Prepreg sheet manufacturing apparatus and manufacturing method.

Abstract

To provide an apparatus and method for producing a prepreg sheet with uniform quality, capable of imparting a resin uniformly to each strengthened fiber bundle.SOLUTION: A plurality of drawn-out strengthened fiber bundles are divided into fiber bundle units made of one or more strengthened fiber bundles by a thread guide control mechanism. A specified quantity of resin is independently and continuously imparted to the strengthened fiber bundle units passing through a fiber bundle unit passage area by a resin imparting mechanism disposed in the vicinity of the thread guide control mechanism.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an apparatus and a method for manufacturing a prepreg sheet in which a reinforcing fiber bundle is impregnated with a resin.

Background Art

[0002] Fiber-reinforced composite materials (FRP) obtained by reinforcing thermoplastic resins or thermosetting resins with reinforcing fibers are used in various fields such as aerospace materials, automotive materials, industrial materials, and sports applications. FRP is manufactured by laminating and molding an intermediate base material (prepreg sheet) obtained by impregnating a reinforcing fiber bundle with a resin.

[0003] A prepreg sheet is a sheet-like material that has very high tensile strength and toughness and excellent formability in its fiber direction (the length direction of the fibers). As a method for manufacturing a prepreg sheet, for example, as in Patent Document 1, a slurry obtained by uniformly dispersing resin particles in water is stored in a slurry tank, and a reinforcing fiber bundle arranged in a sheet shape is immersed therein to impregnate the surface and inside of the reinforcing fiber bundle with resin particles. By performing evaporation removal of water and melting of the resin in a heating step, a method of imparting a resin to the fiber bundle to obtain a prepreg is common. This method can easily impart resin particles to the reinforcing fiber bundle by immersing the reinforcing fiber bundle in the slurry tank and manufacture a prepreg. However, in this method, since the resin impregnated into the reinforcing fiber bundle varies depending on the distribution of the resin particles in the slurry tank and the fibrillation state of the reinforcing fiber bundle, it is difficult to control the amount of resin imparted to the reinforcing fiber bundle. Therefore, there arises a problem that the resin basis weight of the prepreg sheet varies and the sheet quality becomes non-uniform. [[ID=!]]

[0004] Patent Document 2 discloses a method in which a slurry containing resin particles is supplied to a spray nozzle, and the slurry is sprayed onto a reinforcing fiber bundle arranged in a sheet shape to impart resin particles to the reinforcing fiber bundle. Since this method controls the flow rate with a needle valve, it is possible to spray a certain amount of resin particles onto the reinforcing fiber bundle.

Prior Art Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2002-275291 [Patent Document 2] Japanese Patent Publication No. 2008-1915 [Overview of the project] [Problems that the invention aims to solve]

[0006] However, the method described in Patent Document 2 has problems such as difficulty in controlling the scattering range of the slurry, and the fact that a large amount of resin is applied to the reinforcing fiber bundles exposed on the surface, while no resin is applied to the reinforcing fiber bundles embedded inside, resulting in variations in the amount of resin applied to each reinforcing fiber bundle and uneven quality of the prepreg sheet. The object of the present invention is to manufacture a prepreg sheet in which resin is uniformly applied to the reinforcing fiber bundles and the quality is uniform. [Means for solving the problem]

[0007] The present invention, a prepreg sheet manufacturing apparatus that solves the above problems, is characterized in that multiple drawn-out reinforcing fiber bundles are divided into fiber bundle units consisting of one or more reinforcing fiber bundles by a thread guide control mechanism, and resin is independently and continuously applied to the fiber bundle units passing through the fiber bundle unit passage region by a resin application mechanism located near the thread guide control mechanism.

[0008] Specifically, the present invention solves the above problems by the following means. (1) A prepreg sheet manufacturing apparatus that draws out multiple reinforcing fiber bundles, continuously applies resin to the drawn-out reinforcing fiber bundles, and then forms them into a sheet, wherein the multiple reinforcing fiber bundles are divided into fiber bundle units consisting of one or more reinforcing fiber bundles, and resin is applied independently to each fiber bundle unit. (2) A prepreg sheet manufacturing apparatus according to (1), wherein one reinforcing fiber bundle is defined as the fiber bundle unit. (3) A prepreg sheet manufacturing apparatus according to (1) or (2), comprising a thread path control mechanism that forms a fiber bundle unit passage region partitioned by guide portions that restrict at least the widthwise side surface of the fiber bundle unit, wherein the resin is applied within the fiber bundle unit passage region. (4) The prepreg sheet manufacturing apparatus according to (3), wherein the thread guide control mechanism forms a fiber bundle unit passage region by grooves that restrict the bottom surface and widthwise side surface of the fiber bundle unit. (5) The prepreg sheet manufacturing apparatus according to (4), wherein the thread guide control mechanism is a roller or a bar. (6) A prepreg sheet manufacturing apparatus according to any one of (3) to (5), wherein the thread guide control mechanism has a resin discharge port for discharging resin toward the fiber bundle unit passage region. (7) A prepreg sheet manufacturing apparatus according to any one of (3) to (5), having a resin application mechanism independent of the thread guide control mechanism. (8) The prepreg sheet manufacturing apparatus according to (7), wherein the resin application mechanism has a plurality of resin discharge ports that independently discharge resin for each fiber bundle unit passage region. (9) The prepreg sheet manufacturing apparatus according to (7), wherein the resin application mechanism has a slit-shaped resin discharge port for discharging resin to two or more fiber bundle units at once. (10) The prepreg sheet manufacturing apparatus according to (8) or (9), wherein the resin application mechanism includes a resin guide member that guides the resin discharged from the resin discharge port toward the fiber bundle unit passage region. (11) The prepreg sheet manufacturing apparatus according to (10), wherein the resin guide member is a substantially tapered member that becomes narrower as it moves from the resin discharge port toward the fiber bundle unit passage region. (12) The prepreg sheet manufacturing apparatus according to (10) or (11), wherein the resin guide member is detachably attached to the resin application mechanism. (13) A method for manufacturing a prepreg sheet, comprising drawing out a plurality of reinforcing fiber bundles, continuously applying resin to the drawn-out reinforcing fiber bundles, and then forming them into a sheet, wherein the plurality of reinforcing fiber bundles are divided into fiber bundle units consisting of one or more reinforcing fiber bundles, and resin is applied independently to each fiber bundle unit. (14) The method for manufacturing a prepreg sheet according to (13), wherein the reinforcing fiber bundle is a carbon fiber bundle. (15) The method for producing a prepreg sheet according to (13) or (14), wherein the resin is a slurry in which resin particles are dispersed in a solvent. [Effects of the Invention]

[0009] According to the prepreg sheet manufacturing apparatus and manufacturing method of the present invention, by independently controlling the amount of resin applied to each fiber bundle, which is divided into fiber bundle units consisting of one or more reinforcing fiber bundles, the resin basis weight of each fiber bundle unit becomes uniform. As a result, it is possible to obtain a prepreg sheet with a consistent resin basis weight in the width direction and uniform quality. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic diagram of a prepreg sheet manufacturing apparatus according to one embodiment of the present invention. [Figure 2] This is a schematic diagram showing the use of a multi-stage bar as the sheet-forming mechanism in the present invention. [Figure 3] This is a schematic diagram showing the use of a multi-stage nip roll as the sheet-forming mechanism in the present invention. [Figure 4] This is a schematic diagram showing the case where a comb is used as the thread path control mechanism in the present invention. [Figure 5] This is a schematic diagram showing the case in which a groove member is used as the thread guide control mechanism in the present invention. [Figure 6] This is a schematic diagram of a prepreg sheet manufacturing apparatus according to another embodiment of the present invention. [Figure 7] This is a schematic cross-sectional view of the thread guide control mechanism equipped with a resin application function according to the present invention. [Figure 8] Schematic diagram when a tube is used as the resin application mechanism in the present invention. [Figure 9] Schematic diagram when a nozzle is used as the resin application mechanism in the present invention. [Figure 10] Schematic diagram when one resin supply means is used for a plurality of resin application mechanisms in the present invention. [Figure 11] Schematic diagram of a prepreg sheet manufacturing apparatus according to another embodiment of the present invention. [Figure 12] Schematic cross-sectional view when a die having a plurality of resin discharge ports is used as the resin application mechanism in the present invention. [Figure 13] Schematic cross-sectional view when a die having a plurality of resin discharge ports is used as the resin application mechanism in the present invention. [Figure 14] Schematic cross-sectional view when a die having a single resin discharge port is used as the resin application mechanism in the present invention. [Figure 15] Schematic cross-sectional view when a substantially tapered member is used as the resin guiding member in the present invention. [Figure 16] Schematic diagram when a grooved slope is used as the resin guiding member in the present invention.

Embodiments for Carrying Out the Invention

[0011] Preferred embodiments of the present invention will be described below. However, the present invention is not to be construed as being limited thereto, and various modifications are possible without departing from the object and effects of the present invention. As will be apparent to those skilled in the art, the description of the specific embodiments in this specification can also be understood as the description of the manufacturing apparatus of the present invention as a higher concept. Further, although the description mainly focuses on the manufacturing apparatus of the prepreg sheet of the present invention, it will be easily understood that the manufacturing method of the prepreg sheet that can be executed using such a manufacturing apparatus is also an aspect of the present invention.

[0012] Figure 1 is a schematic diagram showing a prepreg sheet manufacturing apparatus according to one embodiment of the present invention. Multiple reinforcing fiber bundles 2 drawn from a bobbin 1 are guided to a thread path control mechanism 4 via a conveyor roller 3. In Figure 1, the thread path control mechanism 4 uses a width regulating guide 11 consisting of multiple plate-shaped members (guide parts) arranged at regular intervals in the direction of arrangement of the reinforcing fiber bundles 2. In the thread path control mechanism 4, each of the multiple reinforcing fiber bundles 2 passes independently through a fiber bundle unit passage region 41 (in Figure 1, the region sandwiched between adjacent plate-shaped members). In other words, in this embodiment, multiple reinforcing fiber bundles 2 are divided into fiber bundle units consisting of one reinforcing fiber bundle. Here, in this specification, a bundle of multiple single reinforcing fiber threads is called a reinforcing fiber bundle, and a bundle of one or more of these fiber bundles is called a fiber bundle unit. Furthermore, a resin application mechanism 5 is provided near the thread path control mechanism 4, and a predetermined amount of resin is applied independently to each of the multiple fiber bundle units passing through the fiber bundle unit passage region 41. Multiple reinforcing fiber bundles 2 coated with resin are joined together by a sheet-forming mechanism 6 to form a single prepreg sheet 7, which is then wound up by a winding device 8.

[0013] In the manufacturing apparatus shown in Figure 1, the widthwise side surface of the fiber bundle unit is restricted by the plate-shaped member of the width restriction guide 11, preventing overlap between fiber bundles in the fiber bundle unit passage region 41. Furthermore, the resin application mechanism 5 allows for independent control of the resin application amount to multiple fiber bundle units passing through the fiber bundle unit passage region 41, thus ensuring uniform resin application to each fiber bundle unit.

[0014] Furthermore, to promote resin impregnation into the reinforcing fiber bundle 2, multiple rollers, bars, comma rolls, and nip rolls can be provided between the resin application mechanism 5 and the winding device 8.

[0015] As the sheeting mechanism 6, a multi-stage bar, a nip roll, a double belt press, or a fiber opening device can be used. In particular, using a multi-stage bar 9 as shown in Figure 2 or a multi-stage nip roll 10 as shown in Figure 3 is preferable because it allows for the simultaneous sheeting and impregnation of the reinforcing fiber bundles.

[0016] Furthermore, if necessary, a drying device, a melting device, or a molding device may be provided between the sheet-forming mechanism 6 and the winding device 8.

[0017] As the reinforcing fiber bundle 2, carbon fibers, glass fibers, metal fibers, metal oxide fibers, metal nitride fibers, etc., can be used, but the present invention is particularly suitable for the production of prepreg sheets using carbon fibers.

[0018] The resin applied to the reinforcing fiber bundle is not particularly limited, and thermoplastic resins, thermosetting resins, photocurable resins, etc., can be used. Furthermore, the type of resin applied is not particularly limited, and liquid resins that are highly fluid at room temperature, heated and melted resins, solutions in which resin is dissolved in a solvent, slurries in which resin particles are dispersed in a solvent, etc., can be used.

[0019] A fiber bundle unit consists of one or more reinforcing fiber bundles. However, the more reinforcing fiber bundles a fiber bundle unit contains, the more likely overlap is to occur between the reinforcing fiber bundles in the region through which the fiber bundle unit passes, and the greater the variation in the amount of resin applied to each reinforcing fiber bundle. The upper limit of the number of reinforcing fiber bundles contained in a fiber bundle unit should be determined by considering the allowable variation in the amount of resin required for the prepreg sheet to be manufactured, and the unit width of the prepreg sheet when laminating and molding as FRP. Generally, 10 or fewer is preferable, and 5 or fewer is more preferable. If a fiber bundle unit contains one reinforcing fiber bundle, a prepreg sheet with resin applied completely uniformly in the width direction can be obtained. As a result, even if any part of the prepreg sheet is cut to any width and used, it is always possible to mold FRP of uniform quality, which is the most preferable. In this invention, all reinforcing fiber bundles used to manufacture one prepreg sheet are divided into at least two or more fiber bundle units. The number of fiber bundle units to be divided can be appropriately determined depending on the size of the prepreg sheet to be manufactured and the properties of the resin to be imparted, but it is preferable to divide it into 10 or more fiber bundle units, and more preferably into 100 or more fiber bundle units.

[0020] In Figure 1, the thread path control mechanism 4 is illustrated as a width-regulating guide 11 consisting of multiple plate-shaped members arranged at regular intervals in the direction of the arrangement of the reinforcing fiber bundles 2. However, it is not limited to this, and any configuration that regulates the width of each fiber bundle unit and prevents overlapping of fiber bundle units is acceptable. For example, as shown in Figures 4(A) and (B), a comb 12 consisting of multiple rod-shaped members may be used. Figure 4(B) shows an example in which the thread is divided into fiber bundle units consisting of two reinforcing fiber bundles 2 and configured to pass through the thread path control mechanism 4 consisting of the comb 12.

[0021] Figure 5 is a schematic diagram showing an example of an embodiment in which a fiber bundle unit passage region 41 is formed by grooves that restrict the bottom surface and widthwise side surface of the fiber bundle unit 21 as the thread path control mechanism 4. In this embodiment, a grooved block 13 having grooves arranged at regular intervals in the direction of arrangement of the reinforcing fiber bundles is used as the thread path control mechanism 4, and the reinforcing fiber bundles are divided into fiber bundle units 21 and pass through. That is, the fiber bundle unit passage region 41 is restricted and partitioned by guide parts consisting of the walls and bottom surfaces of the grooves. A resin application mechanism 5 is provided at a position corresponding to each fiber bundle unit passage region 41, and a predetermined amount of resin is applied independently to each passing fiber bundle unit 21 within the fiber bundle unit passage region 41. In the fiber bundle unit passage region 41 of Figure 5, the widthwise side surface and bottom surface of the fiber bundle unit 21 are restricted, so not only does overlapping of fiber bundle units occur, but vibration in the thickness direction of the fiber bundle units also does not occur. As a result, the distance between the resin application mechanism 5 and the fiber bundle unit 21 is kept constant, and the application of resin to the fiber bundle units can be performed more stably. Furthermore, as the fiber bundle units 21 are pressed against the bottom surface of the groove, the fiber bundle units open up in the width direction. This reduces the thickness of the fiber bundle units 21 in the fiber bundle unit passage region 41, and also provides the effect of impregnating the interior of the fiber bundle units with the applied resin.

[0022] The cross-sectional shape of the grooves in the grooved block 13 is not particularly limited, but from the viewpoint of making the width of the passing fiber bundle units uniform and reducing their thickness, a rectangular shape such as a rectangle or square is more preferable. The depth of the grooves is preferably sufficiently greater than the thickness of the fiber bundle units from the viewpoint of preventing the fiber bundle units from falling out. More specifically, it is preferably 1 mm or more, and more preferably 2 mm or more. The width of the grooves is not particularly limited, but from the viewpoint of preventing excessive friction between the groove walls and the fiber bundle units, it is preferably about the same as the width of the fiber bundle units.

[0023] Figure 6 is a schematic diagram showing another example of an embodiment in which a fiber bundle unit passage region 41 is formed by grooves that restrict the bottom surface and widthwise side surface of the fiber bundle unit 21 as the thread path control mechanism 4. The embodiment in Figure 6 is the same as the embodiment in Figure 1, except that a grooved roller 14 having multiple grooves in the direction of arrangement of the reinforcing fiber bundles 2 is provided as the thread path control mechanism 4. In Figure 6, multiple reinforcing fiber bundles 2 are divided into fiber bundle units and pass through each groove of the grooved roller 14. In Figure 6, since the widthwise side surface of each fiber bundle unit 21 is restricted by the side surface of the groove, overlapping of adjacent fiber bundle units does not occur. In addition, vibration in the thickness direction of the fiber bundle unit is suppressed by pressing the fiber bundle unit against the bottom surface of the groove.

[0024] Furthermore, in the grooved block 13 shown in Figure 5 and the grooved roller 14 shown in Figure 6, if the bottom surface of the groove is curved, the fiber bundle units are pressed against the curved bottom surface of the groove, causing the fiber bundle units to open efficiently in the width direction. This results in a thinner fiber bundle unit thickness in the fiber bundle unit passage region 41, allowing the applied resin to penetrate more easily into the interior of the fiber bundle units. In addition, because the bottom surface of the groove is curved, fuzzing caused by friction between the fiber bundle units and the bottom surface of the groove is also reduced. As a result, a high-quality prepreg sheet can be obtained in which the amount of resin applied to each reinforcing fiber bundle is uniform, the resin penetrates deep into the fiber bundles, and fuzzing is reduced.

[0025] To minimize fluffing caused by friction between the reinforcing fiber bundle 2 and the grooved roller, it is preferable to rotate the grooved roller 14 so that the peripheral speed at the bottom of the grooves is the same as the conveying speed of the reinforcing fiber bundle 2, thereby reducing friction between the bottom of the grooved roller 14 and the reinforcing fiber bundle 2. If some of the single filaments of the fiber bundle unit wrap around the roller when the grooved roller 14 is rotated, it is preferable to make the peripheral speed at the bottom of the grooves of the grooved roller 14 slower than the conveying speed of the reinforcing fiber bundle 2, thereby suppressing the wrapping of the single filaments. If some of the resin accumulates inside the grooves of the grooved roller 14, it is preferable to stop the rotation of the grooved roller 14 and use it as a fixed bar, as this prevents the resin applied to the fiber bundle unit from remaining in the grooves of the grooved roller 14, thus stabilizing the amount of resin applied to the fiber bundle. The cross-sectional shape of the grooves of the grooved roller 14 is not particularly limited, but a rectangular shape such as a rectangle or square is more preferable from the viewpoint of making the width of the passing fiber bundle unit uniform and reducing the thickness. From the viewpoint of preventing fiber bundles from falling out, the depth of the groove is preferably sufficiently greater than the thickness of the fiber bundles. More specifically, it is preferably 1 mm or more, and more preferably 2 mm or more. The width of the groove is not particularly limited, but from the viewpoint of preventing excessive friction between the groove wall and the fiber bundles, it is preferably about the same as the width of the fiber bundles.

[0026] Alternatively, the grooved roller 14 shown in Figure 6 can be configured not to rotate, and a fixed bar can be used as the thread guide control mechanism 4.

[0027] The surface properties of the yarn guide control mechanism 4 are not particularly limited, but from the viewpoint of preventing fraying due to friction of the fiber bundles, it is preferable that the contact area with the fiber bundles be smooth. Furthermore, by using a material with a low coefficient of friction or a surface treatment with a low coefficient of friction as the material of the yarn guide control mechanism 4, it is possible to prevent fraying due to friction of the fiber bundles.

[0028] In Figures 1 and 6, the thread path control mechanism 4 and the resin application mechanism 5 are installed independently, but the thread path control mechanism 4 may also have the function of the resin application mechanism. That is, the thread path control mechanism 4 may have a resin discharge port that discharges resin toward the fiber bundle unit passage region 41. Figure 7 is a schematic cross-sectional view of a thread path control mechanism 15 equipped with a resin application function, viewed from the X direction in Figure 1. The thread path control mechanism 15 in Figure 7 uses grooved blocks 13 arranged at regular intervals in the direction of the arrangement of the reinforcing fiber bundles, similar to Figure 5. The bottom surface of the grooved block 13 is provided with a resin discharge port 16 for applying resin to the passing fiber bundle units 21, and resin is supplied to the resin discharge port 16 from a resin supply device 18 through a resin supply pipe 17. In the thread path control mechanism 15 in Figure 7, resin seeps out from the resin discharge port 16 to the contact surface with the fiber bundle units 21, and resin is applied independently to each passing fiber bundle unit 21. Furthermore, because resin is interposed between the bottom surface of the thread guide control mechanism 15 and the passing fiber bundle unit 21, when the fiber bundle unit 21 is pressed against the bottom surface of the groove of the grooved block 13, the fiber bundle unit opens in the width direction, and the resin also spreads thinly in the width direction, resulting in the effect of uniformly impregnating the inside of the opened fiber bundle unit with resin.

[0029] When the resin application mechanism 5 is provided independently of the thread guide control mechanism 4, the resin application mechanism 5 only needs to be a mechanism that can independently apply a predetermined amount of resin to each of the divided fiber bundle units 21. For example, multiple tubes 19 may be used in a row as shown in Figure 8, or a nozzle 20 may be used as shown in Figure 9. As the nozzle 20, for example, a dispenser nozzle, syringe, brush, spray nozzle, spray gun, etc., can be used. The means for supplying resin to each resin application mechanism 5 is not particularly limited, and various pumps can be used. Specifically, diaphragm pumps, syringe pumps, snake pumps, and centrifugal pumps can be given as examples. Alternatively, a pressurized feeding method in which a tank storing resin is pressurized may be used without using a pump. Furthermore, the resin supply means may be provided independently for each resin application mechanism 5, or a configuration in which resin is supplied from one resin supply means to multiple resin application mechanisms 5 may be used.

[0030] Figure 10 is a schematic diagram showing an embodiment in which resin is supplied from one resin supply means to a resin supply mechanism 5 consisting of multiple nozzles 20, and is a view of the resin supply mechanism from the X direction shown in Figure 1. The resin supplied from the resin supply device 18 branches through the resin supply piping 17 and is supplied to the multiple nozzles 20. Furthermore, multiple flow rate adjustment mechanisms 22 are provided upstream of each nozzle 20. Providing such flow rate adjustment mechanisms 22 is preferable because it makes it possible to independently adjust the flow rate of resin supplied to each nozzle 20 even if there is variation in the amount of resin supplied from each nozzle 20. Reasons for variation in the amount of resin supplied from each nozzle 20 include slight differences in the shape of each nozzle and differences in the pressure loss in the resin supply piping leading to each nozzle. Of course, if each nozzle is manufactured with high precision and the pressure loss in the resin supply piping is made uniform, a flow rate adjustment mechanism is unnecessary. The configuration of the flow rate adjustment mechanism 22 is not particularly limited, but needle valves, ball valves, diaphragm valves, etc., can be used.

[0031] Figure 11 is a schematic diagram showing an embodiment in which a die 52 is used as the resin application mechanism 5. Figure 12 is a schematic cross-sectional view in which a die 52 having multiple resin discharge ports 524 is used as the resin application mechanism 5. Figure 12 is a view of the yarn path control mechanism 4 from the X direction shown in Figure 11. Figure 13 is a schematic cross-sectional view of the die 52 from the Y direction shown in Figure 12. Inside the die 52, there is a resin inlet 521 into which the resin flows, a manifold 522 for widening the incoming resin in the width direction (Y direction in Figure 12), and multiple slit-shaped flow channels 523 for straightening the resin flow. The resin is applied to the divided fiber bundle units 21 through the multiple resin discharge ports 524. By using a die with a widening space and straightening flow channels inside in this way, it becomes possible to discharge a uniform amount of resin from each resin discharge port 524, and it becomes possible to apply a uniform amount of resin to each fiber bundle unit 21 without providing a flow rate adjustment mechanism for each resin discharge port. As a result, the equipment configuration is simplified while the quality of the resulting prepreg sheets is improved.

[0032] Figure 12 shows an example in which the die 52 has multiple slit-shaped channels 523 and multiple resin discharge ports 524 corresponding to the fiber bundle unit passage region through which each fiber bundle unit 21 passes. However, it is not limited to this, and a die having slit-shaped channels and resin discharge ports that discharge resin to two or more fiber bundle units 21 at once can also be used. For example, as shown in Figure 14, the die may be designed to have only one slit-shaped resin discharge port 526 by providing only one long slit-shaped channel 525. In such a case, the surface of the die 52 having the resin discharge port 526 is brought into contact with the yarn guide control mechanism 4 so that the discharged resin is supplied to each fiber bundle unit passage region 41, i.e., to the groove of the yarn guide control mechanism 4, thereby allowing resin to be applied independently to each fiber bundle unit 21.

[0033] Alternatively, as shown in Figure 15, the die 52 and the thread path control mechanism 4 may be installed spaced apart, and a resin guide member 53 may be provided on the surface of the die 52 having the resin discharge port 526 to guide the flow of resin so that the resin discharged from the resin discharge port 526 is supplied to each fiber bundle unit passage region 41. As shown in Figure 15, if the resin guide member is a substantially tapered member that becomes narrower from the resin discharge port 526 toward the fiber bundle unit passage region 41 of the fiber bundle unit 21, the resin discharged from the resin discharge port 526 will be evenly divided and supplied to each fiber bundle unit passage region 41, making it possible to reliably guide the resin toward the fiber bundle unit 21.

[0034] As a resin guide member, a grooved slope 54 may be used, as shown in Figure 16. In Figure 16, the resin discharged from the die 52 is divided by passing through each groove of the grooved slope 54 and supplied to each fiber bundle unit passage region 41, and then applied to the fiber bundle unit 21. When a grooved slope 54 is used as a resin guide member in this way, even if the flow rate of the resin discharged from the die 52 fluctuates due to pulsation of the pump, which is the resin supply means, the flow rate fluctuations are absorbed as the resin flows down the grooved slope 54, making it possible to apply a uniform amount of resin to the fiber bundle unit 21 in the longitudinal direction. Preferably, the spacing between the grooves and width of the grooved slope 54 is the same as the width and spacing of the arranged fiber bundle units, and preferably the depth of the grooves is such that the discharged resin does not leak in the width direction. Alternatively, a combination of the tapered member shown in Figure 15 and the grooved slope shown in Figure 16 may be used as a resin guide member.

[0035] Designing such a resin guide member as a detachable component from the resin application mechanism 5 is preferable because it facilitates maintenance such as cleaning. [Explanation of symbols]

[0036] 1 bobbin 2 Reinforcement fiber bundles 3. Conveyor rollers 4. Thread guide control mechanism 5. Resin application mechanism 6-seat mechanism 7 Prepreg Sheets 8. Winding device 9 Multi-stage bar 10 Multi-stage Nip Roll 11. Width Restriction Guide 12 combs 13 Grooved blocks 14 Grooved rollers 15. Thread guide control mechanism 16 Resin discharge port 17 Resin supply piping 18 Resin supply device 19 tubes 20 nozzles 21 Fiber bundle units 22 Flow rate adjustment mechanism 41 Fiber bundle unit passage region 52 Dies 53 Resin guide member 54 Grooved ramp 521 Resin Inlet 522 Manifold 523 Slit-shaped channel 524 Resin discharge port 525 Slit-shaped channel 526 Resin discharge port

Claims

1. A prepreg sheet manufacturing apparatus that draws out multiple reinforcing fiber bundles, continuously applies resin to the drawn reinforcing fiber bundles, and then forms them into a sheet, wherein the multiple reinforcing fiber bundles are divided into fiber bundle units consisting of one or more reinforcing fiber bundles, and resin is applied independently to each fiber bundle unit, The yarn path control mechanism has a fiber bundle unit passage region that is partitioned by a guide portion that restricts at least the widthwise side surface of the fiber bundle unit, and the resin is applied within the fiber bundle unit passage region. Furthermore, it has a resin application mechanism independent of the thread path control mechanism, the resin application mechanism has a slit-shaped resin discharge port for discharging resin to two or more fiber bundle units at once, and includes a resin guidance member for guiding the resin discharged from the resin discharge port toward the respective fiber bundle unit passage region. The resin guide member is a substantially tapered member that becomes narrower as it moves from the resin discharge port toward the fiber bundle unit passage region, in a prepreg sheet manufacturing apparatus.

2. A prepreg sheet manufacturing apparatus that draws out multiple reinforcing fiber bundles, continuously applies resin to the drawn reinforcing fiber bundles, and then forms them into a sheet, wherein the multiple reinforcing fiber bundles are divided into fiber bundle units consisting of one or more reinforcing fiber bundles, and resin is applied independently to each fiber bundle unit, The yarn path control mechanism has a fiber bundle unit passage region that is partitioned by a guide portion that restricts at least the widthwise side surface of the fiber bundle unit, and the resin is applied within the fiber bundle unit passage region. Furthermore, it has a resin application mechanism independent of the thread path control mechanism, the resin application mechanism has a slit-shaped resin discharge port for discharging resin to two or more fiber bundle units at once, and includes a resin guidance member for guiding the resin discharged from the resin discharge port toward the respective fiber bundle unit passage region. The resin guide member is a grooved, slope-shaped member that extends from the resin discharge port toward the fiber bundle unit region, in a prepreg sheet manufacturing apparatus.

3. The prepreg sheet manufacturing apparatus according to Claim 1, wherein the resin guide member is a substantially tapered member that becomes narrower as it moves from the resin discharge port toward the fiber bundle unit passage region, and has a grooved slope shape toward the fiber bundle unit region.

4. The apparatus for manufacturing a prepreg sheet according to any one of claims 1 to 3, wherein the resin is a slurry obtained by dispersing resin particles in a solvent.

5. A method for manufacturing a prepreg sheet, comprising drawing out multiple reinforcing fiber bundles, continuously applying resin to the drawn-out reinforcing fiber bundles, and then forming them into a sheet, A method for manufacturing a prepreg sheet, comprising dividing the aforementioned plurality of reinforcing fiber bundles into fiber bundle units consisting of one or more reinforcing fiber bundles, and independently applying resin to each fiber bundle unit, The resin is applied within the fiber bundle unit passage region, using a thread path control mechanism that forms a fiber bundle unit passage region partitioned by guide portions that restrict at least the widthwise side surface of the fiber bundle unit. Furthermore, by using a resin application mechanism independent of the thread guide control mechanism, The resin application mechanism has a slit-shaped resin discharge port for discharging resin to two or more fiber bundle units at once, and includes a resin guidance member for guiding the resin discharged from the resin discharge port toward the respective fiber bundle unit passage region. A method for manufacturing a prepreg sheet, wherein the resin guide member is a substantially tapered member that becomes narrower as it moves from the resin discharge port toward the fiber bundle unit passage region.

6. A method for manufacturing a prepreg sheet, comprising drawing out multiple reinforcing fiber bundles, continuously applying resin to the drawn-out reinforcing fiber bundles, and then forming them into a sheet, A method for manufacturing a prepreg sheet, comprising dividing the aforementioned plurality of reinforcing fiber bundles into fiber bundle units consisting of one or more reinforcing fiber bundles, and independently applying resin to each fiber bundle unit, The resin is applied within the fiber bundle unit passage region, using a thread path control mechanism that forms a fiber bundle unit passage region partitioned by guide portions that restrict at least the widthwise side surface of the fiber bundle unit. Furthermore, by using a resin application mechanism independent of the thread guide control mechanism, The resin application mechanism has a slit-shaped resin discharge port for discharging resin to two or more fiber bundle units at once, and includes a resin guiding member for guiding the resin discharged from the resin discharge port toward the fiber bundle unit passage region. A method for manufacturing a prepreg sheet, wherein the resin guide member is a grooved, slope-shaped member extending from the resin discharge port toward the fiber bundle unit region.

7. The method for manufacturing a prepreg sheet according to Claim 5, wherein the resin guide member is a substantially tapered member that becomes narrower as it moves from the resin discharge port toward the fiber bundle unit passage region, and has a grooved slope shape toward the fiber bundle unit region.

8. A method for producing a prepreg sheet according to any one of claims 5 to 7, wherein the resin is a slurry obtained by dispersing resin particles in a solvent.

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