JP2012246391A - Method of impregnating reinforcing fiber with resin and impregnation device - Google Patents
Method of impregnating reinforcing fiber with resin and impregnation device Download PDFInfo
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本発明は、繊維強化複合材料に使用される強化繊維への樹脂含浸方法及びそのための含浸装置に関し、特に長繊維の糸条（トウ）に樹脂を含浸してトウプリプレグを製造する方法及びそのための装置に関する。 The present invention relates to a resin impregnation method for a reinforcing fiber used in a fiber reinforced composite material and an impregnation apparatus therefor, and more particularly, a method for producing a tow prepreg by impregnating a resin into a long fiber thread (tow) and for the same Relates to the device.
炭素繊維、ガラス繊維、芳香族ポリアミド繊維等の強化繊維とエポキシ樹脂からなる複合材料は、比強度、比弾性率に優れているため、スポーツ用途、航空機等の構造材料、土木材料、ガスボンベなどの圧力容器等の分野に広く使用されている。 Composite materials consisting of reinforced fibers such as carbon fiber, glass fiber, aromatic polyamide fiber and epoxy resin are excellent in specific strength and specific elastic modulus, so it can be used for sports applications, structural materials for aircraft, civil engineering materials, gas cylinders, etc. Widely used in fields such as pressure vessels.
これらの複合材料を製造するため、強化繊維をそのまま加工用材料として用いる場合もあるが、多くの場合は樹脂を含浸して織物プリプレグ、チョップドファイバープリミックス、シートプリプレグ、トウプリプレグ等の中間加工材料として使用される場合が多い。 In order to produce these composite materials, reinforcing fibers may be used as processing materials as they are, but in many cases, they are impregnated with resin and used as intermediate processing materials such as woven prepregs, chopped fiber prepregs, sheet prepregs, and tow prepregs. Often used as.
いずれの場合においても最終製品である複合材料成形品の製造コストを低減させ、一方では品質を高くすることが望まれている。特に複合材料成形品の繊維とマトリックス樹脂との割合をコントロールすることは、複合材料成形品の強度、弾性率、熱膨張率等の物性を高くし、品質の安定した製品を得る上で極めて重要なことである。 In any case, it is desired to reduce the manufacturing cost of the composite material molded product, which is the final product, while increasing the quality. In particular, controlling the ratio of fibers and matrix resin in composite material molded products is extremely important for improving the properties of composite material molded products such as strength, elastic modulus, and coefficient of thermal expansion, and obtaining products with stable quality. It is a thing.
トウプリプレグは、ＦＷ(フィラメントワインディング)成形、組み紐、織物等の製造に用いられており、既存の方法に比べトウプリプレグを用いると、毛羽立ちが少なく、歩留りが良いことによる作業効率の高さと、樹脂含浸工程が不要になること等によって、製造コストを低減することが可能である。 Toe prepregs are used in the manufacture of FW (filament winding) molding, braided braids, woven fabrics, etc. When using toe prepregs, compared to existing methods, there is less fuzz and a higher yield, resulting in higher working efficiency and resin. Manufacturing costs can be reduced by eliminating the impregnation step.
トウプリプレグを製造するには、トウを樹脂を溜めたレジンバスに潜らせて、その後、ニップロール等で余剰の樹脂を搾り取るレジンバス法が知られているが、余剰樹脂の搾り取りに際して強化繊維、特に炭素繊維では毛羽立ちの発生が問題となる。 In order to manufacture a tow prepreg, a resin bath method is known in which a tow is immersed in a resin bath in which a resin is stored, and then a surplus resin is squeezed with a nip roll or the like. In fibers, the occurrence of fuzz becomes a problem.
これに対してロール転写法は、所定厚みの樹脂層をロール表面に形成し、この樹脂層を有するロールにトウを接触させて転写する方法で、毛羽立ちの発生が抑制される。図３は、従来のロール転写法に用いる含浸装置を説明する概念図である。炭素繊維２５へ含浸させる樹脂２２を溜める樹脂槽２１内に下部を浸漬させながら含浸ロール２３が回動している。そして、樹脂槽２１の樹脂液面より上方の位置で、含浸ロール２３の上に均一な厚みの樹脂膜を形成する膜厚調整用ドクターブレード２４が設けられている。また図中２６，２７は、含浸ロール２３表面に炭素繊維２５を接触させ樹脂を含浸させるガイドロール等の炭素繊維案内手段である。２５’は樹脂含浸後の炭素繊維を示す。 On the other hand, the roll transfer method is a method in which a resin layer having a predetermined thickness is formed on the roll surface and transferred by bringing the tow into contact with the roll having the resin layer, and generation of fuzz is suppressed. FIG. 3 is a conceptual diagram illustrating an impregnation apparatus used in a conventional roll transfer method. The impregnation roll 23 rotates while the lower part is immersed in the resin tank 21 in which the resin 22 to be impregnated into the carbon fiber 25 is stored. A film thickness adjusting doctor blade 24 for forming a resin film having a uniform thickness on the impregnation roll 23 is provided at a position above the resin liquid level in the resin tank 21. In the figure, reference numerals 26 and 27 denote carbon fiber guide means such as a guide roll for bringing the carbon fiber 25 into contact with the surface of the impregnation roll 23 and impregnating the resin. 25 'shows the carbon fiber after resin impregnation.
含浸ロール上で所定厚みに規制された樹脂層は、トウと接触してトウのロール当接面から対向面に向かって浸透するが、トウは常に一定の幅を維持していないことで経時的に樹脂含量の差違が生じることがある。図４の（ａ）はトウがよれた状態を示しており、このようなよれた部分は含浸ロールとトウとの当接面積が減少して樹脂含量が少なくなる場合がある。また、図４の（ｂ）では、トウの一部がつぶれて幅が広がってしまうと、樹脂含量がその幅の変動部分で多くなってしまう。さらに、含浸樹脂中には機械的強度を向上させるためのゴム粒子や、硬化反応が含浸ロール上で進行することを抑制するカプセル化した潜在硬化剤等の添加剤が含まれることがある。図５に示すように、樹脂中の液状成分３２は繊維３１の隙間を通って当接面から対向面への移動可能であるが、樹脂中の固形分３３は対向面への移動が困難であり、当接面側の濃度が高く、対向面側の濃度が低下しやすい。その結果、形成されたトウプリプレグの両面で機械的強度の差違や硬化反応速度の差違が発生する場合がある。 The resin layer regulated to a predetermined thickness on the impregnating roll comes into contact with the tow and penetrates from the roll contact surface of the tow toward the opposite surface, but the tow does not always maintain a constant width, so that Differences in resin content may occur. FIG. 4A shows a state in which the tow is twisted, and in such a twisted portion, the contact area between the impregnation roll and the tow may decrease and the resin content may decrease. Further, in FIG. 4B, when a part of the tow is crushed and the width is widened, the resin content is increased at the fluctuation portion of the width. Furthermore, the impregnating resin may contain additives such as rubber particles for improving the mechanical strength and an encapsulated latent curing agent that suppresses the progress of the curing reaction on the impregnating roll. As shown in FIG. 5, the liquid component 32 in the resin can move from the contact surface to the opposing surface through the gaps of the fibers 31, but the solid content 33 in the resin is difficult to move to the opposing surface. Yes, the density on the abutting surface side is high, and the density on the facing surface side tends to decrease. As a result, a difference in mechanical strength and a difference in curing reaction speed may occur on both sides of the formed tow prepreg.
本発明者は先に、トウの両面から均一に樹脂を含浸させる方法として、２つのノズルから所定量の樹脂をトウのそれぞれの面に供給する方法を提案している。このような方法によれば、添加剤を含む樹脂でもトウの両面から一定量の樹脂が供給されることで、機械的強度などの低下を抑制することができる（特許文献１）。 The inventor has previously proposed a method in which a predetermined amount of resin is supplied to each surface of the tow from two nozzles as a method for uniformly impregnating the resin from both surfaces of the tow. According to such a method, even if the resin contains an additive, a certain amount of resin is supplied from both sides of the tow, so that a decrease in mechanical strength or the like can be suppressed (Patent Document 1).
特許文献１における２つのノズルを用いる方法は確かに優れた方法であるが、このようなノズルを用いる方法は、ギアポンプ等の定量ポンプを用いて樹脂量を一定にする必要があることから、ロール転写法に比較して設備費やポンプのメンテナンス費がかかり、コストが上がってしまっていた。 The method using two nozzles in Patent Document 1 is certainly an excellent method, but the method using such a nozzle requires a constant amount of resin using a metering pump such as a gear pump. Compared to the transfer method, equipment costs and pump maintenance costs were incurred, raising costs.
そこで、高価な設備を必要としないロール転写法にて、トウ等の強化繊維に均等に樹脂を供給する装置及び樹脂含浸方法が望まれる。 Therefore, an apparatus and a resin impregnation method for supplying a resin evenly to reinforcing fibers such as tow by a roll transfer method that does not require expensive equipment are desired.
本発明者は、上記課題を解決するために鋭意検討した結果、ロール転写法では、トウと接触しない含浸ロールの表面にも所定の厚みに規制された樹脂が存在することに着目し、トウの接触部周囲の所定範囲の樹脂をトウと含浸ロールとの接触面以外の面に供給することで、トウに均等に樹脂を供給できることを見出した。 As a result of intensive studies to solve the above problems, the present inventor has paid attention to the fact that there is a resin regulated to a predetermined thickness on the surface of the impregnating roll that does not come into contact with the tow in the roll transfer method. It has been found that the resin can be evenly supplied to the tow by supplying a predetermined range of resin around the contact portion to a surface other than the contact surface between the tow and the impregnation roll.
すなわち、本発明の一実施形態によれば、
強化繊維に樹脂を含浸する装置であって、
樹脂を表面に保持し、回動する含浸ロールと、
含浸ロール表面に保持された樹脂を所定の厚みに規制する規制手段と、
前記規制手段を通過後の含浸ロール表面に強化繊維を案内し、含浸ロール表面に強化繊維を接触させて樹脂を転写し、転写後の強化繊維を含浸ロールから引き離す案内手段と、
前記含浸ロールと強化繊維との接触部において、前記強化繊維を囲み、該強化繊維の側方の含浸ロール表面の樹脂を所定範囲で掻き取り、強化繊維の含浸ロール接触面とは異なる部位に供給する樹脂供給手段と、
を有する前記装置が提供される。
That is, according to one embodiment of the present invention,
An apparatus for impregnating a reinforcing fiber with a resin,
An impregnating roll that holds and rotates the resin on the surface;
A regulating means for regulating the resin held on the surface of the impregnation roll to a predetermined thickness;
Guiding means for guiding the reinforcing fibers to the surface of the impregnating roll after passing through the regulating means, transferring the resin by bringing the reinforcing fibers into contact with the surface of the impregnating roll, and pulling the reinforcing fibers after the transfer away from the impregnating roll;
Surrounding the reinforcing fiber at the contact portion between the impregnating roll and the reinforcing fiber, scraping the resin on the surface of the impregnating roll on the side of the reinforcing fiber within a predetermined range, and supplying the resin to a different part from the impregnating roll contacting surface of the reinforcing fiber Resin supply means to perform,
There is provided the apparatus comprising:
また、本発明の別の実施形態によれば、
表面に所定の膜厚の樹脂層の形成された含浸ロールと強化繊維とを接触させ、樹脂を強化繊維に転写するロール転写により強化繊維に樹脂を含浸する方法であって、
前記強化繊維の側方で、該強化繊維と接触していない含浸ロール上の樹脂を所定量掻き取り、強化繊維の含浸ロール接触面とは異なる部位に供給することを特徴とする樹脂含浸方法が提供される。
Also, according to another embodiment of the present invention,
A method of impregnating a reinforcing fiber with a resin by roll transfer in which an impregnated roll having a resin layer having a predetermined film thickness formed on the surface is brought into contact with the reinforcing fiber and transferring the resin to the reinforcing fiber,
A resin impregnation method characterized by scraping a predetermined amount of resin on an impregnation roll that is not in contact with the reinforcing fiber at a side of the reinforcing fiber and supplying the resin to a site different from the impregnation roll contact surface of the reinforcing fiber. Provided.
本発明の実施形態に係る装置によれば、トウなどの強化繊維によれ等が発生しても経時的に均等に樹脂を含浸する装置が安価に提供できる。 According to the apparatus according to the embodiment of the present invention, an apparatus that uniformly impregnates a resin with time can be provided at a low cost even if a reinforcing fiber such as tow is generated.
また、本発明の実施形態に係る方法によれば、強化繊維中を浸透困難な補強材や潜在硬化剤などの固形分を含む樹脂を強化繊維の両面それぞれに供給する場合でも、強化繊維の両面で強度や硬化反応速度を均一化することができ、特性の優れた強化繊維複合材料を提供することができる。 Further, according to the method according to the embodiment of the present invention, both sides of the reinforcing fiber can be used even when a resin containing solids such as a reinforcing material or a latent curing agent that is difficult to penetrate into the reinforcing fiber is supplied to both sides of the reinforcing fiber. Thus, the strength and curing reaction rate can be made uniform, and a reinforced fiber composite material having excellent characteristics can be provided.
以下、本発明の実施形態について、図面を参照しつつ説明する。
図１は、本発明の一実施形態例に係る強化繊維プリプレグ、特に強化繊維として炭素繊維を用い、トウ状態の炭素繊維に樹脂を含浸する装置の概略を示す図であり、（ａ）は側面図、（ｂ）は上面図、（ｃ）は部分拡大斜視図を示す。
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a diagram showing an outline of a reinforcing fiber prepreg according to an embodiment of the present invention, particularly an apparatus for impregnating a resin in a towed carbon fiber using carbon fiber as a reinforcing fiber, and (a) is a side view. (B) is a top view, (c) is a partially enlarged perspective view.
図１において、樹脂槽１にはトウに含浸する樹脂２が蓄えられており、不図示の加熱手段により樹脂が所定の転写可能な粘度となるように加熱されている。樹脂槽１の樹脂２は回動する含浸ロール３と接触し、含浸ロール３の表面に保持される。含浸ロール３の表面に保持された樹脂液はドクターブレードなどの規制手段４により、所定の膜厚となるように規制され（樹脂層の形成）、余剰の樹脂は樹脂槽１に戻される。樹脂を含浸すべきトウ５は、案内ロール６、７により紙面左方向から搬送され、含浸ロール３の頂部で所定の張力で接触して樹脂が転写される。また、含浸ロール３の頂部ではトウ５の幅よりも広い所定の幅を有する樹脂供給手段８が設けられており、トウ５の側方の含浸ロール３上の樹脂を掻き取り、トウ５の含浸ロール５との接触面以外の面に樹脂が供給される。以上の構成のうち、樹脂供給手段８を除く含浸装置の構成は、図３に示す従来の含浸装置と同等であり、従来公知の装置を用いることが可能であることが理解される。また、樹脂供給手段８を除く含浸装置の構成のうち、樹脂槽１に代えて、従来公知のアプリケータ手段を用いても良い。さらに、必要に応じて公知の他の手段、例えば、強化繊維に樹脂を転写後、含浸ロール上に残存する樹脂層を掻き取るクリーニング手段や、含浸ロール３と樹脂槽１との間に別途樹脂を巻き上げ、含浸ロールに樹脂を転写する転写ロール等を含む構成であっても良く、上記構成に限定されるものではない。 In FIG. 1, a resin 2 impregnating tow is stored in a resin tank 1, and the resin is heated to a predetermined transferable viscosity by a heating means (not shown). The resin 2 in the resin tank 1 comes into contact with the rotating impregnation roll 3 and is held on the surface of the impregnation roll 3. The resin liquid held on the surface of the impregnation roll 3 is regulated by a regulating means 4 such as a doctor blade so as to have a predetermined film thickness (formation of a resin layer), and excess resin is returned to the resin tank 1. The tow 5 to be impregnated with the resin is conveyed from the left direction of the paper by the guide rolls 6 and 7, and is contacted with a predetermined tension at the top of the impregnating roll 3 to transfer the resin. A resin supply means 8 having a predetermined width wider than the width of the tow 5 is provided at the top of the impregnation roll 3, and the resin on the impregnation roll 3 on the side of the tow 5 is scraped to impregnate the tow 5. Resin is supplied to a surface other than the contact surface with the roll 5. Of the above configuration, the configuration of the impregnation apparatus excluding the resin supply means 8 is equivalent to the conventional impregnation apparatus shown in FIG. 3, and it is understood that a conventionally known apparatus can be used. Further, in the configuration of the impregnation apparatus excluding the resin supply means 8, a conventionally known applicator means may be used instead of the resin tank 1. Further, if necessary, other known means, for example, a cleaning means for scraping off the resin layer remaining on the impregnating roll after transferring the resin to the reinforcing fiber, or a separate resin between the impregnating roll 3 and the resin tank 1 It is possible to include a transfer roll that transfers the resin to the impregnating roll, and is not limited to the above configuration.
樹脂供給手段８は、トウ５の側方の所定の範囲の含浸ロール上の樹脂（樹脂層２Ｌ）を掻き取り、トウ５の接触面以外の面、特に扁平なトウを用いる場合には含浸ロールとの接触面と対向する面に樹脂を供給できるものであればいずれも使用することができる。そのため、樹脂供給手段８は、樹脂撥液性を有する材料であることが好ましく、また、樹脂の加熱温度下に安定な材料であることが好ましい。例えば、シリコーン系やフッ素系の樹脂材料を樹脂２との接触面に少なくとも設けることが好ましい。樹脂の掻き取りを行う範囲は、含浸ロール上に形成される樹脂層の厚み、樹脂を含浸すべき強化繊維（トウ）の幅や厚さに応じて、適宜調整すればよいが、例えば、強化繊維（トウ）の幅が３〜８ｍｍ程度の場合、その１．５〜２倍の幅の範囲の樹脂層を掻き取り、含浸ロールとの接触面以外に供給することができる。また、樹脂供給手段は、トウと非接触であっても、一部接触していても良い。なお、接触するとは、含浸ロール上に樹脂層が形成されていない状態でトウと接触することを意味し、含浸ロール上に樹脂層が形成され、それを掻き取ってトウの含浸ロールとの接触面以外に供給した場合には、薄い樹脂層がトウとの間に介在することになる。一部接触する場合、例えば、含浸ロール上の上流側（図１（ａ）の左手側）でトウと非接触状態として、下流側で接触するような構成とすることができる。このような構成とすることで、トウ表面の樹脂層をより均一にすることができる。このような接触部位を設ける場合、繊維の毛羽立ちを抑制するために、柔軟性のある材料であることが好ましい。また、幅の広い強化繊維に適用するため、樹脂供給手段８の内面側（非接触部位）に複数の溝を両側から中心方向に斜め（上流側から下流側）に形成することで、幅広の強化繊維の中心側にも均一な樹脂供給が可能となる。なお、図１では含浸ロール上で１本のトウへの含浸を行う構成を示しているが、複数のトウを同時に処理することも可能であり、その場合、樹脂供給手段８を各トウに設置すればよい。樹脂供給手段８を各トウの形状に応じて適正化すると、形状の異なるトウを同時に処理することが可能となる場合がある。 The resin supply means 8 scrapes off the resin (resin layer 2L) on the impregnation roll in a predetermined range on the side of the tow 5, and when using a surface other than the contact surface of the tow 5, particularly a flat tow, the impregnation roll Any material can be used as long as the resin can be supplied to the surface facing the contact surface. Therefore, the resin supply means 8 is preferably a material having resin repellency, and is preferably a material that is stable at the heating temperature of the resin. For example, it is preferable to provide at least a silicone-based or fluorine-based resin material on the contact surface with the resin 2. The range in which the resin is scraped may be appropriately adjusted according to the thickness of the resin layer formed on the impregnation roll and the width and thickness of the reinforcing fiber (tow) to be impregnated with the resin. When the width of the fiber (tow) is about 3 to 8 mm, the resin layer in the range of 1.5 to 2 times the width can be scraped and supplied to other than the contact surface with the impregnation roll. Further, the resin supply means may be in non-contact with the tow, or may be partially in contact. The contact means that the resin layer is formed on the impregnating roll, and the resin layer is formed on the impregnating roll. The resin layer is scraped off to contact the impregnating roll. When supplied to other than the surface, a thin resin layer is interposed between the tow. In the case of partial contact, for example, a configuration can be adopted in which the tow is not in contact with the tow on the upstream side (left hand side in FIG. 1A) on the impregnating roll and is in contact with the downstream side. With such a configuration, the resin layer on the tow surface can be made more uniform. When providing such a contact part, in order to suppress the fluff of a fiber, it is preferable that it is a flexible material. Further, in order to apply to a wide reinforcing fiber, a plurality of grooves are formed obliquely (from upstream side to downstream side) from both sides to the center direction on the inner surface side (non-contact portion) of the resin supply means 8, thereby increasing the width. A uniform resin can be supplied also to the center side of the reinforcing fiber. Although FIG. 1 shows a configuration in which one tow is impregnated on an impregnation roll, a plurality of tows can be processed at the same time. In this case, a resin supply means 8 is installed in each tow. do it. If the resin supply means 8 is optimized according to the shape of each tow, it may be possible to process tows having different shapes at the same time.
樹脂供給手段８の具体的な構造としては、例えば、図２に示すように、含浸ロール３の上流側では、トウ５から上方向及び左右方向に所定の間隙を設けて掻き取る領域を規定し、下流側にその間隙を徐々に狭くしていくことで、掻き取られた樹脂（２Ｌ−ｉｎ）がトウ５の含浸ロール３との接触面以外に供給されるようになる。図２は、本発明の含浸装置における樹脂供給手段８の一例を示す概略図であり、（ａ）は上面図、（ｂ）は側面図、（ｃ）〜（ｅ）は、それぞれ、Ａ−Ａ線、Ｂ−Ｂ線、Ｃ−Ｃ線での断面図を示す。また、樹脂供給手段８は、図１（ａ）に示す紙面上下方向に移動可能な機構を有し、トウ５を含浸ロール３上に初期配置する際には含浸ロール３から引き離して配置作業を容易にすることができる。また、含浸ロール３の回動による振動などによる樹脂供給手段８の浮き上がりを抑制するため、所定の圧力で含浸ロール３側に押しつけておくことが好ましい。なお、接触部位を設ける場合は、接触部位が過剰にトウに対して圧力を付加することは、毛羽立ちなどの悪影響を引き起こし好ましくないことから、そのような悪影響がないように加圧を偏在化させるなどの手段を講じることが好ましい。なお、図２では、樹脂供給手段８の断面を略矩形の形状で説明しているが、これに限定されず、樹脂含浸を行う強化繊維の形状に応じて適宜変更することができる。 As a specific structure of the resin supply means 8, for example, as shown in FIG. 2, on the upstream side of the impregnating roll 3, a region to be scraped by providing a predetermined gap from the tow 5 in the upward direction and the lateral direction is defined. By gradually narrowing the gap downstream, the scraped resin (2L-in) is supplied to a portion other than the contact surface of the tow 5 with the impregnation roll 3. FIG. 2 is a schematic view showing an example of the resin supply means 8 in the impregnation apparatus of the present invention, where (a) is a top view, (b) is a side view, and (c) to (e) are A- Sectional drawing in A line, BB line, and CC line is shown. The resin supply means 8 has a mechanism that can move in the vertical direction of the paper surface shown in FIG. 1A. When the tow 5 is initially placed on the impregnation roll 3, the resin supply means 8 is separated from the impregnation roll 3 to perform the placement work. Can be easily. Further, in order to suppress the resin supply means 8 from being lifted by vibrations caused by the rotation of the impregnating roll 3, it is preferably pressed against the impregnating roll 3 with a predetermined pressure. In addition, when a contact part is provided, it is not preferable that the contact part applies excessive pressure to the tow, which causes undesirable effects such as fuzzing, so that the pressure is unevenly distributed so as not to have such an adverse effect. It is preferable to take measures such as. In FIG. 2, the cross section of the resin supply unit 8 is described as a substantially rectangular shape. However, the cross section is not limited thereto, and can be appropriately changed according to the shape of the reinforcing fiber to be impregnated with the resin.
簡便には、樹脂供給手段８はシリコーンチューブなどを所定の形状に加工して形成することができる。また、金属材料など剛性の高い材料を所定の形状に成形し、シリコーン樹脂などでライニングすることで形成すると、樹脂含量の均一性をより好ましいものとすることができる。 Conveniently, the resin supply means 8 can be formed by processing a silicone tube or the like into a predetermined shape. Further, when a highly rigid material such as a metal material is formed into a predetermined shape and is lined with a silicone resin or the like, the uniformity of the resin content can be made more preferable.
樹脂供給手段８を設置する位置は、トウ５と含浸ロール３との接触開始点よりも下流側に設けることが好ましい。特に、図１に示すように、含浸ロール３の頂部付近に設置することが好ましい。これは、トウ５の下の含浸ロール３上の樹脂層２Ｌがある程度トウ５に含浸された後、接触面以外の面に樹脂を供給することで、接触面側の樹脂含量が変動することがないためである。接触開始点近傍に樹脂供給手段８を設置すると、トウ３の下側に樹脂が回り込んで接触面側の樹脂含量が増加したり、接触面側の樹脂含量が逆に少なくなる場合もある。 The position where the resin supply means 8 is installed is preferably provided downstream of the contact start point between the tow 5 and the impregnation roll 3. In particular, as shown in FIG. 1, it is preferably installed near the top of the impregnating roll 3. This is because, after the resin layer 2L on the impregnation roll 3 under the tow 5 is impregnated to some extent, the resin content on the contact surface side may fluctuate by supplying the resin to a surface other than the contact surface. This is because there is not. If the resin supply means 8 is installed in the vicinity of the contact start point, the resin may wrap around the lower side of the tow 3 and the resin content on the contact surface side may increase or the resin content on the contact surface side may decrease.
このように、本発明では、高価なギアポンプ等の供給装置を用いることなく、従来の転写ロール法による含浸装置に本発明による樹脂供給手段を付加するという簡単な構成で、含浸ロール３の接触面以外にも所定量の樹脂を供給することが可能となる。また、供給する樹脂量は樹脂供給手段８の入り口側の幅で規定される範囲となることで、トウのよれや幅の変動が生じたとしても常に一定の樹脂が供給されることになり、複合材料中の樹脂含量をより均一にすることができる。 As described above, in the present invention, the contact surface of the impregnating roll 3 can be obtained with a simple configuration in which the resin supply means according to the present invention is added to the impregnating apparatus according to the conventional transfer roll method without using an expensive gear pump or the like. In addition to this, a predetermined amount of resin can be supplied. In addition, the amount of resin to be supplied is in a range defined by the width of the inlet side of the resin supply means 8, so that a constant resin is always supplied even if a tow or a variation in width occurs. The resin content in the composite material can be made more uniform.
樹脂含浸後のトウ５’は案内ロール７を介して他の装置、例えば、乾燥装置、巻取り装置へと移動し、ロール状に巻き取ることができる。また、直接、フィラメントワインディング装置に接続して、圧力容器などの物品の製造に供することもできる。 The tow 5 ′ after impregnation with the resin moves to another device such as a drying device or a winding device via the guide roll 7 and can be wound up in a roll shape. Further, it can be directly connected to a filament winding apparatus and used for manufacturing an article such as a pressure vessel.
次に、本発明の製造方法をさらに詳細に説明する。
本発明の製造方法に用いる強化繊維としては、含浸ロールの幅よりも狭い幅であることはいうまでもないが、強化繊維の側方に樹脂の掻き取り代を十分に残し得る程度の幅のものである。ロール転写法による製造に適した扁平なトウであることが好ましい。トウとしては強化繊維フィラメントを数千本から数万本扁平に束ねたものであって、例えば、幅と厚みの比が通常１０〜１０００：１、好ましくは３０〜１００：１の範囲となる扁平形状のトウが挙げられる。該強化繊維は特に限定されず、例えば、炭素繊維、ガラス繊維、アルミナ繊維、炭化珪素繊維、ボロン繊維、アラミド繊維等が挙げられ、特に炭素繊維の使用が好ましい。また、樹脂が含浸し難い、繊維径が６μｍ以下でかつ繊度が８００ｇ／ｋｍ以上の炭素繊維を用いる場合、本発明の装置及び方法は優れた効果を発揮する。
Next, the production method of the present invention will be described in more detail.
Needless to say, the reinforcing fiber used in the production method of the present invention is narrower than the width of the impregnating roll, but has a width enough to leave a sufficient amount of resin scraping on the side of the reinforcing fiber. Is. A flat tow suitable for production by a roll transfer method is preferred. The tow is a bundle of several thousand to several tens of thousands of reinforcing fiber filaments, for example, a flatness in which the ratio of width to thickness is usually in the range of 10 to 1000: 1, preferably 30 to 100: 1. Shaped tow. The reinforcing fiber is not particularly limited, and examples thereof include carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, boron fiber, and aramid fiber, and the use of carbon fiber is particularly preferable. In addition, when carbon fibers that are difficult to be impregnated with resin, have a fiber diameter of 6 μm or less, and a fineness of 800 g / km or more are used, the apparatus and method of the present invention exhibit excellent effects.
本発明の製造方法に用いる樹脂の主剤（マトリックス樹脂）は特に限定されず、トウプリプレグ用として用いられる熱硬化性樹脂が挙げられ、特にエポキシ樹脂が取扱い性の点で好ましい。 The main resin (matrix resin) of the resin used in the production method of the present invention is not particularly limited, and examples thereof include thermosetting resins used for tow prepregs. Epoxy resins are particularly preferable from the viewpoint of handleability.
樹脂槽１に貯留される樹脂２は、前記マトリックス樹脂に加えて、該マトリックス樹脂を硬化させるための硬化剤を含む。該硬化剤は、マトリックス樹脂の種類に応じて適宜選択でき、その配合割合もマトリックス樹脂の種類やプリプレグへの含量に応じて適宜決定することができる。特に、本発明では、プリプレグ製造過程での樹脂の硬化を抑制するという観点から、潜在硬化剤を用いることが好ましい。 The resin 2 stored in the resin tank 1 includes a curing agent for curing the matrix resin in addition to the matrix resin. The curing agent can be appropriately selected according to the type of the matrix resin, and the blending ratio thereof can be appropriately determined according to the type of the matrix resin and the content in the prepreg. In particular, in the present invention, it is preferable to use a latent curing agent from the viewpoint of suppressing the curing of the resin during the prepreg manufacturing process.
前記樹脂は、マトリックス樹脂を溶解する溶媒や硬化促進剤を含んでいても良い。さらに、本発明では、複合材料の機械的強度を高めるゴム粒子等の補強剤、難燃性を高める難燃剤等の添加剤を含有していても良い。 The resin may contain a solvent for dissolving the matrix resin and a curing accelerator. Furthermore, in this invention, you may contain additives, such as reinforcing agents, such as a rubber particle which improves the mechanical strength of a composite material, and a flame retardant which improves a flame retardance.
樹脂中に潜在硬化剤やゴム粒子等の固形分を含む場合に本発明は特に有効である。 The present invention is particularly effective when the resin contains a solid component such as a latent curing agent or rubber particles.
複合材料中の樹脂含有量の制御方法については、糸速あるいは樹脂の供給量（含浸ロール上の膜厚）を種々変更することで任意の樹脂含有量を有するトウプリプレグを得ることができる。糸速はどのような手段でも制御することができるが、含浸ロールや案内ロールの回転速度を所定の速度とすることによって一定の糸速を維持することが好ましい。また、未含浸のトウ又は含浸後のトウの移動速度を非接触に検知する糸速センサを設けて、含浸ロールや案内ロールの回転速度を調整するようにしても良い。 Regarding the method for controlling the resin content in the composite material, a tow prepreg having an arbitrary resin content can be obtained by variously changing the yarn speed or the amount of resin supplied (film thickness on the impregnating roll). The yarn speed can be controlled by any means, but it is preferable to maintain a constant yarn speed by setting the rotation speed of the impregnation roll and the guide roll to a predetermined speed. A rotational speed of the impregnation roll or the guide roll may be adjusted by providing a yarn speed sensor that detects the non-impregnated tow or the impregnated tow in a non-contact manner.
糸速は強化繊維の種類により好ましい範囲が存在する。炭素繊維の場合は、通常５〜２００ｍ／ｍｉｎ、好ましくは５〜１５０ｍ／ｍｉｎの糸速で作業することができる。炭素繊維の糸速が５ｍ／ｍｉｎ未満ではトウプリプレグの生産性が悪く好ましくなく、また２００ｍ／ｍｉｎを超えると糸切れや毛羽が発生しやすくなる。また糸速は樹脂の粘度、特に樹脂供給時あるいは含浸時の粘度により好ましい範囲が存在する。 The yarn speed has a preferred range depending on the type of reinforcing fiber. In the case of carbon fiber, it can work normally at a yarn speed of 5 to 200 m / min, preferably 5 to 150 m / min. If the yarn speed of the carbon fiber is less than 5 m / min, the productivity of the tow prepreg is poor and undesirable, and if it exceeds 200 m / min, yarn breakage and fluff are likely to occur. The yarn speed has a preferable range depending on the viscosity of the resin, particularly the viscosity at the time of resin supply or impregnation.
樹脂の粘度が０．００１〜１Ｐａ・ｓの場合には、通常５〜２００ｍ／ｍｉｎ、好ましくは５〜１５０ｍ／ｍｉｎの糸速で作業することができる。樹脂の粘度が１Ｐａ・ｓを超え、１０Ｐａ・ｓ以下の場合には、通常５〜１５０ｍ／ｍｉｎ、好ましくは５〜１２０ｍ／ｍｉｎの糸速で作業することができる。 When the viscosity of the resin is 0.001 to 1 Pa · s, it is possible to work at a yarn speed of usually 5 to 200 m / min, preferably 5 to 150 m / min. When the viscosity of the resin is more than 1 Pa · s and not more than 10 Pa · s, the work can be usually performed at a yarn speed of 5 to 150 m / min, preferably 5 to 120 m / min.
樹脂の粘度が１０Ｐａ・ｓを超え、３０Ｐａ・ｓ以下の場合には、通常５〜１２０ｍ／ｍｉｎ、好ましくは５〜１００ｍ／ｍｉｎの糸速で作業することができる。樹脂の粘度が３０Ｐａ・ｓより大きい場合には、糸速は低速化し、粘度が０．００１Ｐａ・ｓより小さい場合は高速化することが可能であるが、液だれや液とびが発生しやすくなってしまうので好ましくない。 When the viscosity of the resin is more than 10 Pa · s and not more than 30 Pa · s, the work can be usually performed at a yarn speed of 5 to 120 m / min, preferably 5 to 100 m / min. When the viscosity of the resin is greater than 30 Pa · s, the yarn speed can be reduced, and when the viscosity is less than 0.001 Pa · s, the yarn speed can be increased, but dripping or jumping easily occurs. This is not preferable.
樹脂槽１での加熱以外に、樹脂含浸時、あるいは含浸後に、樹脂および／またはトウをそれぞれ樹脂の硬化温度より３０℃低い温度を上限として加熱してトウ内部への樹脂の含浸性を高めることができ、通常１５〜１５０℃の範囲、好ましくは１５〜９０℃の範囲で加熱することで樹脂の粘度を容易に安定させることができる。 In addition to heating in the resin tank 1, the resin and / or tow is heated up to 30 ° C. lower than the curing temperature of the resin, respectively, at the time of resin impregnation or after impregnation to increase the resin impregnation property inside the tow. The viscosity of the resin can be easily stabilized by heating in the range of usually 15 to 150 ° C, preferably 15 to 90 ° C.
以下、実施例を参照して本発明を具体的に説明するが、本発明はこれらの実施例のみに限定されるものではない。 EXAMPLES Hereinafter, although this invention is demonstrated concretely with reference to an Example, this invention is not limited only to these Examples.
実施例１
炭素繊維として、東レ社製、商品名「トレカＴ８００Ｓ−２４ｋ」（長さ３９００ｍ）を使用し、本発明の手法により、ＪＸ日鉱日石エネルギー社製エポキシ樹脂「２５ＪＸ−１」（商品名）を用いてトウプリプレグの製造を行った（目標樹脂含量＝２９ｗｔ％）。製造したトウプリプレグについて、１００ｍ毎に１ｍ長さでサンプリングし、重量および繊維ＴＥＸから樹脂含量を測定した。
Example 1
As a carbon fiber, a product name “Torayca T800S-24k” (length: 3900 m) manufactured by Toray Industries, Inc. is used, and an epoxy resin “25JX-1” (product name) manufactured by JX Nippon Oil & Energy is used according to the method of the present invention. A tow prepreg was produced using the resin composition (target resin content = 29 wt%). The produced tow prepreg was sampled at a length of 1 m every 100 m, and the resin content was measured from the weight and fiber TEX.
なお、含浸装置は、市販のロール含浸装置に樹脂供給手段としてトウ幅より広い径を有するシリコーンチューブを斜めにカットし、さらに斜めカットした上端側にトウ幅より広い幅（トウ幅の１．５倍の幅）に矩形の切り込みを形成したものを用い、矩形の切り込みが含浸ロールの回転の上流側、斜めカットした下端が下流側となるようにセットした。 In addition, the impregnation apparatus cuts a silicone tube having a diameter wider than the tow width obliquely as a resin supply means in a commercially available roll impregnation apparatus, and further has a width wider than the tow width (1.5 tow width on the upper end side). The width was set to be the upstream side of the rotation of the impregnation roll, and the lower end of the oblique cut was the downstream side.
また、７．５リットル容量のアルミライナーにフィラメントワインディング装置で上記で得られたトウプリプレグを所定量巻きつけた後、１４０℃で２時間、硬化を行い、圧力容器を得た。この容器の破裂強度として水圧によるバースト試験をＫＨＫＳ１１２１(２０００)に従って実施し、バースト強度を測定した。サンプル数ｎ＝６。結果を表１に示す。 Further, after winding a predetermined amount of the tow prepreg obtained above on a 7.5 liter capacity aluminum liner with a filament winding apparatus, curing was performed at 140 ° C. for 2 hours to obtain a pressure vessel. As the burst strength of this container, a burst test by water pressure was performed according to KHKS1121 (2000), and the burst strength was measured. Number of samples n = 6. The results are shown in Table 1.
比較例１
樹脂供給手段を設けなかった以外は同じ装置を用いて、同じ炭素繊維トウに同じエポキシ樹脂を含浸させながら、トウプリプレグの製造を行った。製造したトウプリプレグについて、同様に１００ｍ毎にサンプリングを行い、樹脂含量を測定した。また、このように製造したトウプリプレグを用いて、実施例１と同様に圧力容器を作製し、同様に破裂強度を測定した。結果を表１に示す。
Comparative Example 1
A tow prepreg was produced using the same apparatus except that the resin supply means was not provided while impregnating the same carbon fiber tow with the same epoxy resin. The produced tow prepreg was similarly sampled every 100 m to measure the resin content. Moreover, using the tow prepreg thus produced, a pressure vessel was produced in the same manner as in Example 1, and the burst strength was measured in the same manner. The results are shown in Table 1.
表１に示すように、実施例１では、比較例１よりも樹脂含量の経時的な均一性が向上していることが分かる。また、トウの両面での樹脂の物性が同等になることで、本発明により製造されるプリプレグを使用した圧力容器では、破裂強度が向上している。 As shown in Table 1, it can be seen that in Example 1, the uniformity of the resin content over time is improved as compared with Comparative Example 1. In addition, since the physical properties of the resin on both sides of the tow are equivalent, the burst strength is improved in the pressure vessel using the prepreg produced according to the present invention.
１ 樹脂槽
２ 樹脂
３ 含浸ロール
４ 膜厚規制手段
５ トウ
６，７ 案内ロール
８ 樹脂供給手段
DESCRIPTION OF SYMBOLS 1 Resin tank 2 Resin 3 Impregnation roll 4 Film thickness control means 5 Tow 6, 7 Guide roll 8 Resin supply means
Claims (10)
樹脂を表面に保持し、回動する含浸ロールと、
含浸ロール表面に保持された樹脂を所定の厚みに規制する規制手段と、
前記規制手段を通過後の含浸ロール表面に強化繊維を案内し、含浸ロール表面に強化繊維を接触させて樹脂を転写し、転写後の強化繊維を含浸ロールから引き離す案内手段と、
前記含浸ロールと強化繊維との接触部において、前記強化繊維を囲み、該強化繊維の側方の含浸ロール表面の樹脂を所定範囲で掻き取り、強化繊維の含浸ロール接触面とは異なる部位に供給する樹脂供給手段と、
を有する前記装置。 An apparatus for impregnating a reinforcing fiber with a resin,
An impregnating roll that holds and rotates the resin on the surface;
A regulating means for regulating the resin held on the surface of the impregnation roll to a predetermined thickness;
Guiding means for guiding the reinforcing fibers to the surface of the impregnating roll after passing through the regulating means, transferring the resin by bringing the reinforcing fibers into contact with the surface of the impregnating roll, and pulling the reinforcing fibers after the transfer away from the impregnating roll;
Surrounding the reinforcing fiber at the contact portion between the impregnating roll and the reinforcing fiber, scraping the resin on the surface of the impregnating roll on the side of the reinforcing fiber within a predetermined range, and supplying the resin to a different part from the impregnating roll contacting surface of the reinforcing fiber Resin supply means to perform,
Said device.
前記強化繊維の側方で、該強化繊維と接触していない含浸ロール上の樹脂を所定量掻き取り、強化繊維の含浸ロール接触面とは異なる部位に供給することを特徴とする樹脂含浸方法。 A method of impregnating a reinforcing fiber with a resin by roll transfer in which an impregnated roll having a resin layer having a predetermined film thickness formed on the surface is brought into contact with the reinforcing fiber and transferring the resin to the reinforcing fiber,
A resin impregnation method characterized by scraping a predetermined amount of resin on an impregnation roll that is not in contact with the reinforcing fiber at a side of the reinforcing fiber and supplying the scraped resin to a portion different from the surface of the reinforcing fiber impregnating roll.
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| JP2011119244A JP2012246391A (en) | 2011-05-27 | 2011-05-27 | Method of impregnating reinforcing fiber with resin and impregnation device |
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| JP2011119244A JP2012246391A (en) | 2011-05-27 | 2011-05-27 | Method of impregnating reinforcing fiber with resin and impregnation device |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113733400A (en) * | 2021-09-08 | 2021-12-03 | 浙江抟原复合材料有限公司 | Dry-method winding pre-impregnated yarn preparation equipment and preparation process thereof |
| JP7421944B2 (en) | 2020-02-17 | 2024-01-25 | 本田技研工業株式会社 | Tow prepreg manufacturing equipment and manufacturing method |
-
2011
- 2011-05-27 JP JP2011119244A patent/JP2012246391A/en not_active Withdrawn
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP7421944B2 (en) | 2020-02-17 | 2024-01-25 | 本田技研工業株式会社 | Tow prepreg manufacturing equipment and manufacturing method |
| CN113733400A (en) * | 2021-09-08 | 2021-12-03 | 浙江抟原复合材料有限公司 | Dry-method winding pre-impregnated yarn preparation equipment and preparation process thereof |
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