Dispersion material supply method and material supply device

Abstract

To provide a material supply method and a material supply device of the present invention for supplying materials to be dispersed, for uniformly dispersing a large number of materials to be dispersed, such as short fibers, resin powder, and strip-shaped resin reinforcing tape materials, in a predetermined dispersion area.SOLUTION: In a material supply method and a material supply device that supply a large number of materials 1 to be dispersed to a predetermined dispersion area B so as to be uniformly dispersed, the materials to be dispersed are arranged so as to cover a carrier surface of a carrier 21 which has a large number of intake ports through which the material to be dispersed does not pass, air is taken in from a side opposite to the carrier surface to adsorb the material to be dispersed to the intake port, the carrier moves while adsorbing the material to be dispersed, the material to be dispersed is separated from the carrier surface and dispersed in the dispersion area.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a material supply method and material supply device for uniformly dispersing and scattering a large number of dispersion materials, such as short fibers, resin powder, and strip-shaped resin reinforcement tape materials, in a predetermined dispersion area. [Background technology]

[0002] Fiber-reinforced composite materials with a thermoplastic or thermosetting resin matrix can be manufactured into molded composite products using a sheet substrate in which short cut fibers made from reinforcing fibers such as carbon fiber or glass fiber are dispersed in resin (SMC molding; sheet molding compound molding), or by dispersing thermoplastic resin powder in the cut fibers and putting them into a mold and manufacturing a molded composite material product using a heat and pressure molding method, or by slitting a resin-reinforced sheet material in which reinforcing fiber bundles are impregnated or semi-impregnated with resin to create a strip-shaped resin-reinforced tape material (for example, 5 mm wide x 20 mm long), and then dispersing and scattering the resin-reinforced tape material, and manufacturing a molded composite material product using a heat and pressure molding method.

[0003] In either manufacturing method, the important step is to uniformly disperse the dispersion material, such as short fibers, resin powder, or strip-shaped resin reinforcing tape, in the desired region. Apparatuses for manufacturing SMC molding sheet substrates are proposed in, for example, Patent Document 1, apparatuses for dispersing resin powder are proposed in, for example, Patent Document 2 and Patent Document 3, and apparatuses for dispersing fibers are proposed in, for example, Patent Document 4.

[0004] Patent Document 1 describes a method and device for continuously cutting rovings with a cutting device and dropping them onto a carrier sheet. If the rovings are supplied aligned at equal intervals in the width direction and continuously cut, the cut rovings will be uniformly dispersed and drop onto the desired areas on the carrier sheet.

[0005] Patent Document 2 describes an apparatus that rotates a spreader roller disposed below a powder storage tank to spread powder adhering to the spreader roller. Patent Document 3 describes an apparatus that drops powder using a brush roller attached to the spreader roller. By providing spreader rollers that are equal to or longer than the width of the area to be dispersed, it is possible to disperse powder in the width direction of the area to be dispersed.

[0006] Patent Document 4 describes an apparatus in which multiple types of fiber groups are introduced into a cylindrical container together with an air flow, and the strong air flow inside the cylindrical container mixes and uniformly disperses the fiber groups, and then the fibers are sucked through the fiber suction port of the cylindrical container onto a moving collection net equipped with a suction device inside, thereby accumulating the fibers. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 2018-126975 [Patent Document 2] Japanese Patent Application Laid-Open No. 2004-58018 [Patent Document 3] Japanese Patent Application Laid-Open No. 2012-228639 [Patent Document 4] JP 8-134760 Summary of the Invention [Problem to be solved by the invention]

[0008] The method and device described in Patent Document 1, in which rovings are aligned and supplied at equal intervals in the width direction, cut continuously, and dropped onto a carrier sheet, can be applied to continuous rovings and fiber bundles, but cannot be used with pre-cut fibers, powders, strip-shaped resin-reinforced tape materials, etc.

[0009] The devices described in Patent Documents 2 and 3, which rotate a spray roller disposed below a powder storage tank and spray powder adhering to the spray roller, have a problem in that the amount of resin powder adhering to the spray roller is unstable. In other words, the resin powder does not adhere uniformly to the entire surface of the spray roller, resulting in sparse adhesion. In this state, the powder material cannot be dispersed uniformly.

[0010] Patent Document 4 aims to uniformly blend multiple types of fibers, with each fiber group being mixed and uniformly dispersed in a strong air flow inside a cylindrical container. The device then collects the fibers in this flow field by sucking them onto a moving collection net through the fiber suction port of the cylindrical container. Because of the strong flow field, each fiber moves at high speed, and when collecting the fibers on the moving collection net by suction force, it is difficult to uniformly distribute the fibers and collect them entirely on a specified area of ​​the moving collection net. Partial accumulation or fibers that have already accumulated tend to move again along the inner surface due to the strong air flow. In other words, there is a problem of fibers not being uniformly distributed on a specified area of ​​the moving collection net.

[0011] The present invention has been made in consideration of the above-mentioned problems, and its purpose is to provide a material supply method and material supply device for a dispersed material, such as short fibers, resin powder, or strip-shaped resin reinforcement tape material, for uniformly dispersing a large number of dispersed materials in a specified dispersion area. [Means for solving the problem]

[0012] The method for supplying a material to be dispersed according to the present invention comprises the steps of: Multiple strip shapes A material supplying method for supplying a material to be dispersed in a predetermined dispersion region so as to be uniformly dispersed, multiple The dispersion material is placed so as to cover the support surface of the support on which the intake port is formed. Continuously in a uniformly dispersed stateair is drawn in from the opposite side of the support surface to adsorb the dispersion material to the air intake port, and the support is moved in a state in which the dispersion material is adsorbed, and the dispersion material is released from the support surface and transferred to the dispersion region. Continuously spray Furthermore, the material to be dispersed is stored in a storage section in which an opening adjustment member is formed and which is disposed with a gap between it and the carrying surface, and In the intake port The particles pass through the gap while being attracted to the support surface. In a uniformly distributed state Furthermore, the dispersion material stored in the storage section is stirred so as not to remain. In the intake port The dispersed material that is not adsorbed onto the support surface is recovered. The material to be dispersed is placed The air is sucked within a predetermined range. Furthermore, the dispersion material that has been released from the support surface is Uniformly distributed in the dispersion region The dispersion material is dispersed in a sheet-like pile on the upper surface of a conveying body that moves relatively to the dispersion region. Uniformly distributed in the dispersion region The dispersion material is dispersed so as to pile up along the upper surface of the mold body which moves relatively to the dispersion region. uniformly dispersed in the dispersion region, The light is dispersed onto the upper surface of a diffusion member disposed in correspondence with the dispersion region, and is diffused over an area wider than the dispersion region by the operation of the diffusion member.

[0013] The dispersion material supply device according to the present invention comprises: Multiple strips A material supplying device that supplies a material to be dispersed so as to be uniformly dispersed in a predetermined dispersion area, multiple a transfer section that has a carrier having an intake port formed therein and that transfers the dispersion material while carrying it on the carrier; and a transfer section that stores the dispersion material and covers the dispersion material on the carrying surface of the carrier. Continuously in a uniformly dispersed state a storage section to be placed on the support, The material to be dispersed is placed a suction section that sucks air from the intake port within a predetermined range and adsorbs the dispersed material disposed on the support surface; a separation section that separates the dispersion material from the support surface and continuously scatters and disperses the dispersion material in the dispersion region;Furthermore, the storage section is provided with an opening adjustment member that is arranged with a gap between it and the carrying surface, and the suction section adsorbs the dispersion material stored in the storage section onto the carrying surface, causing the dispersion material to pass through the gap and be released onto the carrying surface. In a uniformly distributed state Furthermore, the storage section is provided with a blocking prevention member that breaks up the dispersion material. Furthermore, the detachment section is provided with a brush roll that comes into contact with the dispersion material placed on the support surface to detach it. Furthermore, the detachment section is provided with an air discharge section that detaches the dispersion material by an air flow discharged from the surface of the support surface. Furthermore, the support body is provided with a hollow cylindrical ventilation roll in which the air intake port is formed. Furthermore, the suction section is arranged inside the ventilation roll and is provided on the support body. The material to be dispersed is placed The dispersion device further includes a suction roll having suction ports formed therein corresponding to predetermined ranges, and a recovery section for recovering the dispersion material that is not adsorbed to the support surface. [Effects of the Invention]

[0014] In the present invention, dispersed materials such as short fibers, resin powder, and strip-shaped resin reinforcement tape material are arranged to cover the support surface of a support body having a large number of air intake ports formed thereon, and are moved while adsorbed to the support surface, and then detached from the support surface and dispersed into a predetermined dispersion area, thereby enabling a large number of dispersed materials to be uniformly dispersed and sprayed into the dispersion area. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a schematic side view of a material supplying device for a dispersion material according to the present invention. [Figure 2] 10 is an explanatory diagram of the positional relationship between the holding surface in the storage portion and the opening adjustment member. FIG. [Figure 3] FIG. 2 is an explanatory view of a storage section of the material supplying device shown in FIG. [Figure 4] 10 is a schematic front view of another material supplying device for a dispersion material according to the present invention. FIG. [Figure 5] FIG. 5 is a schematic cross-sectional view of the material supplying device shown in FIG. [Figure 6] FIG. 5 is an explanatory view of a moving part of the material supplying device shown in FIG. [Figure 7] FIG. 5 is an explanatory view of a suction section of the material supplying device shown in FIG. [Figure 8] 5 is an explanatory diagram of air suction and air discharge of the material supplying device shown in FIG. 4. [Figure 9] 5 is a schematic side view of the material supplying device shown in FIG. 4 in which a recovery unit is arranged. FIG. [Figure 10] 2 is a schematic side view of a mold body placed in the material supplying device shown in FIG. 1 and a material to be dispersed in the mold body. FIG. [Figure 11] FIG. 2 is a schematic side view of the material supplying device shown in FIG. 1, in which a diffusion member is disposed and the material to be dispersed is dispersed into a mold body by the diffusion member. DETAILED DESCRIPTION OF THE INVENTION

[0016] The following describes in detail the embodiments of the present invention. Note that the embodiments described below are preferred examples for carrying out the present invention, and therefore various technical limitations are imposed thereon. However, the present invention is not limited to these embodiments unless otherwise specified in the following description to limit the invention.

[0017] 1 shows a schematic side view of a material supplying device for a material to be dispersed 1 according to the present invention. In this example, the material supplying device is made up of a moving section 2, a storage section 3, a suction section 4, a separation section 5, and a recovery section 6. The moving section 2 is configured such that an endless carrier 21 is wound around a pair of pulleys 22 spaced a certain distance apart. A drive motor (not shown) is connected to one of the pair of pulleys 22, and by rotating the drive motor, power is transmitted to the carrier 21 via the pulley, causing the carrier 21 to move in one direction.

[0018] Examples of the dispersion material 1 include short fibers, resin powder, and rectangular resin reinforcement tape. The short fibers used as the dispersion material 1 are short fibers obtained by cutting reinforced fibers such as carbon fibers and glass fibers, or thermoplastic resin fibers such as polypropylene fibers, polyamide 6 fibers, polyamide 66 fibers, and polyether ether ketone fibers into lengths of several millimeters to several tens of millimeters. When dispersing short fibers, the length is preferably approximately 1 mm to 10 mm. As fibers become longer, they tend to entangle with each other, making it difficult to uniformly disperse and scatter them. Note that fiber bundles consisting of several to tens of thousands of fibers cut into short pieces are also considered short fibers. Fiber bundles can prevent entanglement even when the cut length is long. In the case of fiber bundles, the cut length is preferably approximately 5 mm to 50 mm.

[0019] The resin powder used as the dispersion material 1 is a finely divided powder of thermoplastic resins such as polypropylene, polyamide (nylon 6, nylon 66, nylon 12, etc.), polycarbonate, acrylonitrile-butadiene-styrene copolymer (ABS), polyetherimide, polyethersulfone, polyphenylene sulfide, polyetherketone, polyetheretherketone, or polymer alloy resins that are a mixture of two or more of these thermoplastic resins. Various particle sizes, ranging from a few micrometers to several hundred micrometers, can be used. When using these resin powders as the dispersion material, one type of resin powder can be used, or several types can be mixed and used.

[0020] The strip-shaped resin-reinforced tape material used as the dispersion target material 1 is a tape-like material obtained by cutting a prepreg sheet material, which is made by impregnating or semi-impregnating a thermoplastic resin such as polyamide 6 resin or a thermosetting resin such as epoxy resin, using reinforcing fibers such as carbon fiber or glass fiber as a reinforcement, into strips several millimeters to several tens of millimeters wide and several millimeters to several tens of millimeters long. To ensure uniform dispersion, the shape is preferably in the range of 5 mm to 50 mm wide, 5 mm to 50 mm long, and 20 μm to 200 μm thick.

[0021] The material to be dispersed 1 may be one of short fibers, resin powder, strip-shaped resin reinforcement tape material, etc., or two or more of these may be mixed together, for example, a combination of short fibers and resin powder, or a strip-shaped resin reinforcement tape material and resin powder.

[0022] In the material supply device of Fig. 1, the carrier 21 is made of an endless belt and is provided with a large number of air intake ports that are large enough that the dispersion material 1 does not pass through. Such a carrier can be made endless by joining together sheet materials that have a large number of perforated portions that serve as air intake ports (for example, a mesh belt). Note that the air intake ports are set to a size that prevents the dispersion material 1 being used from passing through, and it is desirable that they are scattered all over the belt.

[0023] In the material supply device of FIG. 1 , a suction cavity pipe 41, which serves as the suction section 4, is disposed between a pair of pulleys 22. The suction cavity pipe 41 is connected to an air suction device (not shown), and is configured so that air is sucked in through the opening of the suction cavity pipe 41. The opening of the suction cavity pipe 41 is in contact with the carrier 21, and when air is sucked into the suction cavity pipe 41, the air is sucked in through an air intake port from the side of the carrier 21 opposite the side in contact with the opening of the suction cavity pipe 41, thereby sucking in and adsorbing the dispersion material 1. Here, the surface of the carrier 21 to which the dispersion material is adsorbed is the support surface. It is desirable to control the amount of air sucked in by the air suction device, and it is advisable to control the amount of air sucked in depending on the degree to which the dispersion material 1 is adsorbed to the support surface.

[0024] In this embodiment, a material storage area A is set on the support surface by surrounding it with an opening adjustment member 31 and a storage wall member 32 that form the storage section 3. The material storage area A allows the dispersion material 1 to be arranged so as to cover the support surface. As shown in Fig. 2, a gap C is set between the support surface and the opening adjustment member 31, and as shown in Fig. 3, the storage wall member 32 is set so as to contact the opening adjustment member 31 on both inside sides of the support surface.

[0025] 2 is set depending on the size of the dispersion material 1, the amount of dispersion material 1 to be dispersed in the dispersion region B, etc. Then, by setting the opening adjustment member 31 parallel to the support surface and making the opening amount of the gap C constant, the dispersion material 1 can be arranged in a more uniformly dispersed state on the support surface and the support 21 can be moved, and the amount of dispersion material 1 dispersed in the dispersion region B can be made uniform.

[0026] The positions of the storage wall members 32 set on both inner sides of the support surface shown in Fig. 3 are set depending on the range of the dispersion region B. Note that, while the support 21 is moving, if the storage wall members 32 are moved on the support surface in a direction perpendicular to the moving direction of the support 21, the region in which the dispersion material 1 is dispersed can also be changed.

[0027] The dispersion material 1 is stored in the material storage area A, but depending on the state of the dispersion material 1, for example, if it is slightly sticky or has fluffy fibers, the dispersion materials 1 may stick together and solidify into blocks in the material storage area A. When this state occurs, it becomes difficult for the dispersion materials 1 to be dispersed uniformly on the support surface and to pass continuously through the gaps C. Therefore, it is desirable to install and operate an anti-blocking member 33 in the material storage area A that prevents the dispersion materials 1 from sticking together and solidifying, and to keep the dispersion materials 1 in a dispersed state in the material storage area A.

[0028] As the anti-blocking member 33, for example, a brush roll or the like can be used, which is made by forming a large number of bristle holes on the outer circumferential surface of a roll and implanting resin or metal bristles in each of the bristle holes. The brush roll is then installed inside the material storage area A and rotated by connecting it to a drive device such as a motor (not shown), thereby breaking up the multiple dispersion materials 1 and preventing them from sticking together and solidifying. Note that it is desirable to install the anti-blocking member 33 near the carrier 21 and the opening adjustment member 31 so that the dispersion materials 1 can pass through the gap C smoothly and continuously.

[0029] By moving the support 21 with the dispersion material 1 adsorbed to the support surface and passing through the gap C formed between the opening adjustment member 31 and the support surface, the dispersion material 1 can be arranged in a more uniformly dispersed state on the support surface and moved. By setting the gap C to be narrow, it is possible to prevent the dispersion material 1 from being arranged unevenly on the support surface. In this case, if the dispersion material 1 is not adsorbed to the support surface, there is a possibility that the dispersion material 1 will interfere with each other as it passes through the narrowed gap C, causing the arrangement of the dispersion material 1 on the support surface to be uneven. However, by adsorbing the dispersion material 1 to the support surface, the adsorbed dispersion material 1 is fixed on the support surface even if there is interference between the dispersion material 1, and it can pass through the gap C while maintaining a uniform dispersion state.

[0030] In the material supply device of Figure 1, the carrier 21 moves with the material to be dispersed 1 placed on the carrier surface, and the carrier 21 is rotated by the pulley 22. When the carrier 21 rotates, if there is no air suction action on the carrier surface, the material to be dispersed 1 will not be adsorbed to the carrier surface and will be in a state where it will be easy to detach from the carrier surface of the carrier 21. Then, as the carrier 21 rotates, the material to be dispersed 1 is affected by the action of gravity and detaches from the carrier surface.

[0031] It is desirable to provide a release part to ensure that the dispersion material 1 is released from the support surface. In the material supply device in the embodiment of Fig. 1, a rotating brush roll 51 is provided as the release part 5. When the rotating brush roll 51 is positioned so that the tips of the brush bristles come into contact with the support surface, and the brush roll 51 is rotated so that the tips of the brush bristles are in the same direction as the movement direction of the support 21, the dispersion material 1 can be actively released from the support surface.

[0032] 1, a conveying body 81 is disposed below the material supplying device and is moved by a drive system (not shown). The conveying body 81 may be a metal sheet, a metal belt, a resin sheet, a resin belt, release paper, or the like.

[0033] A dispersion region B is set above the conveying body 81. In the present invention, the dispersion region B is set to have an elongated shape. The longitudinal direction of the elongated shape is set in a direction perpendicular to the movement direction of the conveying body 81. The length in the width direction of the support surface in the region where a large number of dispersion materials 1 are adsorbed to the support surface is set to match the longitudinal length of the elongated shape. In other words, the length can be set by adjusting the spacing length in the width direction of the support surface of the paired storage wall members 32. Here, the support surface width direction refers to the direction perpendicular to the movement direction of the support body 21. Note that the dispersion materials 1 spread as they separate from the support surface and fall, so it is necessary to adjust the spacing length of the paired storage wall members 32 in consideration of this spreading.

[0034] The length of the short side of the dispersion region B is adjusted by the degree of spreading of the dispersion material 1 as it separates from the support surface and falls. The higher the height from which the dispersion material 1 falls from the support surface, the greater the degree of spreading of the dispersion material 1, but the further outward the spreading, the less the dispersion amount of the dispersion material 1 decreases, impairing uniform dispersion. Therefore, it is desirable to set the length of the short side of the dispersion region B within a range in which the dispersion material 1 is uniformly dispersed.

[0035] As the dispersion material 1 separates from the support surface and falls onto the conveying body 81, it tends to spread in the direction of movement of the conveying body 81 and in a direction perpendicular to the direction of movement. However, it is also possible to prevent the dispersion material 1 from spreading by providing a plate-shaped prevention wall (not shown) to prevent diffusion between the point where the dispersion material 1 separates from the support surface and the conveying body 81.

[0036] In the embodiment of Figure 1, a dispersion region B is set above a conveying body 81 moving in one direction, and the dispersion material 1 is sprayed thereon. By moving the carrier 21, on which the dispersion material 1 is uniformly dispersed and arranged on the support surface, and the conveying body 81 at a constant speed, a continuous sheet of a constant width on which the dispersion material 1 is uniformly dispersed can be produced on the conveying body 81. Note that by increasing the speed of the carrier 21 or slowing the speed of the conveying body 81, the amount of dispersion material 1 piled up on the conveying body 81 can be increased, and a sheet with a heavier weight per unit area can be produced.

[0037] One method for evaluating the dispersion state of the dispersion material 1 is to take samples from the area where the dispersion material 1 has been sprayed and measure their weight. In the embodiment of FIG. 1, the sheet-like dispersion material 1 sprayed on the conveyor 81 is equally divided in a direction perpendicular to the width direction (in this case, the direction of movement of the conveyor 81), and each sample is taken out in a certain length in the length direction (in this case, the direction of movement of the conveyor 81), for example, a length equal to the division length in the width direction. The weight of the taken samples is then measured, and if the weight of each sample is within a certain range, it can be evaluated that the dispersion material 1 is uniformly dispersed. The number of divisions in the width direction can be selected appropriately depending on the sheet width. For example, if the sheet width is around 300 mm, it is desirable to divide it into about 3 to 6 divisions, if the sheet width is around 500 mm, it is desirable to divide it into about 5 to 10 divisions, and if the sheet width is around 1000 mm, it is desirable to divide it into about 10 to 20 divisions.

[0038] Although it depends on the intended use of the sheet in which the dispersion material 1 is uniformly dispersed, it is desirable for the weight of each divided sample to be within ±20 percent of the average weight derived from the weights of the individual samples, and even more desirable for it to be within ±10 percent.

[0039] In the embodiment of Fig. 1, the material supply device is provided with a recovery section 6. Recovery means 61 is set as the recovery section 6, which recovers the dispersion material 1 that is not adsorbed to the support surface. In the embodiment of Fig. 1, after the support 21 moves and passes through the opening adjustment member 31 of the storage section 3 while adsorbing the dispersion material 1 to the support surface, suction-type recovery means 611 is set, which sucks in and recovers the dispersion material 1 that is not adsorbed to the support surface. When the support 21 passes through the recovery section 6, the dispersion material 1 is left adsorbed to the support surface, and the dispersion material 1 that is not adsorbed to the support surface is sucked in and recovered.

[0040] The carrier 21 moving through the material storage area A has the dispersion material 1 loaded on top of the dispersion material 1 adsorbed on the carrier surface, and when the carrier 21 passes through the opening adjustment member 31, the amount of the dispersion material 1 loaded is adjusted by the gap formed by the carrier surface and the opening adjustment member 31. The narrower the gap, the smaller the amount of the dispersion material 1 loaded.

[0041] As the carrier 21 passes through the gap formed by the carrier surface and the opening adjustment member 31, a substantially uniform amount of dispersion material 1 is loaded over the entire surface of the carrier surface. However, if the dispersion material 1 loaded on top of the dispersion material 1 adsorbed to the carrier surface is collected, and only the adsorbed dispersion material 1 remains on the carrier surface, a more uniform amount of dispersion material 1 can be placed on the carrier surface.

[0042] 4 and 5 show a schematic front view of a material supplying device according to another embodiment of the present invention and a schematic cross-sectional view taken along line XX' in Fig. 4. In this example, the material supplying device is made up of a moving section 2, a storage section 3, a suction section 4, and a removal section 5. The moving section 2 is made up of a carrier 21 having a cylindrical structure.

[0043] The transfer section 2 in this embodiment will be described with reference to FIG. 6. In this embodiment, the support 21 constituting the transfer section 2 has a hollow cylindrical shape and is a permeable roll structured with numerous air intake ports through which the dispersion material 1 does not pass. Examples of such a support include a hollow roll made of aluminum or iron, with the outer cylinder provided with numerous through-holes large enough to prevent the dispersion material from passing through. Alternatively, a hollow roll made of a porous ceramic material can be used as a different support. Porous ceramic materials are materials in which pores are formed inside by firing ceramic powder at a temperature around its melting point at which it does not densify, leaving pores, or by subsequently removing a pore-forming agent that has been contained therein by some method. The numerous pores are connected in series to form air intake ports through which air can pass. The size of the pores can be adjusted, and in the present invention, they are adjusted to a size that prevents the dispersion material from passing through.

[0044] The moving unit 2 in this embodiment is composed of a support 21 which is a ventilation roll, a shaft 23 which supports the support 21, a motor 24 for rotating the support 21, pulleys 25 and 26 and a drive transmission belt 27 which transmit the rotational drive of the motor 24, and a ball bearing 28 which smoothly rotates the support 21. The shaft 23 is composed of side plates 231 which are attached to both ends of the support 21 without any gaps, and a cylindrical shaft core 232 which is attached so as to penetrate the center of the side plates 231.

[0045] A suction roll 42 constituting the suction unit 4 is disposed inside the support 21. The suction unit 4 is shown in FIG. 7. The suction unit 4 is composed of the suction roll 42, which is a hollow cylinder made of aluminum, iron, resin, or other material, with a portion of the cylinder cut out, and a shaft 43 that supports the suction roll 42. The suction roll 42 has a portion cut out, which serves as a suction port corresponding to the portion of the hollow cylindrical support 21 from which air is to be sucked. The shaft 43 is composed of side plates 431 that are attached tightly to both ends of the suction roll 42, and a cylindrical shaft core 432 that is attached so as to penetrate the center of the side plates 431.

[0046] The end of the shaft 432 of the suction unit 4 is connected to an air suction pump (not shown) by an air suction hose (not shown). By operating the air suction pump, air is sucked into the hollow interior of the suction roll 42, and the interior of the suction roll 42 becomes an air suction region D. Although the shafts 432 are located on both sides of the suction roll 42, air may be sucked from both sides, or one side may be closed and air may be sucked from the other side. When the pressure in the air suction region D drops below atmospheric pressure, a flow of suction air is generated from the support surface corresponding to the suction port.

[0047] The arrangement of the moving unit 2 and the suction unit 4 will be explained with reference to Figure 6. The carrier 21 of the moving unit 2 is arranged outside the suction roll 42 of the suction unit 4. The suction roll 42 and the carrier 21 are arranged so that the outer peripheral surface of the suction roll 42 is in contact with the inner peripheral surface of the hollow cylindrical carrier 21, or so that a small gap is provided. When air is sucked through a hollowed-out portion (suction port) in the outer cylindrical portion of the suction roll 42, air is sucked from the bearing surface of the carrier 21 that corresponds to that portion.

[0048] The shaft cores 432 on both sides that support the suction roll 42 are fixed by supports 71 and 72, respectively. The inner peripheral surfaces of the shaft cores 232 on both sides that support the carrier 21 are respectively arranged with the outer peripheral surfaces of the shaft cores 432 via ball bearings 28, so that the carrier 21 can rotate outside the fixed suction roll 42.

[0049] The rotation of the support 21 is controlled by a motor 24. A pulley 25 is attached to the motor shaft of the motor 24 attached to the support 72, and a pulley 26 is attached to the shaft core 231 of the support 21, and the pulleys 25 and 26 are connected by a drive transmission belt 27. With this mechanism, the rotation speed of the support 21 can be controlled by controlling the rotation speed of the motor 24.

[0050] The operation of the material supply device in this embodiment will be described with reference to Figures 4 and 5. Above the support 21, which is an aeration roll, a material storage area A is formed by an opening adjustment member 31, storage wall members (not shown) arranged in pairs in the longitudinal direction of the support 21, and a storage stopper member 34, and the material to be dispersed 1 is introduced into this area.

[0051] The position of the storage wall member is adjusted according to the longitudinal length of the dispersion region, as in the embodiment of Fig. 1. The storage stopper member 34 is arranged on the side facing the opening adjustment member 31, and is arranged so that the dispersion material 1 remains in the material storage region A.

[0052] A brush roll type anti-blocking member 33 is disposed within the material storage area A and rotates to break up the dispersion material 1 so that it remains within the material storage area A.

[0053] The carrier 21, which is an aerated roll, rotates in one direction at a constant speed, but in the range from inside the material storage area A to the point where the dispersion material 1 leaves, air is sucked in from the suction port of the suction roll 42, causing the dispersion material 1 to be adsorbed to the carrying surface of the carrier 21. A gap is formed between the opening adjustment member 31 and the carrying surface, and by passing through this gap, the dispersion material 1 is more uniformly dispersed on the carrying surface and is adsorbed, and the carrier 21 continues to rotate.

[0054] The detachment section 5 is placed at a position where it is desired to detach the dispersion material 1 from the support 21. One method for detaching the dispersion material 1 from the support 21 is to first stop the air suction from the support surface. When the air suction from the support surface stops working, the dispersion material 1 becomes more likely to detach from the support surface, and if this position is below the support 21 which is an aerated roll, the dispersion material 1 will detach from the support 21 and fall downward due to the action of gravity. Note that a method for stopping air suction from the support surface is to leave the outer cylinder of the suction roll 42 in the part that you do not want to suction, so that no air suction flow occurs on the support surface corresponding to that part.

[0055] There is also a method of releasing the dispersion material 1 from the support surface by discharging air from the support surface of the support 21, which is a breathable roll. Specifically, this will be explained using the explanatory diagram of Figure 8. An air discharge section 54 is provided inside the support 21, which is a breathable roll, so as to be in contact with the support 21, and an air hose (not shown) is connected to send air into the air discharge section 54, creating an air discharge area D with increased air pressure. In this way, air can be discharged from the support surface of the support 21, making it possible to actively release the dispersion material 1 from the support surface of the support 21.

[0056] 1, there is also a method in which a rotating brush roll 51 is placed at a position where it is desired to remove the dispersion material 1 from the support surface so that the tips of the brush bristles come into contact with the support surface, and the brush roll 51 is rotated so that the tips of the brush bristles rotate in the direction in which the dispersion material 1 is removed from the support 21, thereby removing the dispersion material 1 from the support surface. The rotation of the brush roll 51 is achieved by transmitting the rotational drive of the motor 52 via the shaft roll 53, and the rotation is controlled by controlling the motor 52.

[0057] As a method for separating the dispersed material 1 from the support surface, any one of the following three methods may be implemented, or a combination of them may be implemented: a method of stopping the suction of air from the support surface, a method of exhausting air from the support surface, or a method of using a brush roll.

[0058] The dispersion material 1 that has detached from the support surface is dispersed in a dispersion region B set on the conveying body 81. As in the embodiment of Figure 1, the conveying body 81 moves in one direction. By moving the support 21, on which the dispersion material 1 has been uniformly dispersed and arranged on the support surface, and the conveying body 81 at a constant speed, a continuous sheet of a constant width on which the dispersion material 1 has been uniformly dispersed can be produced on the conveying body 81.

[0059] Figure 9 is a schematic diagram seen from the side of the material supplying apparatus shown in Figures 4 and 5, which is equipped with a recovery section 6. Recovery means 61 is set as the recovery section 6, which recovers the dispersion material 1 that has not been adsorbed to the support surface. While suction-type recovery means 611 is set in the material supplying apparatus of Figure 1, Figure 9 sets forth blow-out type recovery means 612 that blows air onto the dispersion material 1 loaded on the support surface to shake it off. This shows a method in which the blow-out type recovery means 612 actively shakes off the dispersion material 1 that has not been adsorbed onto the support surface, and the dispersion material 1 is then recovered in a recovery container 62.

[0060] Figure 10 is a schematic side view showing a method for uniformly dispersing the dispersion material 1 inside the mold body 82 using the material supply device shown in Figure 1. The dispersion material 1 is dispersed in the dispersion region B by the material supply device, and by setting the dispersion region B on the surface of the mold body 82 where the material is introduced and moving the mold body 82, it is possible to load the dispersion material 1 uniformly and distribute it on the mold body 82. The required weight is loaded.

[0061] Fig. 11 is a schematic side view showing another method for uniformly dispersing the dispersion material 1 inside the mold body 82 using the material supply device shown in Fig. 1. The dispersion material 1 released from the support surface is diffused and dispersed in a set dispersion region B, but the dispersion region B is arranged on the upper surfaces of the right diffusion member 91 and left diffusion member 92, which are diffusion members 9, and the right diffusion member 91 and left diffusion member 92 move by swinging, so that the dispersion material 1 can be dispersed in a material diffusion region F, which is an area larger than the dispersion region B.

[0062] For example, a flat plate-shaped member larger than the dispersion area can be used as the diffusion member. If the surface of the flat plate-shaped member is treated with a Teflon (registered trademark) coating or a silicone coating to provide slipperiness, the material to be dispersed can slide off more easily. As shown in Figure 11, a support rod or the like is passed through one side of the flat plate-shaped member and connected to a drive device such as a motor (not shown). By rotating the support rod forward and backward in a short period of time, the other side of the flat plate-shaped member can be swung at a set angle and for a set time. This movement allows the material to be dispersed that has fallen into the dispersion area to fall and be dispersed over a wider area than the dispersion area.

[0063] By aligning the material diffusion region F with the region of the mold body 82 where the dispersion material 1 is to be dispersed, the dispersion material 1 can be dispersed onto the mold body 82 without moving the mold body 82. [Example]

[0064] [Example 1] <Materials used> Fiber material: Carbon fiber bundle (Toray Industries, Inc.; T700SC-60E-12000 strands / bundle, single fiber diameter 0.007 mm) Thermoplastic resin material: PA6 resin film (Mitsubishi Plastics, Inc.; Diamilon, width 180 mm, thickness 0.02 mm)

[0065] <Method of manufacturing thermoplastic thin-layer semi-prepreg sheet> The experiment was carried out using a known thermoplastic thin-layer semi-prepreg sheet manufacturing apparatus (for example, an apparatus in which the extrusion molding device portion in the apparatus configuration shown in FIG. 5 of the apparatus described in FIG. 5 and FIG. 6 of Japanese Patent No. 6718101 has been removed and a mechanism for feeding a thermoplastic resin film has been installed), and a known fiber-spreading device (for example, the fiber-spreading device shown in FIG. 15A and FIG. 15B described in Japanese Patent No. 5553074) was attached to both sides of the thermoplastic thin-layer semi-prepreg sheet manufacturing apparatus.

[0066] In addition, the device described in FIG. 5 of Japanese Patent No. 6718101 has two heating rolls, but in this example, the device has one heating roll and two cooling rolls.

[0067] The conveyor belt used was a fluorine belt (G-type belt) manufactured by Chukoh Belt Co., Ltd. The set temperature of the heating roll was 270°C, and the pressure between the heating rolls was set to a linear pressure of 25 kgf / cm. The heating roll was rotated by a drive motor at a processing speed of 20 m / min, and the cooling roll was set to rotate freely.

[0068] In each spreading device, five carbon fiber bundles were spread to 38 mm, respectively, to form a spread fiber sheet with a width of 190 mm and a basis weight of approximately 21 g / m, and each spread fiber sheet was continuously introduced from both sides into the heating rolls shown in FIG. 5 described in Japanese Patent No. 6718101 with the end of each spread fiber bundle slightly shifted in the width direction so that it would not overlap in the thickness direction.

[0069] Then, a PA6 resin film was introduced along with the spread fiber sheet from one of a series of heating rolls shown in FIG. 5 of Japanese Patent No. 6718101, and when the PA6 resin film was in a molten state, the PA6 resin film was pressed while sandwiching the spread fiber sheet by the series of heating rolls, and the spread fiber sheet was made into a semi-prepreg state in which the PA6 resin film was slightly impregnated with the spread fiber sheet.

[0070] The sheet was then cooled by passing through a cooling roll, and after being peeled off from the conveyor belt, both ends were slit and the sheet was continuously wound around a 3-inch paper tube as a thermoplastic thin-layer semi-prepreg sheet.

[0071] The manufacturing equipment was operated for approximately 50 minutes, yielding a thermoplastic thin-layer semi-prepreg sheet measuring 160 mm wide and approximately 1,000 m long. The resulting thermoplastic thin-layer semi-prepreg sheet had a basis weight of 65 g / m2 (fiber basis weight of approximately 42 g / m2), a calculated thickness in the impregnated state of approximately 0.043 mm, and a fiber volume content of approximately 54%. The thickness of the manufactured thermoplastic thin-layer semi-prepreg sheet was measured at 10 locations using an outside micrometer (manufactured by Mitutoyo Corporation) with a minimum display scale of 0.001 mm, and the average measurement value was approximately 0.063 mm.

[0072] <Method of manufacturing the dispersed material> In this example, a strip-shaped resin-reinforced tape material was used as the dispersion material 1. The strip-shaped resin-reinforced tape material was produced by cutting the thermoplastic thin-layer semi-prepreg sheet into 5 mm width intervals along the fiber direction and then into 20 mm length intervals in the direction perpendicular to the fiber direction using a sheet material supply mechanism and a sheet material cutting mechanism in a known pseudo-isotropic reinforced sheet material manufacturing device (for example, the manufacturing device shown in FIG. 4 of Japanese Patent No. 6638131). The supply speed of the thermoplastic thin-layer semi-prepreg sheet was set to approximately 30 m / min.

[0073] <Material supply device> In this example, the material supply device shown in Figure 1 was used without the separation section 5 and recovery section 6. A 400 mm wide SUS mesh belt (manufactured by Kansai Wire Mesh Co., Ltd.) was used as the carrier 21. The mesh belt is made of a combination of spirals and rods, and the gaps between them act as air intakes to draw in air. The size of the gaps is determined by the shape, wire diameter, and pitch of the spirals and rods. In this example, an A3 type mesh belt with specifications of A3-2.5-1.8-0.8-0.8 was used. With this type, the dispersed material 1 used in this example would not have passed through the air intakes.

[0074] As shown in Figure 1, a suction tunnel pipe 41 was placed between the pulleys on the opposite side of the support surface of the support body 21, with its opening in contact with the support surface. The opening measured 400 mm in the width direction of the support body 21 and 300 mm in the running direction, and air was suctioned so that the suction air speed on the support surface side was 2.5 m / sec. An opening adjustment member 31 made of a resin plate and a storage adjustment member 32 made of the same material were placed on top of the support body 21, spaced 300 mm apart, to define a material storage area A. The opening adjustment member 31 was positioned approximately in the center of the air suction area D in the running direction of the support body 21. The gap C between the opening adjustment member 31 and the support surface was set to 4 mm. A blocking prevention member made of a polyamide 6 resin brush roll was placed within the material storage area A and rotated at a constant speed to facilitate dispersion of the dispersion material 1.

[0075] <Dispersion state of dispersed material> A rectangular resin-reinforced tape material serving as the dispersion material was supplied to the material storage area A of the material supply device, and a mesh belt serving as a carrier was run at a processing speed of 3 m / min. The dispersion material was continuously distributed across the mesh belt at a width of approximately 300 mm. As the mesh belt carrier rotated around the pulley, air suction was not performed where the pulley and mesh belt were in contact, causing the dispersion material to fall downward. Below the material supply device, a Teflon® sheet serving as a carrier, approximately 500 mm wide, moved at a speed of approximately 3 m / min. A dispersion area B of approximately 300 mm in width was set above the Teflon® belt, and the dispersion material was continuously sprayed in this area. Measurements of the dispersion amount of the dispersion material were taken out in 1-meter lengths at 100 mm intervals across the width, yielding approximately 40 g / m, approximately 48 g / m, and approximately 46 g / m, with an average of approximately 44.7 g / m. The variation from the average weight was in the range of -10.5% to +7.4%, and was distributed uniformly within ±20%.

[0076] [Example 2] In Example 2, the same materials and the same material supply device as in Example 1 were used, and a recovery member 6 was set up to recover the dispersion material that was not adsorbed onto the support surface from the dispersion material that was loaded and arranged on the support surface.

[0077] <Materials used> The same fiber material and thermoplastic resin material as in Example 1 were used.

[0078] <Method of manufacturing thermoplastic thin-layer semi-prepreg sheet> A thermoplastic thin-layer semi-prepreg sheet was produced in the same manner as in Example 1.

[0079] <Method of manufacturing the dispersed material> Using the same manufacturing method as in Example 1, a resin-reinforced tape material in the shape of a strip having a width of 5 mm and a length of 20 mm was manufactured from the thermoplastic thin-layer semi-prepreg sheet, and used as the dispersion material 1.

[0080] <Material supply device> In the material supply device used in Example 1, the recovery unit 6 was placed in the range where air was sucked from the support surface as shown in Figure 1. The recovery unit 6 used suction-type recovery means 611 as shown in Figure 1. The suction-type recovery means 611 used in this example consisted of a nozzle with a rectangular suction port 30 mm long in the running direction of the support 21 and 350 mm in the width direction of the support 21, a suction pump (not shown in Figure 1) that sucks air, and a connecting hose that connects the nozzle and the pump. The suction pump was then operated to generate a suction air velocity of 1.5 m / sec at the tip of the nozzle.

[0081] The suction wind speed on the support surface side, the positions of the opening adjustment member 31 and the storage adjustment member 32, the gap C, the position and rotation speed of the blocking prevention member, etc. were the same as in Example 1.

[0082] <Dispersion state of dispersed material> A strip-shaped resin-reinforced tape material serving as the dispersion material was supplied to material storage area A of the material supply device, and a mesh belt serving as a carrier was run at a processing speed of 3 m / min, whereupon the mesh belt, which had passed through opening adjustment member 31, was continuously arranged with a width of approximately 300 mm. When the mesh belt passed through suction-type recovery means 611 in this state, the dispersion material loaded on top of the dispersion material adsorbed to the carrier surface was sucked in, and a smaller amount of dispersion material 1 than in Example 1 was uniformly adsorbed to the carrier on the mesh belt serving as a carrier.

[0083] As in Example 1, the dispersion material fell downward as the mesh belt, which served as a carrier, rotated around the pulley. Below the material supply device, a Teflon® sheet, which served as a carrier and was approximately 500 mm wide, moved at a speed of approximately 3 m / min. A dispersion region B, approximately 300 mm in width, was set above the Teflon® belt, and the dispersion material was continuously sprayed into this region. Measurements of the dispersion amounts of the dispersion material, taken out in 1 m lengths at 100 mm intervals in the width direction, yielded results of approximately 30 g / m, approximately 25 g / m, and approximately 28 g / m, with an average of approximately 27.7 g / m. The variation from the average weight was within the range of -9.7% to +8.3%, demonstrating uniformity within ±10%.

[0084] In the comparative example, the same material and material supply device as in Example 1 were used to confirm whether the dispersion material would be uniformly arranged when there was no air suction from the support surface.

[0085] [Comparative Example] <Materials used> The same fiber material and thermoplastic resin material as in Example 1 were used.

[0086] <Method of manufacturing thermoplastic thin-layer semi-prepreg sheet> A thermoplastic thin-layer semi-prepreg sheet was produced in the same manner as in Example 1.

[0087] <Method of manufacturing the dispersed material> Using the same manufacturing method as in Example 1, a resin-reinforced tape material in the shape of a strip having a width of 5 mm and a length of 20 mm was manufactured from the thermoplastic thin-layer semi-prepreg sheet, and used as the dispersion material 1.

[0088] <Material supply device> The same material supply device as in Example 1 was used, and the device was set to a state in which air suction from the carrying surface did not occur. The setting of the material storage area A, the positions of the opening adjustment member 31 and the storage adjustment member 32, the gap C, the position and rotation speed of the blocking prevention member, etc. were the same as in Example 1.

[0089] <Dispersion state of dispersed material> When strip-shaped resin reinforcement tape material, which is the material to be dispersed, was supplied to material storage area A of the material supply device and the mesh belt, which is the carrier, was run at a processing speed of 3 m / min, it was confirmed that the resin reinforcement tape material, which is the material to be dispersed, did not pass uniformly through gap C. The carrier moved with some areas where the resin reinforcement tape material was partially loaded on the carrier surface and passing through, and some areas where there was no resin reinforcement tape material on the carrier surface. This confirmed that unless air suction from the carrier surface acts, the resin reinforcement tape material would not be distributed uniformly and continuously on the carrier surface. [Explanation of symbols]

[0090] 1...Material to be dispersed, 2...Moving part, 21...Support body, 22...Pulley, 23...Shaft part, 231...Side plate, 232...Shaft core, 24...Motor, 25, 26...Pulley, 27...Drive transmission belt, 28...Ball bearing, 3...Storage part, 31...Opening adjustment member, 32...Storage wall member, 33...Anti-blocking member, 34...Storage stopper member, 4...Suction part, 41...Suction tunnel tube, 42...Suction roll, 43...Shaft part, 431...Side plate, 432...Shaft core, 5 ···Removal section, 51··Brush roll, 52··Motor, 53··Axis roll, 54··Air discharge section, 6··Recovery section, 61··Recovery means, 611··Suction type recovery means, 612··Blow type recovery means, 62··Recovery container, 71, 72··Support body, 81··Conveyor body, 82··Mold body, 9··Diffusion member, 91···Right diffusion member, 92···Left diffusion member, A··Material storage area, B··Dispersion area, C··Gap, D··Air suction area, E··Air discharge area, F··Material diffusion area

Claims

1. A material supply method for supplying a plurality of strip-shaped dispersed materials so that they are uniformly dispersed in a predetermined dispersion area, comprising: arranging the dispersed materials in a uniformly dispersed state continuously to cover the support surface of a support body having a plurality of air intake ports formed thereon that the dispersed materials do not pass through; drawing in air from the opposite side of the support surface to adsorb the dispersed materials to the air intake ports; moving the support body in a state in which the dispersed materials are adsorbed; and detaching the dispersed materials from the support surface and continuously spraying and dispersing them in the dispersion area.

2. A material supply method for a dispersion material as described in claim 1, wherein the dispersion material is stored in a storage section formed with an opening adjustment member arranged with a gap between it and the support surface, and the dispersion material is adsorbed by the air intake port on the support surface, passes through the gap, and is arranged in a uniformly dispersed state on the support surface.

3. 3. The method for supplying a dispersion material according to claim 2, wherein the dispersion material stored in the storage section is stirred so as not to stagnate.

4. 4. The method for supplying a dispersion material according to claim 1, wherein the dispersion material that has not been adsorbed to the intake port on the support surface is collected while the support is moving.

5. 5. The method for supplying a dispersion material according to claim 1, wherein the support surface is configured to suck air within a predetermined range in which the dispersion material is placed.

6. A material supply method for a dispersion material described in any one of claims 1 to 5, wherein the dispersion material detached from the supporting surface is uniformly dispersed in the dispersion region and piled up on the upper surface of a conveying body that moves relative to the dispersion region to form a sheet.

7. A material supply method for a dispersion material described in any one of claims 1 to 5, wherein the dispersion material detached from the supporting surface is uniformly dispersed in the dispersion region and dispersed so as to pile up along the upper surface of a mold body that moves relative to the dispersion region.

8. A material supply method for a dispersion material described in any one of claims 1 to 5, wherein the dispersion material detached from the supporting surface is dispersed onto the upper surface of a diffusion member arranged corresponding to the dispersion area, and is diffused over an area larger than the dispersion area by the operation of the diffusion member.

9. A material supply device for a dispersible material that supplies a plurality of strip-shaped dispersible materials so that they are uniformly dispersed in a predetermined dispersion area, comprising: a carrier having a plurality of air intake ports formed therein that the dispersible material does not pass through, and a moving section that carries the dispersible material on the carrier and moves it; a storage section that stores the dispersible material and arranges it continuously on the carrier surface of the carrier in a uniformly dispersed state so as to cover the dispersible material; a suction section that sucks air from the air intake ports in a predetermined range where the dispersible material of the carrier is arranged, and adsorbs the arranged dispersible material onto the carrier surface; and a detachment section that detaches the dispersible material from the carrier surface and continuously sprays and disperses it in the dispersion area.

10. A material supply device for a dispersion material as described in claim 9, wherein the storage section is provided with an opening adjustment member arranged with a gap between it and the supporting surface, and the suction section adsorbs the dispersion material stored in the storage section onto the supporting surface, passes it through the gap, and arranges it in a uniformly dispersed state on the supporting surface.

11. 11. The material supplying device for a dispersion material according to claim 9, wherein the storage section is provided with an anti-blocking member that breaks up the dispersion material.

12. A material supply device for a dispersed material described in any of claims 9 to 11, wherein the detachment section is provided with a brush roll that contacts and detaches the dispersed material placed on the supporting surface.

13. A material supply device for a dispersed material described in any of claims 9 to 12, wherein the detachment section is provided with an air discharge section that detaches the dispersed material by an air flow discharged from the surface of the supporting surface.

14. A material supply device for a material to be dispersed as described in any of claims 9 to 13, wherein the carrier is provided with a hollow cylindrical ventilated roll in which the air intake port is formed.

15. A material supply device for a material to be dispersed as described in Claim 14, wherein the suction section is arranged inside the aeration roll and comprises a suction roll having a suction port formed therein corresponding to a predetermined range in which the material to be dispersed on the carrier is arranged.

16. A material supply device for a dispersed material described in any of claims 9 to 15, which is provided with a recovery section for recovering the dispersed material that is not adsorbed onto the support surface.

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