三合流流路83aにて、図7に示すように、第一接続流路82aからの熱可塑性樹脂Sと、第一合流流路82cからの熱可塑性樹脂S及びUDテープ100が合流する。このとき、第三合流流路83a内にて、第一接続流路82aからの熱可塑性樹脂Sが、第一合流流路82cからのUDテープ100の表面を覆う。このため、第三合流流路83a内のUDテープ100は、熱可塑性樹脂Sの内部に配置する。また、第三合流流路83a内にて、UDテープ100は、合流した熱可塑性樹脂Sの樹脂圧を受ける。この樹脂圧によって、UDテープ100が熱可塑性樹脂Sに接合される。
The thermoplastic resin S flowing through the first connection flow channel 82a flows from the first connection flow channel 82a to the third merge flow channel 83a. Further, the thermoplastic resin S and the UD tape 100 flowing through the first merge channel 82c flow from the first merge channel 82c to the third merge channel 83a. Therefore, as shown in FIG. 7, the thermoplastic resin S from the first connection flow channel 82 a, the thermoplastic resin S from the first merge flow channel 82 c, and the UD tape 100 merge in the third merge flow channel 83 a. To do. At this time, the thermoplastic resin S from the first connection channel 82a covers the surface of the UD tape 100 from the first junction channel 82c in the third junction channel 83a. For this reason, the UD tape 100 in the third merge channel 83a is disposed inside the thermoplastic resin S. Further, the UD tape 100 receives the resin pressure of the joined thermoplastic resin S in the third merge channel 83a. The UD tape 100 is bonded to the thermoplastic resin S by this resin pressure.
また、第二接続流路82bを流れる熱可塑性樹脂Sは、第二接続流路82bから第四合流流路83bに流れる。また、第二合流流路82dを流れる熱可塑性樹脂S及びUDテープ100は、第二合流流路82dから第四合流流路83bに流れる。従って、第四合流流路83bにて、図7に示すように、第二接続流路82bからの熱可塑性樹脂Sと、第二合流流路82dからの熱可塑性樹脂S及びUDテープ100が合流する。このとき、第四合流流路83b内にて、第二接続流路82bからの熱可塑性樹脂が、第二合流流路82dからのUDテープ100の表面を覆う。このため、第四合流流路83b内のUDテープ100は、熱可塑性樹脂Sの内部に配置する。また、第四合流流路83b内にて、UDテープ100は、合流した熱可塑性樹脂Sの樹脂圧を受ける。この樹脂圧によって、UDテープ100が熱可塑性樹脂Sに接合される。
Further, the thermoplastic resin S flowing through the second connection flow path 82b flows from the second connection flow path 82b to the fourth merge flow path 83b. Further, the thermoplastic resin S and the UD tape 100 flowing through the second merge channel 82d flow from the second merge channel 82d to the fourth merge channel 83b. Accordingly, as shown in FIG. 7, the thermoplastic resin S from the second connection channel 82b and the thermoplastic resin S and the UD tape 100 from the second junction channel 82d are merged in the fourth merge channel 83b. To do. At this time, in the fourth merge channel 83b, the thermoplastic resin from the second connection channel 82b covers the surface of the UD tape 100 from the second merge channel 82d. For this reason, the UD tape 100 in the fourth merge channel 83b is disposed inside the thermoplastic resin S. Moreover, the UD tape 100 receives the resin pressure of the joined thermoplastic resin S in the fourth merge channel 83b. The UD tape 100 is bonded to the thermoplastic resin S by this resin pressure.
第三合流流路83aを流れる熱可塑性樹脂S及び熱可塑性樹脂Sに接合されたUDテープ100は、第三合流流路83aの他方の端部開口を通って第二押出ダイス8から排出される。第三合流流路83aの他方の端部開口を通って第二押出ダイス8から排出された熱可塑性樹脂S及びUDテープ100により、繊維強化樹脂成形体10の左側壁部13が形成される。また、第四合流流路83bを流れる熱可塑性樹脂S及び熱可塑性樹脂Sに接合されたUDテープ100は、第四合流流路83bの他方の端部開口を通って第二押出ダイス8から排出される。第四合流流路83bの他方の端部開口を通って第二押出ダイス8から排出された熱可塑性樹脂S及びUDテープ100により、繊維強化樹脂成形体10の右側壁部14が構成される。なお、繊維強化樹脂成形体10の上側壁部11、下側壁部12、及び中間壁部15は、樹脂導入流路81aから分岐している図6、図7において図示しない分岐流路を経由して第二押出ダイス8から排出された熱可塑性樹脂により、それぞれ構成される。このようにして、第二押出ダイス8内を通過する熱可塑性樹脂Sが分岐及び合流することで、熱可塑性樹脂Sが所定の断面形状に成形される。また、第二押出ダイス8内で、UDテープ100が熱可塑性樹脂Sと合流するとともに、合流した熱可塑性樹脂の樹脂圧により、所定断面形状に成形された熱可塑性樹脂Sの所定領域に接合される。そして、所定領域に接合されたUDテープ100とともに、所定断面形状の熱可塑性樹脂Sが第二押出ダイス8から排出される。
The thermoplastic resin S flowing through the third merge channel 83a and the UD tape 100 joined to the thermoplastic resin S are discharged from the second extrusion die 8 through the other end opening of the third merge channel 83a. . The left side wall 13 of the fiber reinforced resin molded body 10 is formed by the thermoplastic resin S and the UD tape 100 discharged from the second extrusion die 8 through the other end opening of the third merge channel 83a. Further, the thermoplastic resin S flowing through the fourth merge channel 83b and the UD tape 100 joined to the thermoplastic resin S are discharged from the second extrusion die 8 through the other end opening of the fourth merge channel 83b. Is done. The right side wall portion 14 of the fiber-reinforced resin molded body 10 is configured by the thermoplastic resin S and the UD tape 100 discharged from the second extrusion die 8 through the other end opening of the fourth merge channel 83b. In addition, the upper side wall part 11, the lower side wall part 12, and the intermediate wall part 15 of the fiber reinforced resin molded body 10 are routed through a branch channel (not shown in FIGS. 6 and 7) branched from the resin introduction channel 81a. And the thermoplastic resin discharged from the second extrusion die 8. In this way, the thermoplastic resin S passing through the second extrusion die 8 is branched and merged, so that the thermoplastic resin S is formed into a predetermined cross-sectional shape. Further, in the second extrusion die 8, the UD tape 100 merges with the thermoplastic resin S and is joined to a predetermined region of the thermoplastic resin S molded into a predetermined cross-sectional shape by the resin pressure of the merged thermoplastic resin. The Then, the thermoplastic resin S having a predetermined cross-sectional shape is discharged from the second extrusion die 8 together with the UD tape 100 bonded to the predetermined region.
このように、本実施形態に係る繊維強化樹脂成形体10の製造方法は、UDテープ製造工程(第一工程)と、押出成形工程(第二工程)とを含む。UDテープ製造工程では、UDテープ100が製造される。押出成形工程では、UDテープ製造工程にて製造されたUDテープ100が第二押出装置7から排出された溶融した熱可塑性樹脂Sと共に第二押出ダイス8に導入される。そして、第二押出ダイス8内で、熱可塑性樹脂Sの断面形状が所定の断面形状に成形されるとともに、UDテープ100と熱可塑性樹脂Sが合流し、UDテープ100と合流した熱可塑性樹脂Sの樹脂圧によってUDテープ100が所定の断面形状に成形された熱可塑性樹脂Sの所定領域(本実施形態では左側壁部13の内部及び右側壁部14の内部)に接合される。そして、所定領域に接合されたUDテープ100とともに所定の断面形状に成形された熱可塑性樹脂Sが第二押出ダイス8から排出されることにより、繊維強化樹脂成形体10が押出成形される。
Thus, the method for manufacturing the fiber-reinforced resin molded body 10 according to the present embodiment includes the UD tape manufacturing process (first process) and the extrusion molding process (second process). In the UD tape manufacturing process, the UD tape 100 is manufactured. In the extrusion process, the UD tape 100 manufactured in the UD tape manufacturing process is introduced into the second extrusion die 8 together with the molten thermoplastic resin S discharged from the second extrusion device 7. And in the 2nd extrusion die 8, while the cross-sectional shape of the thermoplastic resin S is shape | molded by the predetermined | prescribed cross-sectional shape, the UD tape 100 and the thermoplastic resin S merge, and the thermoplastic resin S which merged with the UD tape 100 With this resin pressure, the UD tape 100 is joined to a predetermined region (in the present embodiment, inside the left side wall 13 and inside the right side wall 14) of the thermoplastic resin S having a predetermined cross-sectional shape. And the thermoplastic resin S shape | molded by the predetermined | prescribed cross-sectional shape with the UD tape 100 joined to the predetermined area | region is discharged | emitted from the 2nd extrusion die 8, and the fiber reinforced resin molded object 10 is extrusion-molded.
本実施形態によれば、UDテープ製造工程にてUDテープ100が製造され、UDテープ製造工程に引き続いて行われる押出成形工程にて、UDテープ100が溶融した熱可塑性樹脂Sと共に第二押出ダイス8に導入される。そして、この第二押出ダイス8を用いて繊維強化樹脂成形体10が押出成形により製造される。つまり、本実施形態においては、繊維強化樹脂成形体10を押出成形するため、その前に製造されたUDテープ100をそのまま押出成形に用いる押出ダイス(第二押出ダイス8)に熱可塑性樹脂Sとともに導入させることができる。これにより、UDテープ100の製造とそれを用いた繊維強化樹脂成形体10の製造とを連続的に行うことができる。このため、押出成形工程前に、UDテープ100を軟化させるためにこれを予熱する工程を要しない。よって、従来のようにUDテープ100を加熱(予熱)するための専用の工程を設ける必要がなく、それ故に、従来に比べて少ない工程で、繊維強化樹脂成形体10を製造することができる。
According to this embodiment, the UD tape 100 is manufactured in the UD tape manufacturing process, and the second extrusion die together with the thermoplastic resin S in which the UD tape 100 is melted in the extrusion process performed following the UD tape manufacturing process. 8 is introduced. And the fiber reinforced resin molding 10 is manufactured by extrusion molding using this second extrusion die 8. That is, in this embodiment, since the fiber reinforced resin molding 10 is extruded, the UD tape 100 manufactured before that is used as it is for extrusion molding (second extrusion die 8) together with the thermoplastic resin S. Can be introduced. Thereby, manufacture of the UD tape 100 and manufacture of the fiber reinforced resin molding 10 using the same can be performed continuously. For this reason, the process of preheating this in order to soften the UD tape 100 is not required before an extrusion molding process. Therefore, there is no need to provide a dedicated process for heating (preheating) the UD tape 100 as in the prior art, and therefore the fiber reinforced resin molded body 10 can be manufactured with fewer processes than in the prior art.
また、UDテープ100は、第二押出ダイス8内で熱可塑性樹脂Sに接合されるため、両者の接合時に外部から気泡が巻き込まれにくい。また、仮に気泡が巻き込まれた場合であっても、UDテープ100と熱可塑性樹脂Sとの接合時にUDテープ100に作用する熱可塑性樹脂Sの樹脂圧によって、巻き込まれた気泡を排除することができる。そのため、UDテープ100と熱可塑性樹脂Sとの接合界面でのボイドの発生を効果的に抑制することができる。
Further, since the UD tape 100 is joined to the thermoplastic resin S in the second extrusion die 8, air bubbles are hardly caught from the outside when the two are joined. Further, even if bubbles are entrained, the entrained bubbles can be eliminated by the resin pressure of the thermoplastic resin S acting on the UD tape 100 when the UD tape 100 and the thermoplastic resin S are joined. it can. Therefore, generation of voids at the bonding interface between the UD tape 100 and the thermoplastic resin S can be effectively suppressed.
また、本実施形態におけるUDテープ製造工程は、繊維束に熱可塑性樹脂を塗布する塗布工程(エマルジョン塗布工程及び乾燥工程)と、塗布工程にて熱可塑性樹脂が塗布された繊維束と、追加樹脂Rとしての溶融した熱可塑性樹脂とを共に第一押出ダイス6に導入し、第一押出ダイス6内で熱可塑性樹脂が塗布された繊維束に追加樹脂Rを所定の樹脂圧で押し付けることにより、繊維束内に熱可塑性樹脂を含浸させる押出含浸工程と、を含む。これによれば、厚膜状のUDテープ100を製造することができる。こうして製造された厚膜状のUDテープ100を用いて繊維強化樹脂成形体10を製造することにより、補強効果の高い繊維強化樹脂成形体を得ることができる。
Moreover, the UD tape manufacturing process in this embodiment includes an application process (emulsion application process and a drying process) for applying a thermoplastic resin to a fiber bundle, a fiber bundle to which a thermoplastic resin is applied in the application process, and an additional resin. By introducing the molten thermoplastic resin as R together into the first extrusion die 6 and pressing the additional resin R against the fiber bundle coated with the thermoplastic resin in the first extrusion die 6 at a predetermined resin pressure, And an extrusion impregnation step of impregnating the fiber bundle with a thermoplastic resin. According to this, the thick film-like UD tape 100 can be manufactured. By manufacturing the fiber reinforced resin molded body 10 using the thick film-like UD tape 100 manufactured in this way, a fiber reinforced resin molded body having a high reinforcing effect can be obtained.
以上、本発明の実施形態について説明したが、本発明は、上記実施形態に限定されるべきものではない。例えば、上記第二実施形態では、UDテープ製造工程と押出成形工程とがそれぞれ独立して連続的に実施されているが、UDテープ製造工程の一部を押出成形工程に組み込むようにしてもよい。例えば、UDテープ製造工程中の押出含浸工程を、押出成形工程に組み込んでもよい。つまり、押出含浸工程が、押出成形工程と同時に実施されてもよい。この場合、押出含浸工程に用いられる第一押出ダイス6と、押出成形工程に用いられる第二押出ダイス8が共通の1個の押出ダイスであるとよい。これによれば、厚膜状のUDテープにより補強された繊維強化樹脂成形体を、一つの押出ダイスを用いて簡単に製造することができる。さらにこの場合、押出含浸工程で用いられる熱可塑性樹脂(追加樹脂R)と、押出成形工程で用いられる熱可塑性樹脂Sが同じであるとよい。
As mentioned above, although embodiment of this invention was described, this invention should not be limited to the said embodiment. For example, in the second embodiment, the UD tape manufacturing process and the extrusion molding process are performed independently and continuously, but a part of the UD tape manufacturing process may be incorporated into the extrusion molding process. . For example, an extrusion impregnation process in the UD tape manufacturing process may be incorporated into the extrusion process. That is, the extrusion impregnation step may be performed simultaneously with the extrusion molding step. In this case, the first extrusion die 6 used in the extrusion impregnation step and the second extrusion die 8 used in the extrusion molding step may be one common extrusion die. According to this, the fiber reinforced resin molding reinforced with the thick film-like UD tape can be easily manufactured using one extrusion die. Furthermore, in this case, the thermoplastic resin (additional resin R) used in the extrusion impregnation step and the thermoplastic resin S used in the extrusion molding step may be the same.
図9は、第一押出ダイス6と第二押出ダイス8とが同一の押出ダイス9により構成され、且つ、追加樹脂Rと押出成形工程で用いられる熱可塑性樹脂Sが同じである場合における、製造ラインを示す図である。図9に示す例によれば、2つの別個の製造ラインにて、開繊工程、塗布工程(エマルジョン塗布工程及び乾燥工程)を経て、熱可塑性樹脂が塗布された繊維束F4がそれぞれ製造される。
FIG. 9 shows a case where the first extrusion die 6 and the second extrusion die 8 are constituted by the same extrusion die 9 and the additional resin R and the thermoplastic resin S used in the extrusion molding step are the same. It is a figure which shows a line. According to the example shown in FIG. 9, the fiber bundles F4 coated with the thermoplastic resin are respectively produced through the fiber opening process and the coating process (emulsion coating process and drying process) in two separate production lines. .
また、押出成形工程では、塗布工程にて熱可塑性樹脂が塗布された2本の繊維束F4が、第二実施形態で示した第二押出装置7に相当する押出装置7Aからの溶融した熱可塑性樹脂と共に押出ダイス9に導入される。押出ダイス9内では、導入された熱可塑性樹脂の断面形状が所定の断面形状に成形されるとともに、繊維束F4と熱可塑性樹脂とが合流する。押出ダイス9内で繊維束F4と合流した熱可塑性樹脂の樹脂圧によって、繊維束F4内に熱可塑性樹脂が含浸されてUDテープ100が成形されるとともに、成形されたUDテープ100が所定の断面形状に成形された熱可塑性樹脂の所定領域に接合される。そして、押出ダイス9から、所定領域にUDテープ100が接合された所定断面形状の熱可塑性樹脂が排出されることにより、繊維強化樹脂成形体10が押出成形される。このようにして、1つの押出ダイスを用いてより簡単に、繊維強化樹脂成形体10を製造することができる。
In the extrusion molding process, the two fiber bundles F4 coated with the thermoplastic resin in the coating process are melted thermoplastic from the extrusion apparatus 7A corresponding to the second extrusion apparatus 7 shown in the second embodiment. It is introduced into the extrusion die 9 together with the resin. In the extrusion die 9, the introduced thermoplastic resin has a cross-sectional shape formed into a predetermined cross-sectional shape, and the fiber bundle F4 and the thermoplastic resin merge. The fiber bundle F4 is impregnated with the thermoplastic resin by the resin pressure of the thermoplastic resin merged with the fiber bundle F4 in the extrusion die 9, and the UD tape 100 is molded, and the molded UD tape 100 has a predetermined cross section. It joins to the predetermined area | region of the thermoplastic resin shape | molded by the shape. And the fiber reinforced resin molding 10 is extrusion-molded by discharging | emitting the thermoplastic resin of the predetermined cross-sectional shape by which the UD tape 100 was joined to the predetermined area | region from the extrusion die 9. FIG. In this way, the fiber-reinforced resin molded body 10 can be more easily manufactured using one extrusion die.
また、上記第二実施形態では、2本のUDテープ100を熱可塑性樹脂Sとともに第二押出ダイス8に導入する例を示したが、第二押出ダイス8に導入されるUDテープの本数は限定されない。図10は、4本のUDテープ100が熱可塑性樹脂Sとともに第二押出ダイス8に導入される例を示す図である。この例によれば、第二押出ダイス8から、断面形状がロ字状の繊維強化樹脂成形体10Aが製造される。そして、繊維強化樹脂成形体10Aの断面を構成する4つの側壁部(上側壁部11A,下側壁部12A,左側壁部13A,右側壁部14A)の内部に、長手方向に沿ってそれぞれUDテープ100が配設されているとともに、それぞれのUDテープ100が各側壁部内で熱可塑性樹脂に接合される。
In the second embodiment, the example in which the two UD tapes 100 are introduced into the second extrusion die 8 together with the thermoplastic resin S has been shown. However, the number of UD tapes introduced into the second extrusion die 8 is limited. Not. FIG. 10 is a diagram showing an example in which four UD tapes 100 are introduced into the second extrusion die 8 together with the thermoplastic resin S. According to this example, a fiber reinforced resin molded body 10 </ b> A having a square cross section is manufactured from the second extrusion die 8. And each of the four side walls (upper side wall part 11A, lower side wall part 12A, left side wall part 13A, right side wall part 14A) constituting the cross section of the fiber reinforced resin molded body 10A, the UD tape along the longitudinal direction. 100 is disposed, and each UD tape 100 is joined to the thermoplastic resin in each side wall portion.
また、繊維強化樹脂成形体10の断面形状は、上記実施形態のような断面形状に限定されない。例えば、平板状、L字状、等の断面形状であってもよい。このように、本発明は、その趣旨を逸脱しない限りにおいて、変形可能である。
Further, the cross-sectional shape of the fiber-reinforced resin molded body 10 is not limited to the cross-sectional shape as in the above embodiment. For example, a cross-sectional shape such as a flat plate shape or an L shape may be used. Thus, the present invention can be modified without departing from the gist thereof.
Claims (9)
- 一方向に引き揃えられた複数の繊維により構成される繊維束に樹脂が含浸されてなる一方向繊維強化部材を製造する第一工程と、
前記第一工程にて製造された前記一方向繊維強化部材を溶融した熱可塑性樹脂と共に押出ダイスに導入し、前記押出ダイス内で、前記熱可塑性樹脂の断面形状を所定の断面形状に成形するとともに、前記一方向繊維強化部材と前熱可塑性樹脂とを合流させ、前記一方向繊維強化部材と合流した前記熱可塑性樹脂の樹脂圧によって前記一方向繊維強化部材を前記所定の断面形状に成形された前記熱可塑性樹脂の所定領域に接合し、前記所定領域に接合された前記一方向繊維強化部材とともに前記所定の断面形状に成形された前記熱可塑性樹脂を前記押出ダイスから排出することにより、前記繊維強化樹脂成形体を押出成形する第二工程と、
を含む、
繊維強化樹脂成形体の製造方法。 A first step of producing a unidirectional fiber reinforced member formed by impregnating a fiber bundle composed of a plurality of fibers aligned in one direction with a resin;
The unidirectional fiber reinforced member produced in the first step is introduced into an extrusion die together with a molten thermoplastic resin, and the cross-sectional shape of the thermoplastic resin is molded into a predetermined cross-sectional shape in the extrusion die. The unidirectional fiber reinforced member and the pre-thermoplastic resin are merged, and the unidirectional fiber reinforced member is molded into the predetermined cross-sectional shape by the resin pressure of the thermoplastic resin merged with the unidirectional fiber reinforced member. By joining the predetermined region of the thermoplastic resin, and discharging the thermoplastic resin formed into the predetermined cross-sectional shape together with the unidirectional fiber reinforced member joined to the predetermined region from the extrusion die, the fiber A second step of extruding the reinforced resin molding,
including,
A method for producing a fiber-reinforced resin molded body. - 請求項1に記載の繊維強化樹脂成形体の製造方法において、
前記第一工程は、
前記繊維束に熱可塑性樹脂を塗布する塗布工程と、
前記塗布工程にて熱可塑性樹脂が塗布された前記繊維束と、追加樹脂としての溶融した熱可塑性樹脂とを共に押出ダイスに導入し、前記押出ダイス内で前記熱可塑性樹脂が塗布された前記繊維束に前記追加樹脂を所定の樹脂圧で押し付けることにより、前記繊維束内に熱可塑性樹脂を含浸させる押出含浸工程と、
を含む、
繊維強化樹脂成形体の製造方法。 In the manufacturing method of the fiber reinforced resin molding of Claim 1,
The first step includes
An application step of applying a thermoplastic resin to the fiber bundle;
The fiber bundle coated with the thermoplastic resin in the coating step and the molten thermoplastic resin as an additional resin are introduced into an extrusion die, and the fiber coated with the thermoplastic resin in the extrusion die. An extrusion impregnation step of impregnating the fiber bundle with a thermoplastic resin by pressing the additional resin against the bundle at a predetermined resin pressure;
including,
A method for producing a fiber-reinforced resin molded body. - 請求項2に記載の繊維強化樹脂成形体の製造方法において、
前記押出含浸工程が、前記第二工程と同時に実施される、
繊維強化樹脂成形体の製造方法。 In the manufacturing method of the fiber reinforced resin molding of Claim 2,
The extrusion impregnation step is performed simultaneously with the second step;
A method for producing a fiber-reinforced resin molded body. - 請求項2又は3に記載の繊維強化樹脂成形体の製造方法において、
前記押出含侵工程に用いられる前記押出ダイスと、前記第二工程にて用いられる前記押出ダイスが、共通の押出ダイスである、
繊維強化樹脂成形体の製造方法。 In the manufacturing method of the fiber reinforced resin molding of Claim 2 or 3,
The extrusion die used in the extrusion impregnation step and the extrusion die used in the second step are common extrusion dies.
A method for producing a fiber-reinforced resin molded body. - 請求項2乃至4のいずれか1項に記載の繊維強化樹脂成形体の製造方法において、
前記追加樹脂と、前記第二工程で用いられる熱可塑性樹脂が同じ材質の熱可塑性樹脂である、
繊維強化樹脂成形体の製造方法。 In the manufacturing method of the fiber reinforced resin molding of any one of Claim 2 thru | or 4,
The additional resin and the thermoplastic resin used in the second step are thermoplastic resins of the same material,
A method for producing a fiber-reinforced resin molded body. - 請求項2乃至5のいずれか1項に記載の繊維強化樹脂成形体の製造方法において、
前記追加樹脂は、前記塗布工程にて前記繊維束に塗布される熱可塑性樹脂と同じ材質の熱可塑性樹脂である、
繊維強化樹脂成形体の製造方法。 In the manufacturing method of the fiber reinforced resin molding of any one of Claims 2 thru | or 5,
The additional resin is a thermoplastic resin of the same material as the thermoplastic resin applied to the fiber bundle in the application step.
A method for producing a fiber-reinforced resin molded body. - 請求項1乃至6のいずれか1項に記載の繊維強化樹脂成形体の製造方法において、
前記第二工程で用いられる熱可塑性樹脂に、強化繊維が含有されている、
繊維強化樹脂成形体の製造方法。 In the manufacturing method of the fiber reinforced resin molding of any one of Claims 1 thru | or 6,
Reinforcing fibers are contained in the thermoplastic resin used in the second step,
A method for producing a fiber-reinforced resin molded body. - 一方向に引き揃えられた複数の繊維により構成される繊維束に熱可塑性樹脂を塗布する塗布工程と、
前記塗布工程にて熱可塑性樹脂が塗布された前記繊維束と、追加樹脂としての溶融した熱可塑性樹脂とを共に押出ダイスに導入し、前記押出ダイス内で前記熱可塑性樹脂が塗布された前記繊維束に前記追加樹脂を所定の樹脂圧で押し付けることにより、前記繊維束内に熱可塑性樹脂を含浸させる押出含浸工程と、
を含む、
一方向繊維強化部材の製造方法。 An application step of applying a thermoplastic resin to a fiber bundle composed of a plurality of fibers aligned in one direction;
The fiber bundle coated with the thermoplastic resin in the coating step and the molten thermoplastic resin as an additional resin are introduced into an extrusion die, and the fiber coated with the thermoplastic resin in the extrusion die. An extrusion impregnation step of impregnating the fiber bundle with a thermoplastic resin by pressing the additional resin against the bundle at a predetermined resin pressure;
including,
A method for producing a unidirectional fiber reinforced member. - 請求項8に記載の一方向繊維強化部材の製造方法において、
前記塗布工程は、熱可塑性樹脂粒子が水に分散されてなる水分散性エマルジョンを、前記繊維束に塗布するエマルジョン塗布工程と、
前記水分散性エマルジョンが塗布された前記繊維束を乾燥させる乾燥工程と、
を含む、
一方向繊維強化部材の製造方法。 In the manufacturing method of the unidirectional fiber reinforced member according to claim 8,
The coating step includes an emulsion coating step in which a water-dispersible emulsion in which thermoplastic resin particles are dispersed in water is coated on the fiber bundle,
A drying step of drying the fiber bundle to which the water-dispersible emulsion is applied;
including,
A method for producing a unidirectional fiber reinforced member.
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JPH01317751A (en) * | 1988-05-09 | 1989-12-22 | Soc Atochem | Manufacture of long-fiber reinforced thermoplastic resin |
JPH02214639A (en) * | 1989-02-14 | 1990-08-27 | Sekisui Chem Co Ltd | Manufacture of continuous composite molded material |
JPH0550517A (en) * | 1991-08-26 | 1993-03-02 | Polyplastics Co | Fiber reinforced thermoplastic resin structure and manufacture thereof |
JP2002518201A (en) * | 1998-06-19 | 2002-06-25 | ティコナ・セルストラン・インコーポレーテッド | Coated long fiber reinforced composite material structure and method for producing the same |
JP2003191236A (en) * | 2001-12-25 | 2003-07-08 | Asahi Fiber Glass Co Ltd | Glass fiber for long fiber reinforced thermoplastic resin molding material and long fiber reinforced thermoplastic resin molding material using the glass fiber |
JP2006117839A (en) * | 2004-10-22 | 2006-05-11 | Idemitsu Kosan Co Ltd | Modified polyolefin-based resin for treating glass fiber, surface-treated glass fiber and fiber-reinforced polyolefin-based resin |
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JPH01317751A (en) * | 1988-05-09 | 1989-12-22 | Soc Atochem | Manufacture of long-fiber reinforced thermoplastic resin |
JPH02214639A (en) * | 1989-02-14 | 1990-08-27 | Sekisui Chem Co Ltd | Manufacture of continuous composite molded material |
JPH0550517A (en) * | 1991-08-26 | 1993-03-02 | Polyplastics Co | Fiber reinforced thermoplastic resin structure and manufacture thereof |
JP2002518201A (en) * | 1998-06-19 | 2002-06-25 | ティコナ・セルストラン・インコーポレーテッド | Coated long fiber reinforced composite material structure and method for producing the same |
JP2003191236A (en) * | 2001-12-25 | 2003-07-08 | Asahi Fiber Glass Co Ltd | Glass fiber for long fiber reinforced thermoplastic resin molding material and long fiber reinforced thermoplastic resin molding material using the glass fiber |
JP2006117839A (en) * | 2004-10-22 | 2006-05-11 | Idemitsu Kosan Co Ltd | Modified polyolefin-based resin for treating glass fiber, surface-treated glass fiber and fiber-reinforced polyolefin-based resin |
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