Method of manufacturing unidirectional prepreg, apparatus of manufacturing unidirectional prepreg, and method of feeding fiber bundle

Abstract

To provide a manufacturing method and a manufacturing apparatus of a unidirectional prepreg capable of preventing a fiber bundle from being partially folded or a fiber from being bent even when an interval of a plurality of flat fiber bundles that run side by side is changed.SOLUTION: A method of manufacturing a unidirectional prepreg includes turning a flat surface of a continuous fiber bundle 1 by 90±15° as viewed from the running direction while running the flat continuous fiber bundle 1 in the longitudinal direction. By using a first inclined guide roll 21A provided so as to be inclined relative to the flat surface of the continuous fiber bundle 1 before being turned by 90±15° when viewed from the running direction of the continuous fiber bundle 1, and a first parallel guide roll 22A provided so as to be parallel to the flat surface of the continuous fiber bundle 1 after being turned by 90±15°, the continuous fiber bundle 1 is run while being in contact with the first inclined guide roll 21A and the first parallel guide roll 22A in turn. Thereby, the flat surface of the continuous fiber bundle 1 is turned by 90±15°.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a method for producing a unidirectional prepreg, an apparatus for producing a unidirectional prepreg, and a method for supplying a fiber bundle. [Background technology]

[0002] Fiber-reinforced plastics (FRP), especially carbon-fiber-reinforced plastics (CFRP) that use carbon fiber as the fiber reinforcement, are lightweight and strong, and are widely used in a variety of applications, such as sports goods and transportation equipment such as aircraft and automobiles. FRP is manufactured using an intermediate material, i.e., prepreg, in which a reinforcing material made of reinforcing fibers is impregnated with resin.

[0003] A unidirectional prepreg (UD prepreg), in which a sheet-like fiber bundle in which fibers are aligned in one direction is impregnated with resin, is a type of prepreg. For example, fiber bundles sent out from multiple creels are gathered and spread while running in parallel, and a resin sheet is laminated on the obtained spread sheet and impregnated with resin.

[0004] As a method for collecting the fiber bundles sent out from each creel and running them in parallel, as shown in Fig. 12, there is a method in which multiple combs 110 are arranged at predetermined intervals in the width direction perpendicular to the running direction of the fiber bundles 120, and each fiber bundle 120 is guided between each comb 110 to adjust the running interval of each fiber bundle 120 to be narrow. However, the fiber bundles 120 used in the manufacture of UD prepregs are flat, and in this method, only one side of the fiber bundle 120 sent out with the flat surface horizontally hits the comb 110, which can cause problems such as the fiber bundle 120 being partially folded during running.

[0005] A method has also been proposed in which, as shown in Fig. 13(A), fiber bundles 120 are sent out from each creel with the flat surface standing vertically, and the running fiber bundles 120 are redirected by guide rolls 112 standing vertically, and the running intervals of each fiber bundle 120 are narrowed as shown in Fig. 13(B) (Patent Document 1). In this method, the flat surface of the fiber bundle 120 contacts the guide rolls 112, so that partial folding of the fiber bundle 120 when it contacts the guide rolls 112 is suppressed. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] International Publication No. 2004 / 015184 Summary of the Invention [Problem to be solved by the invention]

[0007] In the method of Patent Document 1, the flat planes of the parallel fiber bundles 120 are horizontally spread, so that the flat planes of the parallel fiber bundles 120, which stand vertically, need to be rotated 90° to be horizontal. At this time, a twisting force is applied to the fiber bundles 120, which may cause the fibers to break.

[0008] An object of the present invention is to provide a method for producing a unidirectional prepreg, an apparatus for producing a unidirectional prepreg, and a method for supplying a fiber bundle, which can suppress partial folding of the fiber bundle or breakage of the fibers even when the interval between a plurality of parallel flat fiber bundles is changed. In addition to the above objects, the objects of the present invention may be explicitly or implicitly indicated in the present invention. [Means for solving the problem]

[0009] The present invention includes the following configurations. [1] A method for producing a unidirectional prepreg, comprising: running a long, flat fiber bundle in a length direction while rotating the flat surface of the fiber bundle by 90°±15° as viewed from the running direction, A method for producing a unidirectional prepreg, comprising using an inclined guide roll that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° when viewed from the running direction of the fiber bundle, and a parallel guide roll that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°, and running the fiber bundle while contacting the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°. [2] The method for producing a unidirectional prepreg according to [1], wherein the inclination angle of the inclined guide roll with respect to the flat surface of the fiber bundle before being rotated by 90°±15° is 15° or more and 75° or less, as viewed from the running direction of the fiber bundle. [3] The method for producing a unidirectional prepreg according to [1] or [2], wherein a ratio (D / W) of a distance D between the inclined guide roll and the parallel guide rolls in the running direction of the fiber bundle to an initial width W of the fiber bundle is 3 or more. [4] The method for producing a unidirectional prepreg according to any one of [1] to [3], wherein the center-to-center distance between a portion of the traveling fiber bundle in contact with the inclined guide roll and a portion of the traveling fiber bundle in contact with the parallel guide roll is 10 mm or more in a width direction that is horizontal and perpendicular to the traveling direction when viewed from the traveling direction of the fiber bundle. [5] The method for producing a unidirectional prepreg according to any one of [1] to [4], wherein the number of the inclined guide rolls that is brought into contact with the flat surface of the fiber bundle while rotating the flat surface by 90°±15° is one. [6] A method for producing a unidirectional prepreg according to any one of [1] to [5], comprising providing two or more parallel guide rolls and supplying the fiber bundle to a predetermined position by running the fiber bundle in contact with each of the parallel guide rolls in sequence. [7] A method for producing a unidirectional prepreg according to any one of [1] to [6], comprising opening the fiber bundles. [8] The method for producing a unidirectional prepreg according to any one of [1] to [7], wherein the fiber bundles contain carbon fibers. [9] A unidirectional prepreg manufacturing apparatus including a rotating device that rotates a flat surface of a long, flat fiber bundle by 90°±15° as viewed from the running direction while running the long, flat fiber bundle in the length direction, The rotating device is provided with an inclined guide roll that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° when viewed from the running direction of the fiber bundle, and a parallel guide roll that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°, and the fiber bundle is run while being in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°.

[10] A unidirectional prepreg manufacturing apparatus as described in [9], wherein the inclination angle of the inclined guide roll with respect to the flat surface of the fiber bundle before being rotated by 90°±15° is 15° or more and 75° or less, as viewed from the running direction of the fiber bundle.

[11] The apparatus for manufacturing a unidirectional prepreg described in [9] or

[10] , wherein the number of inclined guide rolls that contact the flat surface of the fiber bundle while rotating it by 90°±15° is one.

[12] An apparatus for manufacturing a unidirectional prepreg according to any one of [9] to

[11] , wherein two or more parallel guide rolls are provided, and the fiber bundle is supplied to a predetermined position by being brought into contact with each of the parallel guide rolls in sequence while running.

[13] The apparatus for producing a unidirectional prepreg according to any one of [9] to

[12] , further comprising a fiber spreading device for spreading the fiber bundles.

[14] A method for supplying a fiber bundle, comprising: rotating a flat surface of a long, flat fiber bundle by 90°±15° as viewed from the traveling direction while traveling the fiber bundle in a longitudinal direction, A fiber bundle supplying method using an inclined guide roll that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° as viewed from the running direction, and a parallel guide roll that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°, and running the fiber bundle in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°. Effect of the Invention

[0010] According to the present invention, it is possible to provide a unidirectional prepreg manufacturing method, a unidirectional prepreg manufacturing apparatus, and a fiber bundle supplying method that can prevent partial folding of fiber bundles and breakage of fibers even when the spacing between multiple parallel flat fiber bundles is changed. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic diagram showing a schematic configuration of a manufacturing apparatus for a unidirectional prepreg according to an embodiment. [Diagram 2] FIG. 2 is a schematic diagram showing the rotating device in the manufacturing apparatus of FIG. 1 as viewed from above. [Diagram 3] FIG. 3 is a schematic diagram showing a state in which the rotating device in the manufacturing apparatus in FIG. 1 is seen from the side. [Figure 4] FIG. 4 is a schematic diagram showing how the fiber bundle is turned in the turning device, as viewed from above. [Diagram 5] FIG. 5(A) is a diagram for explaining the inclination angle of the first inclined guide roll, and FIG. 5(B) is a diagram for explaining the inclination angle of the second inclined guide roll. [Figure 6] FIG. 6 is a diagram illustrating the center-to-center distance between a portion of the traveling fiber bundle that contacts the first inclined guide roll and a portion of the traveling fiber bundle that contacts the first parallel guide roll. [Figure 7] FIG. 7 is a diagram illustrating the center-to-center distance between a portion of the traveling fiber bundle that contacts the second inclined guide roll and a portion of the traveling fiber bundle that contacts the second parallel guide roll. [Figure 8] FIG. 8 is a schematic diagram showing a state in which a fiber bundle is rotated in another example of a rotating device, as viewed from above. [Figure 9] FIG. 9 is a schematic diagram showing a state in which a fiber bundle is rotated in another example of a rotating device, as viewed from above. [Figure 10] FIG. 10 is a schematic diagram showing a state in which a fiber bundle is rotated in another example of a rotating device, as viewed from above. [Figure 11]FIG. 11 is a schematic diagram showing how the flat surface of a traveling fiber bundle is rotated by 90° in an embodiment. [Figure 12] FIG. 12 is a schematic diagram showing a conventional method for adjusting the running interval of fiber bundles by using a plurality of combs arranged at predetermined intervals. [Figure 13] FIG. 13 is a schematic diagram showing a conventional method of adjusting the running interval with the flat surface of each fiber bundle standing vertically, where FIG. 13(A) is a plan view seen from above and FIG. 13(B) is a front view seen from the running direction. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, an example of a method for producing a unidirectional prepreg, an apparatus for producing a unidirectional prepreg, and a method for supplying a fiber bundle according to an embodiment will be described with reference to the drawings. Note that the dimensions of the drawings shown in the following description are merely examples, and the present invention is not necessarily limited thereto, and can be appropriately modified and implemented within the scope of the present invention.

[0013] The manufacturing method for a unidirectional prepreg according to the embodiment is a method for manufacturing a prepreg in which a sheet-like fiber bundle in which fibers are aligned in one direction is impregnated with resin, that is, a so-called unidirectional prepreg (UD prepreg), and includes running a long, flat fiber bundle in the length direction while rotating the flat surface of the fiber bundle by 90°±15° when viewed from the running direction. Note that "rotating the flat plane of the fiber bundle by 90°±15°" means that the angle of the flat plane after rotation with respect to the flat plane of the fiber bundle before rotation is 90°±15° as viewed from the running direction. The rotation of the fiber bundle by 90°±15° as viewed from the running direction may be either clockwise or counterclockwise.

[0014] When rotating the flat surface of the running fiber bundle by 90°±15°, an inclined guide roll is used that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° as viewed from the running direction, and a parallel guide roll is used that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°. The fiber bundle is then run in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°. By rotating the flat surface of the fiber bundle while being guided by the inclined guide roll and the parallel guide roll in this manner, it is possible to prevent the fiber bundle from being partially folded or the fibers from being bent, even when the intervals between multiple flat fiber bundles running in parallel are changed. The inclined guide roll and the parallel guide roll may be fixed, or may be rotated in accordance with the running speed of the fiber bundle.

[0015] [Unidirectional prepreg manufacturing equipment] FIG. 1 is a schematic diagram showing a schematic configuration of a unidirectional prepreg manufacturing apparatus 100 (hereinafter also simply referred to as "manufacturing apparatus 100"), which is an example of a manufacturing apparatus that can be used in the manufacturing method of a unidirectional prepreg according to the embodiment. In the following explanation, the positional relationship of each member will be explained with reference to the XYZ directions shown in each figure. In the XYZ directions, the X axis direction is the running direction of the fiber bundle, that is, the horizontal direction from the upstream where the fiber bundle is supplied to the downstream where the prepreg is obtained, and the Y axis direction is the horizontal width direction perpendicular to the running direction. The XY plane is horizontal. The Z axis direction is the vertical direction, perpendicular to the XY plane.

[0016] The manufacturing apparatus 100 includes a plurality of yarn suppliers 10, a rotating device 20, a fiber spreading device 30, a laminating device 40, and an impregnation machine 50.

[0017] (Yam feeder) The yarn supplier 10 delivers a long, flat continuous fiber bundle 1, and may be, for example, one in which the continuous fiber bundle 1 is drawn from an outside bobbin package attached to a creel. Alternatively, the continuous fiber bundle 1 may be drawn from an inside package from which the bobbin has been removed.

[0018] The continuous fiber bundles 1 sent out from the multiple yarn suppliers 10 run parallel to each other at a predetermined interval horizontally and in a direction perpendicular to the running direction (Y-axis direction) to the turning device 20. Guide rolls, dancer rolls, etc. can be appropriately used for running the continuous fiber bundles 1 from the yarn suppliers 10 to the turning device 20. The number of yarn suppliers 10 can be appropriately set depending on the number of filaments in the continuous fiber bundle 1 sent out from each yarn supplier 10, the desired width of the prepreg, and the like.

[0019] (Rotation device) The rotating device 20 is a device that rotates the flat surface of the continuous fiber bundle 1 by 90°±15° as viewed from the running direction while running the continuous fiber bundle 1 in the length direction. The example turning device 20 shown in Figures 1 and 2 includes, in this order, a first inclined guide roll 21A, a first parallel guide roll 22A, a third parallel guide roll 23, a second inclined guide roll 21B, and a second parallel guide roll 22B.

[0020] The first inclined guide roll 21A and the first parallel guide roll 22A are guide rolls for rotating the flat surface 1a of the continuous fiber bundle 1, which runs with the flat surface 1a kept horizontal, by 90°±15° to stand it vertically. The third parallel guide roll 23 is a guide roll for changing the direction of the continuous fiber bundle 1, whose flat surface 1a is vertical, to change its position in the Y-axis direction (width direction) and adjust the running interval of each continuous fiber bundle 1 in the Y-axis direction. The second inclined guide roll 21B and the second parallel guide roll 22B are guide rolls for rotating the flat surface 1a of the continuous fiber bundle 1, which runs with the flat surface 1a standing vertically, by 90°±15° to make it horizontal.

[0021] The guide rolls used for the first inclined guide roll 21A, the first parallel guide roll 22A, the third parallel guide roll 23, the second inclined guide roll 21B, and the second parallel guide roll 22B are typically cylindrical in shape. The diameter of these guide rolls can be set appropriately, for example, to 3 mm or more and 20 mm or less.

[0022] The first inclined guide roll 21A is provided at an incline with respect to the upward-facing horizontal flat surface 1a of the continuous fiber bundle 1 before being rotated by 90°±15° when viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction). The first parallel guide roll 22A is provided parallel to the vertical flat surface 1a of the continuous fiber bundle 1 after being rotated by 90°±15° when viewed from the running direction of the continuous fiber bundle 1.

[0023] In the example shown in Figures 1 to 4, each continuous fiber bundle 1 sent out from the yarn supplier 10 is supplied to the turning device 20 with the flat surface 1a held horizontal, and the guide roll 11 immediately before the turning device 20 is in contact with the lower flat surface 1b of the continuous fiber bundle 1. 3 and 4, in the front half of the rotating device 20, a first inclined guide roll 21A and a first parallel guide roll 22A are successively brought into contact with the lower flat surface 1b of the continuous fiber bundle 1, which runs with the flat surfaces 1a, 1b kept horizontal. As a result, when viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction), the flat surface 1a of the continuous fiber bundle 1 is rotated counterclockwise by 90°±15° and stands in the vertical direction.

[0024] When viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction), the inclination angle θ1 (0°<θ1<90°, FIG. 5(A)) of the first inclined guide roll 21A with respect to the horizontal flat surface 1a of the continuous fiber bundle 1 before being rotated by 90°±15° is preferably 15° or more, more preferably 20° or more, even more preferably 30° or more, and particularly preferably 40° or more. The inclination angle θ1 of the first inclined guide roll 21A is preferably 75° or less, more preferably 70° or less, even more preferably 60° or less, and particularly preferably 50° or less. If the inclination angle θ1 of the first inclined guide roll 21A is within the above range, it is possible to suppress the occurrence of bending of the fiber bundle due to the twisting force generated when the fiber bundle comes into contact with the inclined guide roll and rotates. The preferable lower limit and upper limit of the inclination angle θ1 of the first inclined guide roll 21A can be arbitrarily combined, and for example, it is preferable that it is 15° or more and 75° or less.

[0025] The distance D1 (FIG. 3) between the first inclined guide roll 21A and the first parallel guide roll 22A in the running direction (X-axis direction) for vertically standing the horizontal flat surface 1a of the continuous fiber bundle 1 is preferably 30 mm or more, more preferably 40 mm or more, even more preferably 60 mm or more, and particularly preferably 100 mm or more. If the distance D1 is equal to or more than the lower limit, the twisting force applied to the continuous fiber bundle 1 when the flat surface 1a is rotated becomes smaller, and the fibers in the continuous fiber bundle 1 are further unlikely to break. The distance D1 between the first inclined guide roll 21A and the first parallel guide roll 22A is preferably 500 mm or less, more preferably 300 mm or less, even more preferably 200 mm or less, and particularly preferably 150 mm or less. If the distance D1 is equal to or less than the upper limit, the prepreg manufacturing apparatus can be prevented from becoming excessively large. The preferred lower and upper limits of the distance D1 between the first inclined guide roll 21A and the first parallel guide roll 22A can be arbitrarily combined, and are preferably, for example, 30 mm or more and 500 mm or less.

[0026] The ratio (D1 / W) of the distance D1 between the first inclined guide roll 21A and the first parallel guide roll 22A in the running direction (X-axis direction) of the continuous fiber bundle 1 to the initial width W of the continuous fiber bundle 1 is preferably 3 or more, more preferably 4 or more, even more preferably 7 or more, and particularly preferably 12 or more. If D1 / W is equal to or more than the lower limit, the torsional force applied to the continuous fiber bundle 1 when the flat surface 1a is rotated becomes smaller, and the fibers in the continuous fiber bundle 1 are further unlikely to break. D1 / W is preferably 50 or less, more preferably 40 or less, even more preferably 30 or less, and particularly preferably 15 or less. If D1 / W is equal to or less than the upper limit, the prepreg manufacturing device can be prevented from becoming excessively large. The preferable lower limit and upper limit of D1 / W can be arbitrarily combined, and for example, a range of 3 to 50 is preferable. The "initial width W of the fiber bundle" means the width of the fiber bundle before it is fed to produce the prepreg.

[0027] As shown in FIG. 6, when viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction), the center-to-center distance d1 in the Y-axis direction (width direction) between the part of the running continuous fiber bundle 1 that contacts the first inclined guide roll 21A and the part that contacts the first parallel guide roll 22A is preferably 10 mm or more, more preferably 15 mm or more, and even more preferably 20 mm or more. If the center-to-center distance d1 is equal to or more than the lower limit, it is easy to prevent the continuous fiber bundle 1 from being partially folded. The center-to-center distance d1 is preferably 100 mm or less, more preferably 50 mm or less, and even more preferably 30 mm or less. If the center-to-center distance d1 is equal to or less than the upper limit, it is possible to prevent fluffing caused by contact and rubbing between the first inclined guide roll and the fiber bundle, and between the first parallel guide roll and the fiber bundle. The preferable lower limit and upper limit of the center-to-center distance d1 can be arbitrarily combined, and for example, a range of 10 mm or more and 100 mm or less is preferable. The center-to-center distance d1 means the distance in the Y-axis direction (width direction) between the center of a cross section perpendicular to the fiber length of a portion of the continuous fiber bundle 1 in contact with the first inclined guide roll 21A and the center of a cross section perpendicular to the fiber length of a portion of the continuous fiber bundle 1 in contact with the first parallel guide roll 22A, as viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction). The center distance d1 can be adjusted by adjusting the positions of the first inclined guide roll 21A and the first parallel guide roll 22A in the Y-axis direction (width direction).

[0028] 1 to 4, it is preferable that there is one first inclined guide roll 21A that is brought into contact with the continuous fiber bundle 1 during a 90°±15° turn when the horizontal flat surface 1a of the continuous fiber bundle 1 is set vertically. If there is only one first inclined guide roll 21A that is brought into contact with the continuous fiber bundle 1 during a 90°±15° turn, a fiber bundle with fewer breaks can be supplied without impairing workability and with a small capital investment. The number of the first inclined guide rolls 21A that are brought into contact with the continuous fiber bundle 1 when the continuous fiber bundle 1 is turned by 90°±15° to erect the flat surface 1a of the continuous fiber bundle 1 may be two or more.

[0029] In the example shown in Fig. 2, each continuous fiber bundle 1 with its flat surface 1a standing vertically is made to run while being in contact with the first parallel guide roll 22A and the third parallel guide roll 23 in turn, so that the position of each continuous fiber bundle 1 in the Y-axis direction (width direction) is adjusted to be at equal intervals. In this way, when adjusting the position at which the fiber bundle is supplied, the fiber bundle running with its flat surface standing vertically is turned by two or more vertical parallel guide rolls, so that it becomes easy to prevent the flat fiber bundle from being partially folded. This embodiment is particularly useful when multiple fiber bundles are supplied to a fiber spreader with a narrow running interval, or when multiple fiber bundles are supplied to a fiber spreader with a wide running interval. The fiber bundle traveling with the flat surface standing vertically may be brought into contact with three or more parallel guide rolls in sequence to adjust the position in the Y-axis direction (width direction).

[0030] The second inclined guide roll 21B is provided at an incline with respect to the vertical flat surface 1a of the continuous fiber bundle 1 before being rotated by 90°±15° when viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction). The second parallel guide roll 22B is provided parallel to the horizontal flat surface 1a of the continuous fiber bundle 1 after being rotated by 90°±15° when viewed from the running direction of the continuous fiber bundle 1. 3 and 4, in the rear half of the rotating device 20, the second inclined guide roll 21B and the second parallel guide roll 22B are successively brought into contact with the flat surface 1a of the continuous fiber bundle 1 running with the flat surface 1a standing vertically. As a result, the flat surface 1a of the continuous fiber bundle 1 standing vertically is rotated clockwise by 90°±15° to be horizontal.

[0031] In this manner, in the rotating device 20, the continuous fiber bundle 1 running with the flat surface 1a kept horizontal is rotated counterclockwise by 90°±15° by the first inclined guide roll 21A and the first parallel guide roll 22A to make the flat surface 1a stand in the vertical direction, and then rotated clockwise by 90°±15° by the second inclined guide roll 21B and the second parallel guide roll 22B to make the flat surface 1a of the continuous fiber bundle 1 horizontal.

[0032] The preferred lower and upper limits of the inclination angle θ2 (0°<θ2<90°, FIG. 5(B)) of the second inclined guide roll 21B with respect to the flat surface 1a standing in the vertical direction of the continuous fiber bundle 1 before being rotated by 90°±15° as viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction) are the same as the preferred lower and upper limits of the inclination angle θ1 of the first inclined guide roll 21A described above. Specifically, the inclination angle θ2 of the second inclined guide roll 21B is preferably 15° or more, more preferably 20° or more, even more preferably 30° or more, and particularly preferably 40° or more, while it is preferably 75° or less, more preferably 70° or less, even more preferably 60° or less, and particularly preferably 50° or less. The preferred lower and upper limits of the inclination angle θ2 of the second inclined guide roll 21B can be arbitrarily combined, and for example, 15° or more and 75° or less are preferred.

[0033] The preferred lower and upper limits of the distance D2 (FIG. 3) between the second inclined guide roll 21B and the second parallel guide roll 22B in the running direction (X-axis direction) for horizontally tilting the flat surface 1a of the continuous fiber bundle 1 standing in the vertical direction are the same as the preferred lower and upper limits of the distance D1 between the first inclined guide roll 21A and the first parallel guide roll 22A described above. Specifically, the distance D2 is preferably 30 mm or more, more preferably 40 mm or more, even more preferably 60 mm or more, and particularly preferably 100 mm or more, while it is preferably 500 mm or less, more preferably 300 mm or less, even more preferably 200 mm or less, and particularly preferably 150 mm or less. The preferred lower and upper limits of the distance D2 can be arbitrarily combined, and for example, a range of 30 mm or more and 500 mm or less is preferred.

[0034] The preferred lower and upper limits of the ratio (D2 / W) of the distance D2 between the second inclined guide roll 21B and the second parallel guide roll in the running direction (X-axis direction) of the continuous fiber bundle 1 to the initial width W of the continuous fiber bundle 1 are similar to the preferred lower and upper limits of D1 / W described above. Specifically, D2 / W is preferably 3 or more, more preferably 4 or more, even more preferably 7 or more, and particularly preferably 12 or more, while it is preferably 50 or less, more preferably 40 or less, even more preferably 30 or less, and particularly preferably 15 or less. The preferred lower and upper limits of D2 / W can be arbitrarily combined, and for example, a range of 3 or more and 50 or less is preferred.

[0035] As shown in Fig. 7, when viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction), the center-to-center distance d2 in the Y-axis direction (width direction) between the part of the running continuous fiber bundle 1 that contacts the second inclined guide roll 21B and the part that contacts the second parallel guide roll 22B is the same as the above-mentioned center-to-center distance d1. Specifically, the center-to-center distance d2 is preferably 10 mm or more, more preferably 15 mm or more, and even more preferably 20 mm or more, while it is preferably 100 mm or less, more preferably 50 mm or less, and even more preferably 30 mm or less. The preferable lower limit and upper limit of the center-to-center distance d2 can be arbitrarily combined, and for example, 10 mm or more and 100 mm or less are preferable. The center-to-center distance d2 means the distance in the Y-axis direction (width direction) between the center of a cross section perpendicular to the fiber length of a portion of the continuous fiber bundle 1 in contact with the second inclined guide roll 21B and the center of a cross section perpendicular to the fiber length of a portion of the continuous fiber bundle 1 in contact with the second parallel guide roll 22B, as viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction). The center distance d2 can be adjusted by adjusting the positions of the second inclined guide roll 21B and the second parallel guide roll 22B in the Y-axis direction (width direction).

[0036] 1 to 4, when the flat surface 1a of the continuous fiber bundle 1 standing in the vertical direction is turned horizontally at 90°±15°, it is preferable that the number of second inclined guide rolls 21B that contact the continuous fiber bundle 1 is one. If the number of second inclined guide rolls 21B that contact the continuous fiber bundle 1 at the time of turning at 90°±15° is one, a fiber bundle with fewer breaks can be supplied without impairing workability and with a small amount of capital investment. The number of second inclined guide rolls 21B that are brought into contact with the continuous fiber bundle 1 when the continuous fiber bundle 1 is turned by 90°±15° to tilt the flat surface 1a of the continuous fiber bundle 1 horizontally may be two or more.

[0037] In the example of the rotating device 20 shown in Figures 3 and 4, when viewed from the running direction, the flat surface 1a of the continuous fiber bundle 1 is rotated counterclockwise by 90° ± 15° by the first inclined guide roll 21A and the first parallel guide roll 22A, and then rotated clockwise by 90° ± 15° by the second inclined guide roll 21B and the second parallel guide roll 22B, returning the flat surface 1a of the continuous fiber bundle 1 to a state facing upward, but the present invention is not limited to this form.

[0038] For example, as shown in an example in FIG. 8, a rotating device 20 may be used in which, as viewed from the running direction, the flat surface 1a of the continuous fiber bundle 1 is rotated counterclockwise by 90°±15° using a first inclined guide roll 21A and a first parallel guide roll 22A, and then further rotated counterclockwise by 90°±15° using a second inclined guide roll 21B and a second parallel guide roll 22B, so that the flat surface 1b of the continuous fiber bundle 1 faces upward (a total rotation of 180°). Alternatively, as shown in an example in FIG. 9, a rotating device 20 may be used in which the flat surface 1a of the continuous fiber bundle 1 is rotated clockwise by 90°±15° using a first inclined guide roll 21A and a first parallel guide roll 22A when viewed from the running direction, and then further rotated counterclockwise by 90°±15° using a second inclined guide roll 21B and a second parallel guide roll 22B to return the flat surface 1a of the continuous fiber bundle 1 to a state facing upward.

[0039] When the flat surface of the fiber bundle is rotated by 90°±15°, the inclined guide roll and the parallel guide roll may be brought into contact with different flat surfaces of the fiber bundle. For example, as shown in an example in FIG. 10, when viewed from the running direction, a first inclined guide roll 21A may be brought into contact with the flat surface 1a of the continuous fiber bundle 1, and then a first parallel guide roll 22A may be brought into contact with the flat surface 1b of the continuous fiber bundle 1, thereby rotating the horizontal flat surface 1a counterclockwise by 90°±15° to stand it vertically.

[0040] (Opening device) The opening device 30 shown in FIG. The multiple abrasion bars 31 are parallel to the Y-axis direction and are arranged vertically in a zigzag pattern at intervals in the X-axis direction. Each continuous fiber bundle 1 is subjected to heating, abrasion, oscillation, etc. while passing through each abrasion bar 31, so that it is expanded in the width direction and spread.

[0041] (Lamination device) The laminating device 40 is a device for laminating a resin sheet 3 onto the opened continuous fiber bundle 2. The laminating device 40 includes a first resin sheet supplier 41 arranged above the traveling continuous fiber bundle 2, and a second resin sheet supplier 42 arranged below the traveling continuous fiber bundle 2. The laminating device 40 laminates the resin sheet 3 fed from the first resin sheet supplier 41 and the resin sheet 3 fed from the second resin sheet supplier 42 by bonding them above and below the traveling continuous fiber bundle 2.

[0042] (impregnation machine) The impregnation machine 50 includes a plurality of pairs of impregnation rolls 51 that sandwich and apply a load to a laminate 4, in which the continuous fiber bundles 2 and the resin sheets 3 are laminated, from above and below. The laminate 4 being conveyed is sandwiched between a plurality of pairs of impregnation rolls 51 and pressurized from above and below, whereby the resin forming the resin sheet 3 is impregnated into the continuous fiber bundles 2.

[0043] In the example shown in Fig. 1, a pair of impregnation rolls 51 on the most upstream side of the impregnation machine 50 also serve as laminating rolls that bond the continuous fiber bundle 2 and the resin sheet 3 in the lamination device 40. That is, in the manufacturing device 100 of this example, a load is applied by the impregnation roll 51 at the contact point between the continuous fiber bundle 2 and the resin sheet 3, and impregnation is started. In this way, if impregnation is started at the same time as the continuous fiber bundle 2 and the resin sheet 3 are laminated, the occurrence of misalignment between the continuous fiber bundle 2 and the resin sheet 3 due to the difference in inner and outer circumferences when the transported laminate 4 is held by the rolls is suppressed, and defects are less likely to occur.

[0044] The lamination device 40 may include a laminating roll in addition to the pair of impregnation rolls 51 on the most upstream side of the impregnation machine 50. In this case, it is preferable that the laminate 4 is transported linearly in the X-axis direction from the contact point of the continuous fiber bundle 2 and the resin sheet 3 laminated by the laminating rolls to the pair of impregnation rolls 51 on the most upstream side of the impregnation machine 50. This configuration also makes it possible to suppress the occurrence of misalignment between the continuous fiber bundle 2 and the resin sheet 3 due to the difference between the inner and outer peripheries when the transported laminate 4 is held by the rolls.

[0045] The unidirectional prepreg manufacturing apparatus of the present invention is not limited to the above-mentioned manufacturing apparatus 100, which is equipped with a yarn supplier, a rotating device, a fiber spreading device, a laminating device, and an impregnation machine, and which continuously performs 90°±15° rotation, fiber spreading, laminating, and impregnation in a series of lines. For example, the unidirectional prepreg manufacturing apparatus of the present invention may be equipped with a laminate manufacturing apparatus equipped with a yarn supplier, a rotating device, a fiber spreading device, and a laminating device, and an impregnation device in separate lines. In addition, within the scope of the invention, the components in the above-described embodiments may be replaced with well-known components, and the above-described modified examples may be combined as appropriate.

[0046] [Manufacturing method of unidirectional prepreg] A method for producing a unidirectional prepreg according to an embodiment includes the following winding step, fiber opening step, lamination step, and impregnation step. Rotation step: While a long, flat fiber bundle is traveling in the length direction, the flat surface of the fiber bundle is rotated by 90°±15° when viewed from the traveling direction. Opening step: The fiber bundle is opened. Lamination step: A resin sheet is laminated on the opened fiber bundle. Impregnation step: A load is applied to the laminate to impregnate the fiber bundles with resin. Hereinafter, as an example of a method for producing a unidirectional prepreg according to the embodiment, a case in which the production apparatus 100 is used will be described.

[0047] (Rotation process) First, the continuous fiber bundles 1 are fed from a plurality of yarn suppliers 10 with the flat surface 1 a being horizontal, and are transported to the rotating device 20 . The running speed (line speed) of the continuous fiber bundle 1 is not limited, but can be, for example, 1 to 50 m / min.

[0048] As shown in Figures 3 and 4, each continuous fiber bundle 1 with horizontal flat surfaces 1a, 1b is made to run while being in contact with the first inclined guide roll 21A and the first parallel guide roll 22A in turn, so that the flat surface 1a of each continuous fiber bundle 1 is rotated by 90°±15° to stand in the vertical direction. Next, each continuous fiber bundle 1 with its flat surfaces 1a, 1b standing vertically is changed in direction by a first parallel guide roll 22A and a third parallel guide roll 23, and the positions of each continuous fiber bundle 1 in the Y-axis direction are brought closer to each other to adjust the running intervals to be equal. Next, each continuous fiber bundle 1 with the flat surfaces 1a, 1b standing vertically is made to run while being in contact with the second inclined guide roll 21B and the second parallel guide roll 22B in turn, thereby rotating the flat surface 1a of each continuous fiber bundle 1 by 90°±15° to make it horizontal.

[0049] (Opening process) In the fiber-spreading process, the continuous fiber bundles 1 are made to travel in a zigzag pattern in the X-axis direction in the fiber-spreading device 30 while being in contact with each of the abrading bars 31, and during this process, each continuous fiber bundle 1 is expanded and spread in the Y-axis direction (width direction) by applying heating, abrasion, oscillation, etc.

[0050] (Lamination process) In the laminating process, in a laminating device 40, a resin sheet 3 fed from a first resin sheet supplier 41 and a resin sheet 3 fed from a second resin sheet supplier 42 are laminated above and below the opened continuous fiber bundle 2.

[0051] (Impregnation process) The continuous fiber bundles 2 and the resin sheet 3 are laminated by the impregnation roll 51 on the most upstream side of the impregnation machine 50, and at the same time, a load is applied to start impregnation, and the fiber bundles are impregnated with the resin by multiple pairs of impregnation rolls 51 to obtain a prepreg (UD prepreg) 5. The obtained prepreg 5 can be wound up, for example, by a winder.

[0052] (Fiber bundle) The continuous fiber bundle 1 is a long, continuous fiber bundle made of an aggregate of reinforcing fibers. The reinforcing fiber is not particularly limited, and examples thereof include various inorganic or organic fibers such as carbon fiber, aramid fiber, nylon fiber, high-strength polyester fiber, glass fiber, boron fiber, alumina fiber, and silicon nitride fiber. Among these, carbon fiber, aramid fiber, glass fiber, boron fiber, alumina fiber, and silicon nitride fiber are preferred in terms of specific strength and specific elasticity, and carbon fiber is particularly preferred in terms of mechanical properties and weight reduction. When carbon fiber is used as the reinforcing fiber, it may be surface-treated with a metal. The reinforcing fiber contained in the fiber bundle may be one type or two or more types.

[0053] The fiber diameter of the reinforcing fibers is not limited, but may be, for example, 4 to 10 μm. The number of filaments per spindle of the continuous fiber bundle 1 is not limited, but may be, for example, 1,000 to 100,000. The fiber weight of the continuous fiber bundle 1 is not limited, but may be, for example, 0.2 to 4 g / m.

[0054] (Resin sheet) The resin sheet 3 is formed by applying a resin onto a carrier sheet such as release-treated paper, resin film, etc. The carrier sheet can be peeled off at any time after impregnation. The first resin sheet supplier 41 and the second resin sheet supplier 42 may feed out a carrier sheet on which the resin sheet 3 has already been formed, or the carrier sheet may be fed out and resin may be applied onto the carrier sheet during transport to form the resin sheet 3.

[0055] The resin used for the resin sheet 3 is not particularly limited, and may be a thermosetting resin or a thermoplastic resin. Examples of the thermosetting resin include epoxy resin, vinyl ester resin, unsaturated polyester resin, and phenol resin. Examples of the thermoplastic resin include polyester resin, polyethylene resin, polycarbonate resin, polyether resin, and polyamide resin. The resin used in the resin sheet 3 may be one type or two or more types. The resin may contain additives such as flame retardants, weather resistance improvers, antioxidants, heat stabilizers, UV absorbers, plasticizers, lubricants, colorants, compatibilizers, and conductive fillers, as necessary.

[0056] As described above, in the manufacturing method for a unidirectional prepreg according to the embodiment, the fiber bundle is made to run while being in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat plane of the fiber bundle by 90°±15°. This makes it possible to adjust the running interval of multiple flat fiber bundles and supply them to the spreading process while preventing the fiber bundle from being partially folded or the fibers from being bent.

[0057] The manufacturing method of the present invention is not limited to the method using the above-mentioned manufacturing apparatus 100. For example, the winding step, the opening step, and the laminating step may be continuously performed in a series of lines to manufacture a laminate, and the impregnation step may be performed in a separate line to manufacture a prepreg.

[0058] [How to supply fiber bundles] The fiber bundle supply method according to the embodiment includes rotating the flat surface of the fiber bundle by 90°±15° as viewed from the traveling direction while running a long, flat fiber bundle in the length direction. Similarly to the above-described unidirectional prepreg manufacturing method, an inclined guide roll and a parallel guide roll are used, and the fiber bundle is run while being in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°.

[0059] The supply method of rotating the flat surface of the fiber bundle by 90°±15° using an inclined guide roll and a parallel guide roll is not limited to application in the manufacturing method of UD prepregs, and may also be applied when running a flat fiber bundle for other purposes. EXAMPLES

[0060] The present invention will be specifically described below with reference to examples, but the present invention is not limited to the following description.

[0061] [Example 1] As shown in FIG. 11, a first inclined guide roll 21A and a first parallel guide roll 22A were placed at an interval in the running direction (X-axis direction) of one continuous fiber bundle 1, and the lower flat surface 1b of the continuous fiber bundle 1 running with the flat surfaces 1a, 1b horizontal was brought into contact with the first inclined guide roll 21A and the first parallel guide roll 22A in sequence, and the flat surface of the continuous fiber bundle 1 was rotated by 90° to stand in the vertical direction. As the continuous fiber bundle 1, a flat continuous carbon fiber bundle (manufactured by Mitsubishi Chemical Corporation, product name "TRW50 50L", number of filaments: 50,000, fiber basis weight: 3.8 g / m, initial width W: 14 mm) was used. The inclination angle θ1 (FIG. 5(A)) of the first inclined guide roll 21A with respect to the horizontal flat surface 1a of the continuous fiber bundle 1 before being rotated by 90°±15°, as viewed from the running direction (downstream side in the X-axis direction) of the continuous fiber bundle 1, was 45°. The distance D1 (FIG. 3) between the first inclined guide roll 21A and the first parallel guide roll 22A in the running direction (X-axis direction) was 100 mm, and D1 / W was 7. As viewed from the running direction of the continuous fiber bundle 1 (downstream side in the X-axis direction), the center-to-center distance d1 in the Y-axis direction (width direction) between a portion of the running continuous fiber bundle 1 in contact with the first inclined guide roll 21A and a portion of the running continuous fiber bundle 1 in contact with the first parallel guide roll 22A was set to 20 mm. The running speed (line speed) of the continuous fiber bundle 1 was 5 m / min.

[0062] [Examples 2 to 5] The horizontal flat surface of the running continuous fiber bundle 1 was rotated by 90° to stand in the vertical direction in the same manner as in Example 1, except that the inclination angle θ1 of the first inclined guide roll 21A, the distances D1 and D1 / W between the first inclined guide roll 21A and the first parallel guide roll 22A, and the center-to-center distance d1 were changed as shown in Table 1.

[0063] [Comparative Example 1] The horizontal flat surface of the running continuous fiber bundle 1 was rotated by 90° to stand in the vertical direction in the same manner as in Example 1, except that the first inclined guide roll 21A was not provided.

[0064] [Example 6] As the continuous fiber bundle 1, a flat continuous carbon fiber bundle (manufactured by Mitsubishi Chemical Corporation, product name "TR50S 15L", number of filaments: 15,000, fiber basis weight: 1.0 g / m, initial width W: 8 mm) was used, and the horizontal flat surface of the running continuous fiber bundle 1 was rotated 90° to stand in the vertical direction in the same manner as in Example 1, except that D1 / W was set to 12.

[0065] [Examples 7 and 8] The horizontal flat surface of the running continuous fiber bundle 1 was rotated by 90° to stand in the vertical direction in the same manner as in Example 6, except that the inclination angle θ1 of the first inclined guide roll 21A, the distances D1 and D1 / W between the first inclined guide roll 21A and the first parallel guide roll 22A, and the center-to-center distance d1 were changed as shown in Table 1.

[0066] [Comparative Example 2] The horizontal flat surface of the running continuous fiber bundle 1 was rotated by 90° to stand in the vertical direction in the same manner as in Example 6, except that the first inclined guide roll 21A was not provided.

[0067] [Evaluation method] In each example, the fiber bundle after the flat surface was rotated 90° was photographed continuously for 3 minutes every second from a direction perpendicular to the flat surface to obtain images. The camera used was a Sony HDR-CX680. When photographing, a scale was placed at the same position as the fiber bundle travel position so that the width of the fiber bundle could be measured, and the fiber bundle was photographed together with the scale to obtain images. The width of the fiber bundle after rotation was measured for all the images obtained, and Q1 was calculated from the proportion of images in which the width after rotation was 3.5 mm or more smaller than the total number of images, and Q2 was calculated from the proportion of images in which the width after rotation was 3.0 mm or more smaller. The results are shown in Table 1.

[0068] [Table 1]

[0069] As shown in Table 1, in Examples 1 to 8, in which the flat surface of the fiber bundle was rotated by 90° by running the continuous fiber bundle while contacting the inclined guide roll and the parallel guide roll in turn, the width after rotation did not change, unlike Comparative Examples 1 and 2 in which the inclined guide roll was not used. In other words, the fiber bundle was rotated without bending, and the running interval of the fiber bundle could be adjusted. [Explanation of symbols]

[0070] 1. Continuous fiber bundle 2. Continuous fiber bundle 3 Resin sheet 4. Laminate 5 Prepreg 10 Thread feeder 20 Rotator 21A First inclined guide roll 21B Second inclined guide roll 22A First parallel guide roll 22B 2nd parallel guide roll 23 3rd parallel guide roll 30 Opening device 31 Scraping bar 40 Stacking device 41 First resin sheet supplier 42 Second resin sheet supplier 50 impregnation machine 51 Impregnated roll 100 Unidirectional prepreg manufacturing equipment

Claims

1. A method for producing a unidirectional prepreg, comprising: rotating a flat surface of a long, flat fiber bundle by 90°±15° as viewed from the running direction while running the long, flat fiber bundle in a length direction, A method for producing a unidirectional prepreg, comprising using an inclined guide roll that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° when viewed from the running direction of the fiber bundle, and a parallel guide roll that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°, and running the fiber bundle while contacting the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°.

2. The method for producing a unidirectional prepreg according to claim 1, wherein an inclination angle of the inclined guide roll with respect to a flat surface of the fiber bundle before being rotated by 90°±15° is 15° or more and 75° or less when viewed from the running direction of the fiber bundle.

3. 2. The method for producing a unidirectional prepreg according to claim 1, wherein a ratio (D / W) of a distance D in a running direction of the fiber bundle between the inclined guide roll and the parallel guide roll to an initial width W of the fiber bundle is 3 or more.

4. 2. The method for producing a unidirectional prepreg according to claim 1, wherein a center-to-center distance between a portion of the traveling fiber bundle in contact with the inclined guide roll and a portion of the traveling fiber bundle in contact with the parallel guide roll in a width direction that is horizontal and perpendicular to the traveling direction when viewed from the traveling direction of the fiber bundle is 10 mm or more.

5. The method for producing a unidirectional prepreg according to claim 1, wherein the number of the inclined guide rolls that contact the flat surface of the fiber bundle while rotating the flat surface by 90°±15° is one.

6. The method for producing a unidirectional prepreg according to claim 1, further comprising: providing two or more parallel guide rolls; and supplying the fiber bundle to a predetermined position by running the fiber bundle in contact with each of the parallel guide rolls in sequence.

7. The method for producing a unidirectional prepreg according to claim 1 , further comprising opening the fiber bundles.

8. The method for producing a unidirectional prepreg according to claim 1 , wherein the fiber bundles include carbon fibers.

9. A unidirectional prepreg manufacturing apparatus including a rotating device that rotates a flat surface of a long, flat fiber bundle by 90°±15° as viewed from the traveling direction while running the long, flat fiber bundle in a length direction, The rotating device includes an inclined guide roll that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° when viewed from the running direction of the fiber bundle, and a parallel guide roll that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°, and the fiber bundle is made to run while being in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°.

10. The unidirectional prepreg manufacturing apparatus according to claim 9, wherein an inclination angle of the inclined guide roll with respect to a flat surface of the fiber bundle before being rotated by 90°±15° is 15° or more and 75° or less, as viewed from the running direction of the fiber bundle.

11. The unidirectional prepreg manufacturing apparatus according to claim 9, wherein the number of the inclined guide rolls that contact the flat surface of the fiber bundle while rotating the flat surface by 90°±15° is one.

12. The unidirectional prepreg manufacturing apparatus according to claim 9, wherein two or more parallel guide rolls are provided, and the fiber bundle is supplied to a predetermined position by running the fiber bundle in contact with each of the parallel guide rolls in sequence.

13. The unidirectional prepreg manufacturing apparatus according to claim 9 , further comprising a fiber spreading device for spreading the fiber bundles.

14. A method for supplying a fiber bundle, comprising rotating a flat surface of the fiber bundle by 90°±15° as viewed from the traveling direction while traveling a long, flat fiber bundle in a length direction, A fiber bundle supplying method using an inclined guide roll that is inclined with respect to the flat surface of the fiber bundle before being rotated by 90°±15° as viewed from the running direction, and a parallel guide roll that is parallel to the flat surface of the fiber bundle after being rotated by 90°±15°, and running the fiber bundle in contact with the inclined guide roll and the parallel guide roll in turn, thereby rotating the flat surface of the fiber bundle by 90°±15°.

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