JP6809123B2 - A method for opening a continuous reinforcing fiber bundle, an apparatus for opening the reinforcing fiber bundle, and a method for producing a fiber-reinforced resin using the reinforcing fiber bundle. - Google Patents
A method for opening a continuous reinforcing fiber bundle, an apparatus for opening the reinforcing fiber bundle, and a method for producing a fiber-reinforced resin using the reinforcing fiber bundle. Download PDFInfo
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Description
本発明は、連続した強化繊維束の開繊方法および強化繊維束の開繊装置、ならびに強化繊維束を用いた繊維強化樹脂の製造方法に関する。 The present invention relates to a continuous method for opening a reinforcing fiber bundle, an apparatus for opening a reinforcing fiber bundle, and a method for producing a fiber-reinforced resin using the reinforcing fiber bundle.
従来、連続した強化繊維束にマトリックス樹脂を含浸させてなる繊維強化プラスチックは、比強度、比剛性に優れ、軽量化効果が高い上に、耐熱性、耐薬品性が高いため、航空機、自動車等の輸送機器やスポーツ、電気・電子部品用途へ好ましく用いられている。 Conventionally, fiber reinforced plastics made by impregnating continuous reinforcing fiber bundles with matrix resin have excellent specific strength and rigidity, high weight reduction effect, and high heat resistance and chemical resistance, so that they are used for aircraft, automobiles, etc. It is preferably used for transportation equipment, sports, and electrical / electronic parts.
繊維強化プラスチックはマトリックス樹脂を連続した強化繊維束の束内に十分含浸させて製造される。マトリックス樹脂には熱可塑性樹脂や熱硬化性樹脂が使用されるが、強化繊維束への樹脂の含浸には樹脂の粘度が大きく影響し、束ねられた強化繊維間に樹脂を含浸させるのは困難で、特に熱可塑性樹脂は粘度が非常に高いため、熱可塑性樹脂を溶融させた状態で繊維束をその中に通しても繊維束の外周に被覆ができるだけで、繊維間には殆ど含浸しない。 Fiber reinforced plastics are produced by sufficiently impregnating a bundle of continuous reinforcing fiber bundles with a matrix resin. Thermoplastic resin and thermosetting resin are used for the matrix resin, but it is difficult to impregnate the bundled reinforcing fibers with the resin because the viscosity of the resin greatly affects the impregnation of the resin into the reinforcing fiber bundle. In particular, since the thermoplastic resin has a very high viscosity, even if the fiber bundle is passed through the molten thermoplastic resin, the outer periphery of the fiber bundle can only be coated, and the fibers are hardly impregnated.
そのため、樹脂の含浸を促進させるために、強化繊維束を開繊し、マトリックス樹脂の含浸距離を短くする必要がある。 Therefore, in order to promote the impregnation of the resin, it is necessary to open the reinforcing fiber bundle and shorten the impregnation distance of the matrix resin.
従来、繊維束を開繊する方法としては、丸棒で繊維束を扱いて構成繊維を延し広げる方法、水流や高圧空気流を当てて構成繊維を幅方向へ散ける方法、そして超音波で各繊維を振動させ散けさせる方法等が知られている。しかし、丸棒で繊維束を扱く方法や超音波で繊維を振動させる方法では、繊維に付加される力が強いため毛羽の発生や糸切れが生じやすく、水流を利用した方法では繊維束の乾燥が必要となりコストアップの要因となる。このため、空気流を利用した方法が広く利用されている。 Conventionally, as a method of opening a fiber bundle, a method of handling the fiber bundle with a round bar to spread and spread the constituent fibers, a method of applying a water flow or a high-pressure air flow to disperse the constituent fibers in the width direction, and an ultrasonic wave are used. A method of vibrating and scattering each fiber is known. However, in the method of handling the fiber bundle with a round bar or the method of vibrating the fiber with ultrasonic waves, fluffing and thread breakage are likely to occur because the force applied to the fiber is strong, and the method using water flow of the fiber bundle Drying is required, which causes an increase in cost. For this reason, a method using an air flow is widely used.
空気流を利用した方法としては、特開平２００８−２５５５２９公報のように加圧ガスを容器内で膨張させて繊維束を開繊する方法が知られている。しかし、このような方法ではサイジング剤などで収束された強化繊維の開繊は難しい。そのため、従来は特開平１１−２００１３６公報のように強化繊維束に気流をあて、その反対側を吸引することで繊維束を幅方向に開繊する方法や特開２００３−２１３５３７公報のように吸引気流を繊維束に交差させる方法が知られている。しかし、繊維束を幅方向に広げる方法は、繊維束の周囲にマトリックス樹脂が被覆することに変わりはなく、特に熱可塑性樹脂のような高粘度のマトリックス樹脂では、マトリックス樹脂の含浸に長い含浸時間や強い外力が必要であった。 As a method using an air flow, a method of expanding a pressurized gas in a container to open a fiber bundle is known as in JP-A-2008-255529. However, with such a method, it is difficult to open the reinforcing fibers converged by a sizing agent or the like. Therefore, conventionally, as in JP-A-11-200136, an air flow is applied to the reinforcing fiber bundle and the opposite side is sucked to open the fiber bundle in the width direction, or as in JP-A-2003-213537, suction is performed. A method of crossing an air flow with a fiber bundle is known. However, the method of expanding the fiber bundle in the width direction is still that the matrix resin is coated around the fiber bundle, and especially in a high-viscosity matrix resin such as a thermoplastic resin, the impregnation time of the matrix resin is long. A strong external force was required.
本発明は、これら従来技術の課題に鑑み、毛羽の発生が少なく、マトリックス樹脂の含浸に好適な強化繊維束の開繊方法を提供することを目的とする。 In view of these problems of the prior art, an object of the present invention is to provide a method for opening a reinforcing fiber bundle, which is less likely to generate fluff and is suitable for impregnation with a matrix resin.
上記目的を達成するために、本発明は、主として以下の構成を有する。
［１］連続的に供給される強化繊維束を、側面に吸引部が設けられた容器内に導入し、前記吸引部から空気を吸引することにより前記繊維束の周方向に気流を発生させ、該強化繊維束を周方向に開繊させることを特徴とする強化繊維束の開繊方法。
［２］前記容器内に給糸管と排糸管が間隔をあけて正対するように設けられ、前記排糸管の内部に挿入された形態維持部材に開繊後の繊維束が送り込まれ、前記開繊後の強化繊維束形態を維持させたまま送り出される［１］記載の強化繊維束の開繊方法。
［３］前記形態維持部材の内部から、前記開繊後の強化繊維束に向かって空気が送風される［２］に記載の強化繊維束の開繊方法。
［４］前記強化繊維束を前記容器に導入する前に、該強化繊維束の張力を解除する［１］〜［３］のいずれかに記載の強化繊維束の開繊方法。
［５］前記強化繊維束を前記容器に導入する前に、該強化繊維束を予熱する［１］〜［４］のいずれかに記載の強化繊維束の開繊方法。
［６］前記強化繊維束が炭素繊維である［１］〜［５］のいずれかに記載の強化繊維束の開繊方法。
［７］前記強化繊維束を構成する繊維本数が１，０００〜１００，０００である［１］〜［６］のいずれかに記載の強化繊維束の開繊方法。
［８］強化繊維束を連続的に供給する供給機構と、供給された前記強化繊維束を内部に導入する容器とを備える強化繊維束の開繊装置であって、
前記容器の側面に吸引部が設けられるとともに、前記容器内に給糸管と排糸管が間隔をあけて正対するように設けられ前記繊維束の周方向に気流を発生させて該繊維束を周方向に開繊させるための、前記吸引部から空気を吸引する吸引機構を備えることを特徴とする強化繊維束の開繊装置。
［９］前記排糸管の内部に、開繊後の前記強化繊維束形態を維持できる形態維持部材が設けられている、［８］に記載の強化繊維束の開繊装置。
［１０］前記形態維持部材の内部に、前記開繊後の強化繊維束に空気を送風する送風機構を更に備える、［９］に記載の強化繊維束の開繊装置。
［１１］前記容器の上流側に、前記強化繊維束の張力を解除する解除機構を備える、［８］〜［１０］のいずれかに記載の強化繊維束の開繊装置。
［１２］前記容器の上流側に、前記強化繊維束を予熱する予熱機構を備える、［８］〜［１１］のいずれかに記載の強化繊維束の開繊装置。
［１３］［１］〜［７］のいずれかに記載の強化繊維束の開繊方法により開繊された強化繊維束にマトリックス樹脂を供給して繊維強化樹脂を製造する方法であって、該樹脂が溶融樹脂もしくは粉末樹脂である繊維強化樹脂の製造方法。
［１４］前記樹脂が熱可塑性樹脂である［１３］に記載の繊維強化熱可塑性樹脂の製造方法。
In order to achieve the above object, the present invention mainly has the following configurations.
[1] A continuously supplied reinforcing fiber bundle is introduced into a container provided with a suction portion on the side surface, and air is sucked from the suction portion to generate an air flow in the circumferential direction of the fiber bundle. A method for opening a reinforcing fiber bundle, which comprises opening the reinforcing fiber bundle in the circumferential direction.
[2] The yarn feeding pipe and the yarn discharging pipe are provided in the container so as to face each other at a distance, and the fiber bundle after opening is sent to the shape maintaining member inserted inside the yarn discharging pipe. The method for opening a reinforcing fiber bundle according to [1], wherein the reinforcing fiber bundle is sent out while maintaining the shape of the reinforcing fiber bundle after opening.
[3] The method for opening a reinforcing fiber bundle according to [2], wherein air is blown from the inside of the form-maintaining member toward the reinforcing fiber bundle after opening the fiber.
[4] The method for opening a reinforcing fiber bundle according to any one of [1] to [3], wherein the tension of the reinforcing fiber bundle is released before the reinforcing fiber bundle is introduced into the container.
[5] The method for opening a reinforcing fiber bundle according to any one of [1] to [4], wherein the reinforcing fiber bundle is preheated before being introduced into the container.
[6] The method for opening a reinforcing fiber bundle according to any one of [1] to [5], wherein the reinforcing fiber bundle is a carbon fiber.
[7] The method for opening a reinforcing fiber bundle according to any one of [1] to [6], wherein the number of fibers constituting the reinforcing fiber bundle is 1,000 to 100,000.
[8] A reinforcing fiber bundle opening device including a supply mechanism for continuously supplying the reinforcing fiber bundle and a container for introducing the supplied reinforcing fiber bundle into the inside.
A suction portion is provided on the side surface of the container, and a yarn supply pipe and a yarn discharge pipe are provided in the container so as to face each other at a distance, and an air flow is generated in the circumferential direction of the fiber bundle to generate the fiber bundle. A fiber bundle opening device for reinforcing fiber bundles, which comprises a suction mechanism for sucking air from the suction portion for opening fibers in the circumferential direction.
[9] The fiber-spreading device for a reinforcing fiber bundle according to [8], wherein a shape-maintaining member capable of maintaining the shape of the reinforcing fiber bundle after fiber-spreading is provided inside the thread-extracting pipe.
[10] The fiber-spreading device for a reinforcing fiber bundle according to [9], further comprising a blowing mechanism for blowing air into the fiber-spreading reinforcing fiber bundle inside the form-maintaining member.
[11] The reinforcing fiber bundle opening device according to any one of [8] to [10], further comprising a release mechanism for releasing the tension of the reinforcing fiber bundle on the upstream side of the container.
[12] The fiber-spreading device for a reinforcing fiber bundle according to any one of [8] to [11], which comprises a preheating mechanism for preheating the reinforcing fiber bundle on the upstream side of the container.
[13] A method for producing a fiber-reinforced resin by supplying a matrix resin to the reinforcing fiber bundle opened by the method for opening the reinforcing fiber bundle according to any one of [1] to [7]. A method for producing a fiber-reinforced resin in which the resin is a molten resin or a powder resin.
[14] The method for producing a fiber-reinforced thermoplastic resin according to [13], wherein the resin is a thermoplastic resin.
本発明によれば、以下に説明するとおり、強化繊維束の円周方向に空気流を生じさせることにより、強化繊維束を円周方向に開繊させることができる。このような強化繊維束の開繊方法は、強化繊維束の毛羽の発生が少なく、強化繊維が円周方向に開繊することから繊維同士の間隔が広がり、マトリックス樹脂の含浸に好適な開繊強化繊維束を安定的に製造することができる。 According to the present invention, as described below, the reinforcing fiber bundle can be opened in the circumferential direction by generating an air flow in the circumferential direction of the reinforcing fiber bundle. In such a method of opening the reinforcing fiber bundle, fluffing of the reinforcing fiber bundle is less likely to occur, and since the reinforcing fibers are opened in the circumferential direction, the distance between the fibers is widened, which is suitable for impregnation of the matrix resin. Reinforcing fiber bundles can be stably produced.
以下、本発明の望ましい実施の形態を、図面を参照して説明する。 Hereinafter, desirable embodiments of the present invention will be described with reference to the drawings.
図１、図２および図３は、本発明の一実施態様に係る開繊方法および開繊装置を示している。図４および図５はそれぞれ、本発明により開繊された開繊繊維束、従来の開繊技術により開繊された開繊繊維束の概略断面図である。 FIGS. 1, 2 and 3 show a fiber-spreading method and a fiber-spreading device according to an embodiment of the present invention. 4 and 5 are schematic cross-sectional views of the spread fiber bundle opened by the present invention and the spread fiber bundle opened by the conventional opening technique, respectively.
先ず、図１および図２を用いて本発明の開繊装置および開繊方法について説明する。 First, the fiber-spreading device and the fiber-spreading method of the present invention will be described with reference to FIGS. 1 and 2.
強化繊維束２０は、加熱機構１０で加熱され、張力解除機構１１で張力を解除された後、連続的に給糸口２を通って開繊装置１内に給糸される。開繊装置１の容器８内まで延設された給糸管４から出た強化繊維束２０は、容器８の側面に設けられた吸引部７から空気を吸引することにより、強化繊維束２０の周方向に気流が発生するため、強化繊維束２０を周方向に開繊させることができる。開繊された強化繊維束２０は、給糸管４とギャップ６を介して、容器８内部に延設して設けられた排糸管５に導入され、排糸口３から開繊繊維束２１として排出される。 The reinforcing fiber bundle 20 is heated by the heating mechanism 10, the tension is released by the tension releasing mechanism 11, and then the yarn is continuously fed into the fiber opening device 1 through the yarn feeding port 2. The reinforcing fiber bundle 20 protruding from the yarn feeding pipe 4 extending into the container 8 of the fiber opening device 1 sucks air from the suction portion 7 provided on the side surface of the container 8 to attract the reinforcing fiber bundle 20. Since the airflow is generated in the circumferential direction, the reinforcing fiber bundle 20 can be opened in the circumferential direction. The opened fiber bundle 20 is introduced into the thread discharge pipe 5 extending inside the container 8 via the thread supply pipe 4 and the gap 6, and is used as the spread fiber bundle 21 from the thread discharge port 3. It is discharged.
本発明の開繊装置１の内部は、図２に示すように、密閉された容器８内で吸引管７から空気が吸引されることにより、給糸口２及び排糸口３からギャップ６を通じて吸引管７より排出される空気流を生じさせることができる。この空気流は、図２の矢印で示すように、給糸管４と排糸管５の狭い流路からギャップ６にて急激が広がるため、周方向に空気流を生じさせることができる。この空気流により、ギャップ６を通過する強化繊維束２０を、周方向に開繊させることができる。 As shown in FIG. 2, the inside of the fiber-spreading device 1 of the present invention is sucked by air from the suction pipe 7 in the closed container 8 through the suction pipe from the yarn feeding port 2 and the yarn discharging port 3 through the gap 6. It is possible to generate an air flow discharged from No. 7. As shown by the arrow in FIG. 2, this air flow rapidly spreads in the gap 6 from the narrow flow path of the thread feed pipe 4 and the thread discharge pipe 5, so that an air flow can be generated in the circumferential direction. By this air flow, the reinforcing fiber bundle 20 passing through the gap 6 can be opened in the circumferential direction.
ここで、本発明に用いる強化繊維束２０について説明する。 Here, the reinforcing fiber bundle 20 used in the present invention will be described.
本発明に用いる強化繊維束２０としては、特に限定されないが、例えば、炭素繊維、ガラス繊維、アラミド繊維、アルミナ繊維、炭化珪素繊維、ボロン繊維、金属繊維、ＰＢＯ繊維、高強力ポリエチレン繊維などの高強度、高弾性率繊維が使用でき、１種または２種以上を併用してもよい。中でも、ポリアクリロニトリル（ＰＡＮ）系、ピッチ系、レーヨン系などの炭素繊維が力学特性の向上、成形品の軽量化効果の観点から好ましく、得られる成形品の強度と弾性率とのバランスの観点から、ＰＡＮ系炭素繊維がさらに好ましい。 The reinforcing fiber bundle 20 used in the present invention is not particularly limited, but is, for example, high in carbon fiber, glass fiber, aramid fiber, alumina fiber, silicon carbide fiber, boron fiber, metal fiber, PBO fiber, high strength polyethylene fiber and the like. Strong and high elasticity fibers can be used, and one type or two or more types may be used in combination. Among them, carbon fibers such as polyacrylonitrile (PAN) type, pitch type, and rayon type are preferable from the viewpoint of improving mechanical properties and reducing the weight of the molded product, and from the viewpoint of the balance between the strength and elastic modulus of the obtained molded product. , PAN-based carbon fiber is more preferable.
強化繊維束は、通常、多数本の単繊維を束ねた繊維束を１本または複数本並べて構成される。１本または複数の繊維束を並べたときの繊維束の総フィラメント数（単繊維の本数）は、１，０００〜２，０００，０００本が好ましい。生産性の観点からは、繊維束の総フィラメント数は、１，０００〜１，０００，０００本がより好ましく、１，０００〜６００，０００本がさらに好ましく、１，０００〜３００，０００本が特に好ましい。強化繊維束の総フィラメント数の上限は、分散性や取り扱い性とのバランスも考慮して、生産性と分散性、取り扱い性を良好に保てるようであればよい。 The reinforcing fiber bundle is usually composed of one or a plurality of fiber bundles in which a large number of single fibers are bundled. The total number of filaments (the number of single fibers) of the fiber bundle when one or a plurality of fiber bundles are arranged is preferably 1,000 to 2,000,000. From the viewpoint of productivity, the total number of filaments in the fiber bundle is more preferably 1,000 to 1,000,000, further preferably 1,000 to 600,000, and 1,000 to 300,000. Especially preferable. The upper limit of the total number of filaments of the reinforcing fiber bundle may be such that productivity, dispersibility, and handleability can be kept good in consideration of the balance between dispersibility and handleability.
１本の強化繊維束は、好ましくは平均直径５〜１０μｍである強化繊維束の単繊維を１，０００〜１００，０００本束ねて構成される。 One reinforcing fiber bundle is composed of 1,000 to 100,000 single fibers of a reinforcing fiber bundle having an average diameter of 5 to 10 μm.
また、強化繊維束２０はサイジング剤を付着することができる。付着するサイジング剤の種類、量により、強化繊維束２０の開繊度合い、予熱工程における予熱のしやすさ、張力の解除の容易さが異なる。さらに、サイジング剤が付着されていることにより、集束性、耐屈曲性や耐擦過性を改良し、開繊工程において、毛羽、糸切れの発生を抑制でき、生産性を向上することができる。 Further, the reinforcing fiber bundle 20 can be attached with a sizing agent. The degree of opening of the reinforcing fiber bundle 20, the ease of preheating in the preheating step, and the ease of releasing the tension differ depending on the type and amount of the sizing agent to be attached. Further, since the sizing agent is attached, the focusing property, the bending resistance and the scratch resistance can be improved, the occurrence of fluff and thread breakage can be suppressed in the fiber opening step, and the productivity can be improved.
連続的に給糸される強化繊維束２０は、強化繊維束２０の状態により前処理が必要な場合には、適当な前処理を施すことが好ましい。特に、サイジング剤により強化繊維束２０に柔軟性がない場合は、強化繊維束２０をヒーターや熱風ノズルで加熱する加熱機構１０を設け、サイジング剤を軟化あるいは除去することが好ましい。 The reinforcing fiber bundle 20 to be continuously fed is preferably subjected to an appropriate pretreatment when pretreatment is required depending on the state of the reinforcing fiber bundle 20. In particular, when the reinforcing fiber bundle 20 is not flexible due to the sizing agent, it is preferable to provide a heating mechanism 10 for heating the reinforcing fiber bundle 20 with a heater or a hot air nozzle to soften or remove the sizing agent.
また、連続的に給糸される強化繊維束２０の張力を低くした状態で、開繊装置１の容器８内に導入することが好ましい。連続した強化繊維束２０を開繊装置１に導入する上流側に、張力を解除できる機構１１を設けることにより、開繊装置１内で強化繊維束２０を開繊しやすくすることができる。なお、図１では、加熱機構１０の下流側に張力解除機構１１を設ける態様を示しているが、これに限定されるものではなく、いずれか一方のみ設置したり、逆順に配置したり、複数設置することも可能である。 Further, it is preferable to introduce the reinforcing fiber bundle 20 into the container 8 of the fiber opening device 1 in a state where the tension of the continuously fed reinforcing fiber bundle 20 is lowered. By providing the mechanism 11 capable of releasing the tension on the upstream side where the continuous reinforcing fiber bundle 20 is introduced into the fiber opening device 1, the reinforcing fiber bundle 20 can be easily opened in the fiber opening device 1. Note that FIG. 1 shows an embodiment in which the tension release mechanism 11 is provided on the downstream side of the heating mechanism 10, but the present invention is not limited to this, and only one of them may be installed, or a plurality of them may be arranged in reverse order. It is also possible to install it.
連続的に給糸される強化繊維束２０を開繊装置１に導入する給糸口２と、開繊装置で開繊された開繊繊維束２１を開繊装置１より排糸する排糸口３とは、容器８内における強化繊維束２０の走行方向と実質的に同方向に設けることが好ましい。さらに、排糸口３は、給糸口２に対し実質的に一直線上に、対抗する位置に設けられることが更に好ましい。 A yarn feeding port 2 that introduces a reinforcing fiber bundle 20 that is continuously fed into the fiber opening device 1, and a thread outlet 3 that discharges the fiber opening fiber bundle 21 opened by the fiber opening device from the fiber opening device 1. Is preferably provided in substantially the same direction as the traveling direction of the reinforcing fiber bundle 20 in the container 8. Further, it is more preferable that the thread ejection port 3 is provided at a position that opposes the thread feeding port 2 substantially in line with the thread feeding port 2.
開繊装置１内は、吸引管７から吸入される空気の流れによって容器外よりも圧力が低下した状態になるため、給糸口２や排糸口３からも空気が開繊装置１内に流入しようとする気流が生じる。給糸口２では、更に強化繊維束２０の走行に伴う随伴流が開繊装置１内に流入することがある。給糸口２、排糸口３から流入する空気が多いと、吸引管７から吸入された空気の流線に乱れが生じやすく、開繊を阻害する要因となる。このため、給糸口２、排糸口３の開口面積はできる限り小さいほうが好ましい。 Since the pressure inside the fiber-spreading device 1 is lower than that outside the container due to the flow of air sucked from the suction pipe 7, air will flow into the fiber-spreading device 1 from the thread feeding port 2 and the thread discharging port 3. An air flow is generated. At the yarn feeder 2, an accompanying flow accompanying the running of the reinforcing fiber bundle 20 may flow into the fiber opening device 1. If a large amount of air flows in from the yarn feeding port 2 and the yarn discharging port 3, the streamline of the air sucked from the suction pipe 7 is likely to be disturbed, which is a factor that hinders the fiber opening. Therefore, it is preferable that the opening areas of the yarn feeding port 2 and the thread discharging port 3 are as small as possible.
給糸管４及び排糸管５は、強化繊維の種類、強化繊維の太さ、強化繊維の状態等から、最適寸法や材質を適宜選定することができる。給糸管４の形状は柱状であっても良く、円柱形状であっても良い。さらには給糸口２側から順次円錐状に断面積が大きくなっても良いし、その逆であっても良い。またさらには、給糸口２側もしくは反対側（ギャップ６に連通する開口部）の断面がラッパ状に急激に広がる形状であっても良い。排糸管５も同様の形状とすることができる。 The optimum dimensions and materials of the yarn feeding pipe 4 and the yarn discharging pipe 5 can be appropriately selected from the types of reinforcing fibers, the thickness of the reinforcing fibers, the state of the reinforcing fibers, and the like. The shape of the thread feeder pipe 4 may be a columnar shape or a columnar shape. Further, the cross-sectional area may be sequentially increased in a conical shape from the yarn feeding port 2 side, and vice versa. Furthermore, the cross section of the yarn feeding port 2 side or the opposite side (the opening communicating with the gap 6) may be sharply expanded like a trumpet. The thread discharge pipe 5 can have the same shape.
ギャップ６の間隔は、強化繊維の種類、強化繊維の太さ、強化繊維の状態等から適宜選定することができる。ただし、間隔が狭すぎる場合は気流の発生が限定され、十分に強化繊維束２０が開繊されなくなるおそれがある。逆に間隔が広すぎる場合には、強化繊維束２０に気流が作用しなくなり、十分に開繊されないおそれがある。 The interval of the gap 6 can be appropriately selected from the type of reinforcing fiber, the thickness of the reinforcing fiber, the state of the reinforcing fiber, and the like. However, if the interval is too narrow, the generation of airflow is limited, and the reinforcing fiber bundle 20 may not be sufficiently opened. On the other hand, if the interval is too wide, the airflow does not act on the reinforcing fiber bundle 20, and the fibers may not be sufficiently opened.
吸引管７を通過する流量は１Ｌ／ｍｉｎ〜５０００Ｌ／ｍｉｎが好ましく、５Ｌ／ｍｉｎ〜２０００Ｌ／ｍｉｎがより好ましく、１０Ｌ／ｍｉｎ〜１０００Ｌ／ｍｉｎがさらに好ましい。１Ｌ／ｍｉｎ以下では強化繊維束が開繊するのに十分な空気流が発生せず、５０００Ｌ／ｍｉｎ以上では毛羽の発生が生じやすく、繊維進行方向に発生する空気流の強い流れのために強化繊維束の安定的な走行を妨げる要因となる。 The flow rate passing through the suction pipe 7 is preferably 1 L / min to 5000 L / min, more preferably 5 L / min to 2000 L / min, and even more preferably 10 L / min to 1000 L / min. At 1 L / min or less, sufficient air flow is not generated to open the reinforcing fiber bundle, and at 5000 L / min or more, fluff is likely to occur, and the reinforcing fiber bundle is reinforced due to the strong air flow generated in the fiber traveling direction. It becomes a factor that hinders the stable running of the fiber bundle.
本発明に用いる容器８の形態は特に限定されるものではなく、矩形や柱形が好ましく用いられる吸引管７の本数は特に制限はないものの、強化繊維束２０の走行方向に対して交差するように吸引管７を設けて開繊させることから、向かい合わせで対になるように設けることが好ましい。容器８が直方体の場合には、４つの側面全てに吸引管７を取り付けることができる。吸引管７の位置は特に制限されないが、向かい合う一対の吸引管７を結ぶ中心線が、ギャップ６の中心位置と同じ高さの位置になるように設けると、効率よく強化繊維束２０の周方向に気流を生じさせることができる。 The form of the container 8 used in the present invention is not particularly limited, and the number of suction pipes 7 in which a rectangular shape or a pillar shape is preferably used is not particularly limited, but intersects the traveling direction of the reinforcing fiber bundle 20. Since the suction tube 7 is provided in the tube to open the fiber, it is preferable to provide the suction tube 7 so as to face each other in pairs. When the container 8 is a rectangular parallelepiped, the suction pipe 7 can be attached to all four side surfaces. The position of the suction pipe 7 is not particularly limited, but if the center line connecting the pair of suction pipes 7 facing each other is provided at the same height as the center position of the gap 6, the reinforcing fiber bundle 20 is efficiently provided in the circumferential direction. Can create an air flow.
開繊装置１で開繊された強化繊維束２０は、開繊された開繊繊維束２１となって排糸管５へ送られる。 The reinforcing fiber bundle 20 opened by the fiber opening device 1 becomes the opened fiber bundle 21 and is sent to the yarn discharge pipe 5.
開繊繊維束２１は、繊維の種類、繊維の太さ及び繊維の状態により、排糸管５内で収束する可能性がある。このため、図３に示すように、排糸管５内に開繊状態を維持させる形態維持部材１２を設置しておくと、ギャップ６で得られた開繊状態を維持することができる。 The spread fiber bundle 21 may converge in the yarn ejection tube 5 depending on the type of fiber, the thickness of the fiber, and the state of the fiber. Therefore, as shown in FIG. 3, if the form maintaining member 12 for maintaining the spread state is installed in the yarn discharge pipe 5, the spread state obtained in the gap 6 can be maintained.
形態維持部材１２の形状は特に指定されないが、円周方向に開繊した繊維束の状態を良好に維持するためには円柱状であることが好ましい。また、開繊繊維束との擦過を防ぐために、形態維持部材１２の表面への潤滑剤の塗布や形態維持部材１２から空気の噴出が効果的である。 The shape of the shape-maintaining member 12 is not particularly specified, but it is preferably columnar in order to maintain a good state of the fiber bundle opened in the circumferential direction. Further, in order to prevent scratching with the spread fiber bundle, it is effective to apply a lubricant to the surface of the shape maintaining member 12 and to eject air from the shape maintaining member 12.
本発明の方法により開繊された強化繊維束２０は開繊状態を維持したままマトリックス樹脂を含浸させることにより、繊維強化樹脂とすることができる。含浸方法としては、例えば、フィルム状のマトリックス樹脂を溶融し、加圧することで強化繊維束にマトリックス樹脂を含浸させるフィルム法、粉末状のマトリックス樹脂を強化繊維束における繊維の隙間に分散させた後、粉末状のマトリックス樹脂を溶融し、加圧することで強化繊維束にマトリックス樹脂を含浸させる粉末法、溶融したマトリックス樹脂中に強化繊維束を浸し、加圧することで強化繊維束にマトリックス樹脂を含浸させる引き抜き法が挙げられる。 The reinforcing fiber bundle 20 opened by the method of the present invention can be made into a fiber-reinforced resin by impregnating the matrix resin while maintaining the opened fiber state. Examples of the impregnation method include a film method in which a film-shaped matrix resin is melted and pressed to impregnate the reinforcing fiber bundle with the matrix resin, and a powdered matrix resin is dispersed in the gaps between the fibers in the reinforcing fiber bundle. , A powder method in which a powdered matrix resin is melted and pressed to impregnate the reinforcing fiber bundle with the matrix resin. A reinforcing fiber bundle is immersed in the melted matrix resin and pressed to impregnate the reinforcing fiber bundle with the matrix resin. There is a pull-out method to make it.
本発明に使用されるマトリックス樹脂としては熱可塑樹脂もしくは熱硬化樹脂のいずれを用いてもよい。 As the matrix resin used in the present invention, either a thermoplastic resin or a thermosetting resin may be used.
熱可塑性樹脂としては、例えば、ポリエチレンテレフタレート（ＰＥＴ）樹脂、ポリブチレンテレフタレート（ＰＢＴ）樹脂、ポリトリメチレンテレフタレート（ＰＴＴ）樹脂、ポリエチレンナフタレート（ＰＥＮ）樹脂、液晶ポリエステル樹脂等のポリエステルや、ポリエチレン（ＰＥ）樹脂、ポリプロピレン（ＰＰ）樹脂、ポリブチレン樹脂等のポリオレフィンや、スチレン系樹脂の他や、ポリオキシメチレン（ＰＯＭ）樹脂、ポリアミド（ＰＡ）樹脂、ポリカーボネート（ＰＣ）樹脂、ポリメチレンメタクリレート（ＰＭＭＡ）樹脂、ポリ塩化ビニル（ＰＶＣ）樹脂、ポリフェニレンスルフィド（ＰＰＳ）樹脂、ポリフェニレンエーテル（ＰＰＥ）樹脂、変性ＰＰＥ樹脂、ポリイミド（ＰＩ）樹脂、ポリアミドイミド（ＰＡＩ）樹脂、ポリエーテルイミド（ＰＥＩ）樹脂、ポリスルホン（ＰＳＵ）樹脂、変性ＰＳＵ樹脂、ポリエーテルスルホン樹脂、ポリケトン（ＰＫ）樹脂、ポリエーテルケトン（ＰＥＫ）樹脂、ポリエーテルエーテルケトン（ＰＥＥＫ）樹脂、ポリエーテルケトンケトン（ＰＥＫＫ）樹脂、ポリアリレート（ＰＡＲ）樹脂、ポリエーテルニトリル（ＰＥＮ）樹脂、フェノール系樹脂、フェノキシ樹脂、ポリテトラフルオロエチレン樹脂などのフッ素系樹脂、更にポリスチレン系樹脂、ポリオレフィン系樹脂、ポリウレタン系樹脂、ポリエステル系樹脂、ポリアミド系樹脂、ポリブタジエン系樹脂、ポリイソプレン系樹脂、フッ素系樹脂等の熱可塑エラストマー等や、これらの共重合体、変性体、および２種類以上ブレンドした樹脂などであってもよい。 Examples of the thermoplastic resin include polyesters such as polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN) resin, and liquid crystal polyester resin, and polyethylene (polysulfone). In addition to polyolefins such as PE) resin, polypropylene (PP) resin, and polybutylene resin, and styrene resins, polyoxymethylene (POM) resin, polyamide (PA) resin, polycarbonate (PC) resin, and polymethylene methacrylate (PMMA). Resins, polyvinyl chloride (PVC) resins, polyphenylene sulfide (PPS) resins, polyphenylene ether (PPE) resins, modified PPE resins, polyimide (PI) resins, polyamideimide (PAI) resins, polyetherimide (PEI) resins, polysulfones (PSU) resin, modified PSU resin, polyethersulfone resin, polyketone (PK) resin, polyetherketone (PEK) resin, polyetheretherketone (PEEK) resin, polyetherketoneketone (PEKK) resin, polyarylate (PAR) ) Resin, polyethernitrile (PEN) resin, phenol-based resin, phenoxy resin, fluorine-based resin such as polytetrafluoroethylene resin, and polystyrene-based resin, polyolefin-based resin, polyurethane-based resin, polyester-based resin, polyamide-based resin, It may be a thermoplastic elastomer such as a polybutadiene resin, a polyisoprene resin, or a fluorine resin, a copolymer of these, a modified product, or a resin in which two or more kinds are blended.
熱硬化樹脂としては、例えば、エポキシ樹脂、不飽和ポリエステル樹脂、ビニルエステル樹脂、フェノール樹脂、エポキシアクリレート樹脂、ウレタンアクリレート樹脂、フェノキシ樹脂、アルキド樹脂、ウレタン樹脂、マレイミド樹脂、シアネート樹脂などが挙げられる。 Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, vinyl ester resin, phenol resin, epoxy acrylate resin, urethane acrylate resin, phenoxy resin, alkyd resin, urethane resin, maleimide resin, cyanate resin and the like.
このうち、樹脂粘度が高く含浸の難しい熱可塑性樹脂であれば、本発明の開繊の効果が高く発現でき好ましい。 Of these, a thermoplastic resin having a high resin viscosity and difficult to impregnate is preferable because the effect of opening the fibers of the present invention can be highly exhibited.
本発明によって得られた開繊繊維束２１は、図４に示すように、円周方向に広く、略均一に開繊されたものである。開繊により強化繊維３０同士の間隔が広がることから、マトリックス樹脂３１は容易に強化繊維３０の繊維間に容易に浸透することができる。一方、本発明を用いない場合には、図５に示すように、強化繊維束２０が幅方向に拡がり、繊維中心間までの距離は短くなるものの、強化繊維３０同士の間隔は変化しないため、マトリックス樹脂３１は開繊繊維束３２の周囲のみを被覆する。すなわち、強化繊維３０同士の隙間にまで十分に樹脂が含浸せず、開繊繊維束３２の内部に未含浸部分が生じるため、繊維強化樹脂として十分な機械特性等が発揮できないものとなる。 As shown in FIG. 4, the spread fiber bundle 21 obtained by the present invention is wide in the circumferential direction and spread substantially uniformly. Since the distance between the reinforcing fibers 30 is widened by opening the fibers, the matrix resin 31 can be easily penetrated between the fibers of the reinforcing fibers 30. On the other hand, when the present invention is not used, as shown in FIG. 5, the reinforcing fiber bundle 20 expands in the width direction and the distance between the fiber centers is shortened, but the distance between the reinforcing fibers 30 does not change. The matrix resin 31 covers only the periphery of the spread fiber bundle 32. That is, the resin is not sufficiently impregnated into the gaps between the reinforcing fibers 30, and an unimpregnated portion is generated inside the spread fiber bundle 32, so that sufficient mechanical properties and the like cannot be exhibited as the fiber reinforced resin.
本発明に係る開繊繊維束は従来技術では達成できなかった、マトリックス樹脂の含浸に好適な開繊状態を達成できるため、あらゆる繊維強化プラスチックの製造に利用できる。 Since the spread fiber bundle according to the present invention can achieve a fiber spread state suitable for impregnation with a matrix resin, which could not be achieved by the prior art, it can be used for producing any fiber reinforced plastic.
１ 開繊装置
２ 給糸口
３ 排糸口
４ 給糸管
５ 排糸管
６ ギャップ
７ 吸引管
８ 容器
１０ 加熱機構
１１ 張力解除機構
１２ 形態維持部材
２０ 強化繊維束
２１ 開繊繊維束
３０ 強化繊維
３１ マトリックス樹脂
３２ 開繊繊維束
1 Fiber opening device 2 Thread feeding port 3 Threading port 4 Thread feeding pipe 5 Threading pipe 6 Gap 7 Suction pipe 8 Container 10 Heating mechanism 11 Tension release mechanism 12 Form maintenance member 20 Reinforcing fiber bundle 21 Reinforcing fiber bundle 30 Reinforcing fiber 31 Matrix Resin 32 spread fiber bundle
Claims (14)
前記容器の側面に吸引部が設けられるとともに、前記容器内に給糸管と排糸管が間隔をあけて正対するように設けられ前記繊維束の周方向に気流を発生させて該繊維束を周方向に開繊させるための、前記吸引部から空気を吸引する吸引機構を備えることを特徴とする強化繊維束の開繊装置。 A reinforcing fiber bundle opening device including a supply mechanism for continuously supplying the reinforcing fiber bundle and a container for introducing the supplied reinforcing fiber bundle into the inside.
A suction portion is provided on the side surface of the container, and a yarn supply pipe and a yarn discharge pipe are provided in the container so as to face each other at a distance, and an air flow is generated in the circumferential direction of the fiber bundle to generate the fiber bundle. A fiber bundle opening device for reinforcing fiber bundles, which comprises a suction mechanism for sucking air from the suction portion for opening fibers in the circumferential direction.
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