Prepreg manufacturing equipment

Abstract

To provide prepreg manufacturing equipment capable of manufacturing prepreg of stable width (target width or approximately target width).SOLUTION: A prepreg manufacturing equipment for manufacturing prepreg by heating and welding the resin powder on a sheet-like fiber base material during conveyance to which resin powder is adhered, and is provided with a width detection sensor 100 for detecting the width of the sheet-like fiber base material during conveyance, and a width control means 90 for controlling the width of the sheet-like fiber base material during conveyance so that the width of the sheet-like fiber base material during conveyance detected by the width detection sensor becomes a pre-determined target width.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] This disclosure relates to a prepreg manufacturing apparatus capable of producing prepregs of a stable width (target width or approximately target width). [Background technology]

[0002] A prepreg manufacturing apparatus is known that is configured to adhere charged resin powder to a sheet-like fibrous substrate by the Coulomb force created by an electric field formed between an electrode (high-voltage plate) to which a high voltage is applied and a conveyed sheet-like fibrous substrate, and by the conveying force of air sprayed from an air nozzle (see, for example, Patent Document 1). The sheet-like fibrous substrate to which the resin powder has adhered is heated by a resin welding heater as it passes through the heater. As a result, the resin powder attached to the sheet-like fibrous substrate is welded to the sheet-like fibrous substrate, and a prepreg is manufactured. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Patent No. 6121978 [Overview of the project] [Problems that the invention aims to solve]

[0004] However, as described above, the resin powder heated by the resin welding heater and welded to the sheet-like fibrous substrate shrinks when it cools and solidifies after passing through the resin welding heater. As a result, the width of the sheet-like fibrous substrate (e.g., UD substrate) shrinks after passing through the resin welding heater. In addition, there is variation in the quality of the sheet-like fibrous substrate (e.g., UD substrate). Consequently, there is a challenge in manufacturing prepregs with a stable width (target width or approximately target width).

[0005] Other challenges and novel features will become apparent from the description and accompanying drawings in this specification. [Means for solving the problem]

[0006] A prepreg manufacturing apparatus according to one embodiment is a prepreg manufacturing apparatus that manufactures a prepreg by heating and welding the resin powder to a sheet-like fibrous substrate that is being transported and to which the resin powder is attached, and comprises a width detection sensor for detecting the width of the sheet-like fibrous substrate being transported, and a width control means for controlling the width of the sheet-like fibrous substrate being transported so that the width of the sheet-like fibrous substrate being transported detected by the width detection sensor becomes a predetermined target width. [Effects of the Invention]

[0007] According to the above embodiment, a prepreg manufacturing apparatus can be provided that can manufacture prepregs with a stable width (target width or approximately target width). [Brief explanation of the drawing]

[0008] [Figure 1] This is a plan view showing an overview of the configuration of a prepreg manufacturing apparatus according to the present disclosure. [Figure 2] This is a side view showing an overview of the configuration of a prepreg manufacturing apparatus according to the present disclosure. [Figure 3] This is a view along arrow AA in Figure 2. [Figure 4] This diagram illustrates a manufacturing method for producing prepregs using a prepreg manufacturing apparatus as an example. [Figure 5] This is a schematic diagram of a prepreg manufacturing apparatus using an expander roll 90. [Figure 6] (a) A specific arrangement example of the expander roll 90 and substrate width sensor 100 (enlarged detailed view within the rectangle indicated by the symbol B1 in Figure 5), and (b) A specific arrangement example of the expander roll 90 and substrate width sensor 100 (modified example). [Figure 7] This is a schematic view (diagram) from the direction of arrow AR7 in Figure 6. [Figure 8] This is a system configuration diagram of the control device 110, etc. [Figure 9]It is a flowchart of an operation example (prepreg width control process 1) of a prepreg manufacturing apparatus using an expander roll 90. [Figure 10] It is a figure in which the expander roll 90 in FIG. 7 is replaced with a spiral roll 90A. [Figure 11] It is a system configuration diagram of a control device 110A etc. [Figure 12] It is a flowchart of an operation example (prepreg width control process 2) of a prepreg manufacturing apparatus using a spiral roll 90A. [Figure 13] It is a figure in which the spiral roll 90A in FIG. 10 is replaced with a crown roll 90B. [Figure 14] It is a figure in which the expander roll 90 in FIG. 7 is replaced with a cross guide 90C. [Figure 15] It is a system configuration diagram of a control device 110C etc. [Figure 16] It is a flowchart of an operation example (prepreg width control process 3) of a prepreg manufacturing apparatus using a cross guide 90C.

MODE FOR CARRYING OUT THE INVENTION

[0009] <Reference Example> The prepreg manufacturing apparatus of the reference example will be described with reference to FIGS. 1 to 3.

[0010] The prepreg manufacturing apparatus of the reference example is an apparatus for manufacturing a prepreg by attaching a resin powder 30 to a sheet-like fiber base material 50 such as a carbon fiber fabric or a UD tape. As shown in FIGS. 1 and 2, two chambers 31 and 32 provided on the left and right with the sheet-like fiber base material 50 in between, supply pipes 37 and 38 provided in the chambers 31 and 32 respectively, flat type air nozzles 41 and 42 connected to the ends of the supply pipes 37 and 38 respectively, and powder resin charging parts 43 and 44 provided on the supply pipes 37 and 38 respectively are mainly provided.

[0011] Chambers 31 and 32 have rectangular outer shells 31a and 32a, and roughly rectangular inner shells 31b and 32b with rounded corners, which are provided inside the outer shells 31a and 32a.

[0012] The outer shells 31a and 32a on the side facing the sheet-like fiber substrate 50, that is, the right end (front) of the left chamber 31 and the left end (front) of the right chamber 32, are open, and the sheet-like fiber substrate 50 to which the resin powder 30 adheres is installed between them. On the opposite side of the outer shells 31a and 32a from the side facing the sheet-like fiber substrate 50, that is, the left end (rear) of the left chamber 31 and the right end (rear) of the right chamber 32, discharge ports 35 and 36 are formed. Dust collectors 53 and 54 are attached to the discharge ports 35 and 36 to collect the resin powder 30 discharged from the discharge ports 35 and 36.

[0013] Furthermore, openings 33 and 34 are formed at front positions opposite to the sheet-like fiber base material 50 of the inner shells 31b and 32b, that is, at the right end (front) of the inner shell 31b of the left chamber 31 and at the left end (front) of the inner shell 32b of the right chamber 32. High-voltage plates 51 and 52 are installed around the openings 33 and 34, encircling the entire structure.

[0014] Furthermore, the inner shells 31b and 32b of the chambers 31 and 32 are provided separated from the outer shells 31a and 32a without intersecting, and flow paths (gaps) 45 and 46 are formed between the outer shells 31a and 32a and the inner shells 31b and 32b, such that the resin powder 30 that is discharged with air from the openings 33 and 34 in the upper, lower, left, and right directions and does not adhere is discharged to the outside of the chambers 31 and 32 from the outlets 35 and 36.

[0015] The supply pipes 37 and 38 are located at approximately the center height within the inner shells 31b and 32b of the two chambers 31 and 32, respectively, with one end extending approximately horizontally to the openings 33 and 34. Flat-type air nozzles 41 and 42 are connected to the other ends of the supply pipes 37 and 38.

[0016] The flat-type air nozzles 41 and 42 have main bodies 41a and 42a that extend in the width direction of the two chambers 31 and 32 (in Figure 2, the front and back directions of the paper). Elongated injection slits (not shown) are formed at the sheet-like fibrous substrate 50 side ends of the main bodies 41a and 42a, extending in the width direction of the chambers 31 and 32, similar to the main bodies 41a and 42a, and air is ejected from the injection slits in a curtain-like manner.

[0017] The base ends of the main bodies 41a and 42a of the flat-type air nozzles 41 and 42 are connected to the other ends of input pipes 47 and 48, each having an input port 47a and 48a at one end into which resin powder 30 is introduced. The other ends of the input pipes 47 and 48 are inserted into the inner shells 31b and 32b of the chambers 31 and 32, but one end of the input pipes 47 and 48 is located outside the chambers 31 and 32, and a fixed amount of resin powder 30 is continuously introduced through the input port 47a and 48a at that end by a quantitative feeder or the like.

[0018] Furthermore, compressors 39 and 40 are connected to the approximate center of the inlet pipes 47 and 48 via an air amplification device T. As a result, the compressed air sent from the compressors 39 and 40 has its flow velocity further increased by the air amplification device T and is mixed with the resin powder 30 supplied from the inlet ports 47a and 48a by a metering feeder or the like, and is then pushed into the flat-type air nozzles 41 and 42 as a high-pressure solid-gas two-phase flow.

[0019] The powder resin charging units 43 and 44 are located approximately in the center of the supply pipes 37 and 38, and charge the resin powder 30 negatively (or positively) along with the air, thereby providing the resin powder 30 with a high amount of charge.

[0020] Generally, thermosetting resins are used as the resin powder 30, but thermoplastic resins or natural resins may also be used. Furthermore, the sheet-like fibrous base material 50 may consist of metal fibers other than carbon fibers, mineral fibers, glass fibers, or synthetic fibers.

[0021] Furthermore, the sheet-like fiber substrate 50 is connected to ground, and a high-voltage electric field is applied between it and the high-voltage plates 51 and 52 installed around the openings 33 and 34 formed in the inner shells 31b and 32b of the chambers 31 and 32.

[0022] A method for manufacturing prepregs using a prepreg manufacturing apparatus configured in this way will be described.

[0023] When a fixed amount of resin powder 30 is continuously fed in through the inlet ports 47a and 48a of the input pipes 47 and 48 by a quantitative feeder or the like, the resin powder 30 is mixed inside the input pipes 47 and 48 with high-pressure air whose flow velocity has been further increased by the air amplification device T, which is compressed air sent from the compressors 39 and 40, and then pushed into the flat-type air nozzles 41 and 42.

[0024] As a result, the air velocity is made uniform from the injection slits of the flat-type air nozzles 41 and 42 into the supply pipes 37 and 38, and a fixed two-phase flow of resin powder 30 mixed with air is sent in an air curtain shape, and both the resin powder 30 and the air are negatively charged by the powder resin charging sections 43 and 44 provided in the supply pipes 37 and 38.

[0025] Then, the stationary two-phase flow, which is a mixture of charged resin powder 30 and air, is discharged from the openings 33 and 34 of the chambers 31 and 32 and blown onto the sheet-like fibrous substrate 50. At this time, a high-voltage electric field is applied between the openings 33 and 34 and the sheet-like fibrous substrate 50, which is connected to ground, by high-voltage plates 51 and 52 installed around the openings 33 and 34. Additionally, a negative high voltage is applied to the openings 33 and 34. As a result, the negatively charged resin powder 30 is forcefully discharged from the openings 33 and 34 towards the sheet-like fibrous substrate 50 and adheres to the sheet-like fibrous substrate 50 with strong adhesive force, thereby manufacturing a prepreg.

[0026] Furthermore, when the resin powder 30 is positively charged by the powder resin charging sections 43 and 44, a positive high voltage is applied to the openings 33 and 34 by the high-voltage plates 51 and 52.

[0027] In this specification, prepreg includes semipreg.

[0028] Furthermore, any resin powder 30 that does not adhere to the sheet-like fibrous substrate 50 flows through the channels 45 and 46 formed between the outer shells 31a and 32a and the inner shells 31b and 32b of the two chambers 31 and 32 to the rear side of the outer shells 31a and 32a, and is discharged to the outside of the two chambers 31 and 32 from the outlets 35 and 36.

[0029] The discharged resin powder 30 is collected by dust collectors 53 and 54 connected to the discharge ports 35 and 36 and reused. In this embodiment, as shown in Figure 1, the resin powder 30 collected by the dust collectors 53 and 54 is again fed into the inlet ports 47a and 48a of the input pipes 47 and 48 via a quantitative feeder, and pushed into flat-type air nozzles 41 and 42 along with air via compressors 39 and 40.

[0030] According to this configuration, chambers 31 and 32, each consisting of outer shells 31a and 32a and inner shells 31b and 32b, are provided on either side of a sheet-like fibrous substrate 50, and flat-type air nozzles 41 and 42 are provided in the inner shells 31b and 32b of the chambers 31 and 32, respectively. As a result, the entire apparatus is made smaller and space-saving, and the resin powder 30 can be simultaneously attached to both sides of the sheet-like fibrous substrate 50.

[0031] Furthermore, by employing flat-type air nozzles 41 and 42, the resin powder 30 is mixed with air and pushed in from the rear of the supply pipes 37 and 38 at high pressure and a uniform flow rate. As a result, the solid-gas two-phase flow consisting of the charged resin powder 30 and air within the supply pipes 37 and 38 is fast and uniform, eliminating the need for conventional flow straighteners and blowers. This also allows for miniaturization of the entire device.

[0032] In this reference example, the sheet-like fibrous substrate 50 is fixed between two chambers 31 and 32 to simultaneously adhere the resin powder 30 to both sides. However, by further providing a conveying device capable of continuously transporting the sheet-like fibrous substrate 50 itself in an upward or downward direction, the resin powder 30 can be adhered to both sides of the sheet-like fibrous substrate 50 over a wide area and continuously in a short time.

[0033] Furthermore, in this reference example, high-voltage plates 51 and 52 are installed around the openings 33 and 34 of the chambers 31 and 32 to ensure that the resin powder 30 adheres more firmly to the sheet-like fibrous substrate 50. However, the resin powder 30 can also be adhered to the sheet-like fibrous substrate 50 even without the high-voltage plates 51 and 52 and the powder resin charging sections 43 and 44.

[0034] Next, we will explain a manufacturing method for producing prepregs using the prepreg manufacturing apparatus described in the above reference example.

[0035] Figure 4 is a diagram illustrating a manufacturing method for producing prepregs using a reference example prepreg manufacturing apparatus.

[0036] Hereafter, a UD substrate will be used as the sheet-like fiber substrate 50. A UD substrate is a sheet-like fiber substrate that lacks fibers corresponding to weft threads and is composed of fibers corresponding to warp threads. Hereafter, it will be referred to as UD substrate m1. For the sake of simplicity, only the opening 33 (supply pipe 37) is shown in Figure 4, and the opening 34 (supply pipe 38) has been omitted. The following explanation will also focus on the operation of the opening 33 (supply pipe 37), and the operation of the opening 34 (supply pipe 38) will be omitted.

[0037] As shown in Figure 4, the UD substrate m1 is continuously drawn from a roll body M1 in which the UD substrate m1 is wound into a roll, stretched over driven rollers R1 and R2, and connected to a winding shaft A. The UD substrate m1 is transported (in the direction indicated by arrows AR1 to AR3 in Figure 4) by the rotation of the winding shaft A by a motor (not shown), and passes through the opening 33 (supply pipe 37) located between the driven rollers R1 and R2, and the resin welding heater 60 in that order.

[0038] A high-voltage power supply 70 is electrically connected to the high-voltage plate 51 (electrode plate), and a high voltage V (for example, several tens of kV) is applied. As a result, corona discharge occurs from the high-voltage plate 51 toward the UD substrate m1 which is grounded. Therefore, the resin powder ejected from the opening 33 together with air is charged by ions generated by the corona discharge as it passes through the high-voltage plate 51. This charged resin powder adheres to the UD substrate m1 (front or back surface) passing through the opening 33 due to the Coulomb force created by the electric field formed between the high-voltage plate 51 and the UD substrate m1 and the transport force of the air ejected from the opening 33 (principle of electrostatic powder coating). As shown in Figure 3, the opening 33 is a slit-shaped opening (an example of a resin powder discharge port in this disclosure) that extends in the width direction (left-right direction in Figure 3) of the UD substrate m1. The length L1 of this opening 33 (see Figure 3) corresponds to the width of the UD substrate m1 and is, for example, 400 mm. On the other hand, the width W (slit width; see Figure 3) of this opening 33 is, for example, 20 mm. The air and resin powder that are sprayed from this opening 33 toward the UD substrate m1 are supplied to the opening 33 by the supply pipe 37 (see Figures 1 and 2) and sprayed from the opening 33.

[0039] As described above, the UD substrate m1 to which the resin powder is attached is heated by the resin welding heater 60 as it passes through the heater. This causes the resin powder attached to the UD substrate m1 to weld to the UD substrate m1, and a prepreg m2 (see Figure 4) is manufactured. This manufactured prepreg m2 is wound onto a winding shaft A, which is rotated by a motor (not shown), via a driven roller R2.

[0040] <Embodiment> First, we will explain the problems that the inventors have found in the manufacturing method for producing prepregs using the prepreg manufacturing apparatus described in the above reference example.

[0041] As described above, the resin powder heated by the resin welding heater 60 and welded to the UD substrate m1 shrinks when it cools and solidifies after passing through the resin welding heater 60. Therefore, the width of the UD substrate m1 shrinks after passing through the resin welding heater 60 (for example, a width of 300 mm before passing through the resin welding heater 60 shrinks to 280 mm after passing through the resin welding heater 60), making it difficult to manufacture prepregs with a stable width (target width or approximately target width).

[0042] Furthermore, we found that the UD base material m1 exhibits quality variations, which makes it difficult to manufacture prepregs with a stable width (target width or approximately target width).

[0043] Next, as an embodiment, an example in which a configuration example for solving the above problems is applied to the above reference example will be described.Hereafter, an example using an expander roll 90 will be described as a configuration example for solving the above problems.Hereafter, the same reference numerals will be used for components similar to those in the above reference example, and their descriptions will be omitted as appropriate.Since the flat-type air nozzles 41 and 42 have similar configurations and operations, in order to simplify the explanation, an example using the flat-type air nozzle 41 and supply pipe 37 will be described as a representative example, and the example using the flat-type air nozzle 42 and supply pipe 38 will be omitted.

[0044] Figure 5 is a schematic diagram of a prepreg manufacturing apparatus using an expander roll 90. Figure 6(a) is a specific arrangement example of the expander roll 90 and substrate width sensor 100 (enlarged detailed view within the rectangle indicated by the symbol B1 in Figure 5). Figure 6(b) is a specific arrangement example of the expander roll 90 and substrate width sensor 100 (modified example). Figure 7 is a schematic view from the direction of arrow AR7 in Figure 6(a).

[0045] The expander roll 90 is generally used to automatically remove wrinkles and shrinkage of films and the like during transport, but in this embodiment, it is used to widen the prepreg m2 (UD base material m1 immediately after the resin powder has been welded) during transport. As the expander roll 90, for example, the Varibow EXP manufactured by Kansen Expander Industry Co., Ltd. (https: / / kansenexp.co.jp / products / variable / vcs / ) can be used.

[0046] As shown in Figure 6(a), the expander roll 90 is positioned between the driven rollers R2 and R3. In this case, the rotation axis AX of the expander roll 90 90 It is positioned below the straight line L2 connecting the rotation axis of the driven roller R2 and the rotation axis of the driven roller R3. As a result, the prepreg m2 (UD base material m1 immediately after the resin powder has been welded) has a gripping angle θ 90 It is in contact with the expander roll 90 within the range shown in Figure 6(a). In the case of the expander roll 90, the gripping angle θ 90 A temperature of 30 to 60 degrees is preferable.

[0047] Note that the rotation axis AX of the expander roll 90 90 The expander may be positioned not only below the straight line L2 connecting the rotation axis of the driven roller R2 and the rotation axis of the driven roller R3, but also above the straight line L2. For example, when using a sheet-like fibrous material with a large widening effect (e.g., prepreg m2) (when the frictional force between the expander roll and the sheet-like fibrous material is large), the embrace angle θ 90 To reduce the size and minimize the widening effect, the rotation axis AX of the expander roll 90 90 It is conceivable to position it above the straight line L2. Furthermore, by providing a mechanism to move the driven roller R3 and the expander roll 90 in the up, down, left, and right directions in Figure 6(a), and moving at least one of the driven roller R3 and the expander roll 90 in the up, down, left, and right directions in Figure 6(a), the wrapping angle θ can be adjusted. 90 It can be adjusted.

[0048] Note that the expander roll 90 may contact the prepreg m2 at a holding angle θ from above (see Fig. 6(a)), or may contact the prepreg m2 at a holding angle θ from below (see Fig. 6(b)). 90 Next, the control device 110 of the present embodiment will be described. Fig. 8 is a system configuration diagram of the control device 110 and the like. 90 The control device 110 includes a processor, a RAM, etc. (not shown). As shown in Fig. 8, an expander roll 90, a base material width sensor 100 (an example of the width detection sensor of the present disclosure), and a storage unit 120 are electrically connected to the control device 110. The storage unit 120 is a non-volatile storage unit such as a hard disk device or a ROM, for example. A program 121 and a target width 122 are stored in the storage unit 120. The program 121 is a program executed by the control device 110 (processor). The target width 122 is the target width of the prepreg m2.

[0049] The processor is, for example, a CPU. The processor may be one or a plurality. For example, the processor functions as control means for controlling the vent amount (curvature amount) of the expander roll 90 by executing the program 121 read from the storage unit 120 (for example, ROM) into the RAM.

[0050] The control device 110 controls (feedback control) the bend amount (curvature amount) of the expander roll 90 so that the width of the prepreg m2 (UD base material m1 immediately after the resin powder is welded) being conveyed detected by the base material width sensor 100 becomes a predetermined target width. At that time, the bend amount (curvature amount) of the expander roll 90 is controlled symmetrically with respect to the central axis AX

[0051] (see Fig. 7) in the left-right direction.

[0052] m2 (see Fig. 7) in the left-right direction.

[0053] ​The substrate width sensor 100 is positioned downstream of the expander roll 90 (and driven roller R3) and detects the width W2 of the prepreg m2 after it has passed through the expander roll 90. For example, an edge sensor can be used as the substrate width sensor 100.

[0054] Next, we will explain the principle of widening the width of the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded).

[0055] Figure 7 shows how a prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) with a width W1 before passing through the expander roll 90 is expanded to a width W2 after passing through the expander roll 90.

[0056] The prepreg m2 has an embrace angle θ. 90 When transported in contact with the expander roll 90 within the range shown in Figure 6(a), the rotation axis AX of the expander roll 90 90 It tends to progress in a direction perpendicular to it.

[0057] Here, as shown in Figure 7, the rotation axis AX of the expander roll 90 90 In a plan view, it is curved convexly toward the downstream side in the conveying direction, and the amount of bend (curvature) of this curve is controlled.

[0058] In this process, the prepreg m2 passing through the center of the expander roll 90 moves in a straight line (see arrow ARa in Figure 7). On the other hand, the prepreg m2 passing to the right of the center of the expander roll 90 moves in an angle direction (diagonally to the right) corresponding to its passing position (see arrow ARb in Figure 7, for example). Similarly, the prepreg m2 passing to the left of the center of the expander roll 90 moves in an angle direction (diagonally to the left) corresponding to its passing position (see arrow ARc in Figure 7, for example). As a result, the prepreg m2, which has a width W1 before passing through the expander roll 90, is expanded to a width W2 after passing through the expander roll 90.

[0059] Furthermore, increasing the bend amount (curvature) of the expander roll 90 can increase the width expansion amount (width W2). Conversely, decreasing the bend amount (curvature) of the expander roll 90 can decrease the width expansion amount (width W2).

[0060] Next, an example of the operation of a prepreg manufacturing apparatus using the expander roll 90 configured as described above will be explained.

[0061] Figure 9 is a flowchart showing an example of the operation of a prepreg manufacturing apparatus using an expander roll 90 (prepreg width control process 1).

[0062] The following assumptions are that the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) has an attachment angle θ 90 It is assumed that the device is being transported in contact with the expander roll 90 within the range shown in Figure 6(a).

[0063] First, the width of the prepreg m2 is detected (step S10). This is achieved by the substrate width sensor 100. The substrate width sensor 100 detects the width W2 of the prepreg m2 after it has passed through the expander roll 90 (see Figure 7).

[0064] Next, it is determined whether the width of the prepreg m2 detected in step S10 is the target width (step S11). This is achieved by the control device 110 executing program 121. In this case, the target width used is the target width 122 stored in the storage unit 120.

[0065] In step S11, if it is determined that the width of the prepreg m2 detected in step S10 is the target width (step S11: YES), the process in step S10 is repeated.

[0066] On the other hand, in step S11, if it is determined that the width of the prepreg m2 detected in step S10 is not the target width (step S11: NO), the bend amount (curving amount) of the expander roll 90 is controlled so that the width of the prepreg m2 becomes the target width (step S12). This is achieved by the control device 110 executing program 121. For example, if the width W2 of the prepreg detected in step S10 is smaller than the target width 122, the control device 110 controls the expander roll 90 so that the bend amount (curving amount) is larger. This brings the width W2 of the prepreg m2 after passing through the expander roll 90 closer to the target width 122. On the other hand, if the width W2 of the prepreg detected in step S10 is larger than the target width 122, the control device 110 controls the expander roll 90 so that the bend amount (curving amount) is smaller. This brings the width W2 of the prepreg m2 after passing through the expander roll 90 closer to the target width 122.

[0067] Thereafter, the processes described in steps S10 to S12 above are repeatedly executed.

[0068] This makes it possible to manufacture prepreg m2 with a stable width (target width or approximately target width).

[0069] As described above, according to this embodiment, it is possible to manufacture prepregs with a stable width (target width or approximately target width).

[0070] Next, I will explain some variations. <Example 1> Modification 1 is an example in which a spiral roll 90A is used instead of the expander roll 90 of the above embodiment. Otherwise, the configuration is the same as the above embodiment. The spiral roll 90A is generally used to automatically smooth out wrinkles in films, etc., during transport, but in this Modification 1, it is used to widen the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) during transport.

[0071] Figure 10 shows Figure 7 with the expander roll 90 replaced by a spiral roll 90A.

[0072] As shown in Figure 10, the outer surface of the spiral roll 90A has the axis AX of the spiral roll 90A. 90A Axis AX extends from the center of the direction to both the left and right sides. 90A A spiral groove g is formed that is symmetrical with respect to the center of the direction.

[0073] As shown in Figure 6(a), the spiral roll 90A is positioned between the driven rollers R2 and R3. In this case, the rotation axis AX of the spiral roll 90A 90A It is positioned below the straight line L2 connecting the rotation axis of the driven roller R2 and the rotation axis of the driven roller R3. As a result, the prepreg m2 (UD base material m1 immediately after the resin powder has been welded) has a gripping angle θ 90 It is in contact with the spiral roll 90A within the range shown in Figure 6(a). In the case of the spiral roll 90A, the grip angle θ 90 A range of 90 to 120 degrees is preferable. The same applies to the Crown Roll 90B, which will be discussed later.

[0074] Note that the rotation axis AX of the spiral roll 90A 90A The spiral roll may be positioned not only below the straight line L2 connecting the rotation axis of the driven roller R2 and the rotation axis of the driven roller R3, but also above the straight line L2. For example, when using a sheet-like fibrous material with a large widening effect (e.g., prepreg m2) (when the frictional force between the spiral roll and the sheet-like fibrous material is large), the wrapping angle θ 90A In order to reduce the size and minimize the widening effect, the rotation axis AX of the spiral roll 90A 90A It is conceivable to position it above the straight line L2. Furthermore, by providing a mechanism to move the driven roller R3 and spiral roll 90A in the up, down, left, and right directions in Figure 6(a), and moving at least one of the driven roller R3 and spiral roll 90A in the up, down, left, and right directions in Figure 6(a), the gripping angle θ can be adjusted. 90A It can be adjusted.

[0075] Furthermore, the spiral roll 90A wraps around the prepreg m2 from above at an angle θ. 90A It may be in contact within this range (see Figure 6(a)), or the prepreg m2 may be embraced from below at an angle θ 90A They may touch within this range (see Figure 6(b)).

[0076] Next, the control device 110A of this modified example 1 will be described. Figure 11 is a system configuration diagram of the control device 110A, etc.

[0077] As shown in Figure 11, the control device 110A is electrically connected to the motor M for driving the winding shaft A, the substrate width sensor 100, and the storage unit 120.

[0078] The control device 110A controls the tension of the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) during transport by controlling the torque of the motor M so that the width of the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) detected by the substrate width sensor 100 becomes a predetermined target width. Alternatively, the tension of the prepreg m2 during transport may be controlled using a known tension control means (for example, a dancer mechanism). As a dancer mechanism, for example, one described at https: / / www.shi-mechatronics.jp / solutions / technology / linedrive / adu-as / 794 / can be used.

[0079] Next, we will describe an example of the operation of a prepreg manufacturing apparatus using the spiral roll 90A configured as described above.

[0080] Figure 12 is a flowchart showing an example of the operation of a prepreg manufacturing apparatus using a spiral roll 90A (prepreg width control process 2).

[0081] The following assumptions are that the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) has an attachment angle θ 90 (See Figure 6(a)) The material is assumed to be being transported in contact with the spiral roll 90A within this range.

[0082] First, the width of the prepreg m2 is detected (step S20). This is achieved by the substrate width sensor 100. The substrate width sensor 100 detects the width W2 of the prepreg m2 after it has passed through the spiral roll 90A (see Figure 10).

[0083] Next, it is determined whether the width of the prepreg m2 detected in step S20 is the target width (step S21). This is achieved by the control device 110A executing program 121. In this case, the target width used is the target width 122 stored in the storage unit 120.

[0084] In step S21, if it is determined that the width of the prepreg m2 detected in step S20 is the target width (step S21: YES), the process in step S20 is repeated.

[0085] On the other hand, in step S21, if it is determined that the width of the prepreg m2 detected in step S20 is not the target width (step S21: NO), the tension of the prepreg m2 is controlled so that the width of the prepreg m2 becomes the target width (step S22). This is achieved by the control device 110A executing program 121. For example, if the width W2 of the prepreg m2 detected in step S20 is smaller than the target width 122, the control device 110A controls the torque of the motor M for driving the winding shaft A so that the tension of the prepreg m2 increases. As a result, the spiral roll 90A is pressed more firmly against the prepreg m2, increasing the amount that the prepreg m2 bites into the groove of the spiral roll 90A, and increasing the widening effect. As a result, the width W2 of the prepreg m2 after passing through the spiral roll 90A can be brought closer to the target width 122. On the other hand, if the width W2 of the prepreg detected in step S20 is greater than the target width 122, the control device 110A controls the torque of the motor M for driving the winding shaft A so that the tension of the prepreg m2 is reduced. As a result, the spiral roll 90A is pressed weakly against the prepreg m2, reducing the amount that the prepreg m2 bites into the groove of the spiral roll 90A, and reducing the widening effect. As a result, the width W2 of the prepreg m2 after passing through the expander roll 90 can be brought closer to the target width 122.

[0086] Thereafter, the processes described in steps S20 to S22 above are repeatedly executed.

[0087] This makes it possible to manufacture prepreg m2 with a stable width (target width or approximately target width).

[0088] As explained above, this modified example 1 also makes it possible to manufacture prepregs with a stable width (target width or approximately target width). <Modification 2> Modification 2 is an example in which a crown roll 90B is used instead of the spiral roll 90A in Modification 1. Otherwise, the configuration is the same as in Modification 1. The crown roll 90B is generally used to automatically smooth out wrinkles in films, etc., during transport, but in this Modification 2, it is used to widen the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) during transport.

[0089] As shown in Figure 6(a), the crown roll 90B is positioned between the driven rollers R2 and R3.

[0090] Figure 13 shows Figure 10 with the spiral roll 90A replaced by the crown roll 90B.

[0091] As shown in Figure 13, the crown roll 90B has an axis AX 90B The center is the thickest point, and it extends gently in an arc from the center toward both the left and right sides, along the axis AX. 90B It is constructed symmetrically with respect to the directional center.

[0092] This modified example 2 also allows for the production of prepregs with a stable width (target width or approximately target width) by performing the same process as in Figure 12 (prepreg width control process 2).

[0093] Although not shown in the diagram, a reverse crown roll (also called a concave roller) may be used instead of the crown roll 90B. Unlike the crown roll 90B, the reverse crown roll is narrowest in its axial center, and extends gently in an arc shape from this center to both the left and right sides, and is constructed symmetrically with respect to the axial center. As an example of a reverse crown roll (concave roller), the one described at https: / / katsura-roller.co.jp / product / detail / concave.html can be used. <Variation 3> Modification 3 is an example in which a cross guider 90C is used instead of the expander roll 90 of the above embodiment. Otherwise, the configuration is the same as the above embodiment. The cross guider 90C is generally used to automatically correct the unevenness of cloth or the like during transport, but in this modification 3, it is used to widen the prepreg m2 (UD base material m1 immediately after the resin powder has been welded) during transport.

[0094] Figure 14 shows Figure 7 with the expander roll 90 replaced by a cross guider 90C.

[0095] As shown in Figure 14, the cross guide 90C comprises a left cross guide 90CL (an example of the first cross guide in this disclosure) positioned on the left side of the prepreg m2 being transported, and a right cross guide 90CR (an example of the second cross guide in this disclosure) positioned on the right side.

[0096] The left cross guide 90CL includes a fixed guide roller (not shown in Figure 14) positioned on the back side of the prepreg m2, an operating guide roller 91L positioned on the front side of the prepreg m2, and an actuator 92L (see Figure 15) that moves the operating guide roller 91L to the nip position or non-nip position. Similarly, the right cross guide 90CR includes a fixed guide roller (not shown in Figure 14) positioned on the back side of the prepreg m2, an operating guide roller 91R positioned on the front side of the prepreg m2, and an actuator 92R (see Figure 15) that moves the operating guide roller 91R to the nip position or non-nip position.

[0097] The operating-side guide rollers 91L and 91R are positioned at an angle to the conveying direction, as shown in Figure 14, in order to widen the prepreg m2 during transport. The fixed-side guide rollers are positioned similarly.

[0098] Next, the control device 110C of this modified example 3 will be described. Figure 15 is a system configuration diagram of the control device 110C and other components.

[0099] As shown in Figure 15, the control device 110C is electrically connected to the cross guider 90C (actuators 92L and 92R), the substrate width sensor 100, and the memory unit 120. The control device 110C controls actuator 92L to position the operating-side guide roller 91L in the nip position, so that the left end of the prepreg m2 being transported is nipped between the operating-side guide roller 91L and the fixed-side guide roller. Similarly, the control device 110C controls actuator 92R to position the operating-side guide roller 91R in the nip position, so that the right end of the prepreg m2 being transported is nipped between the operating-side guide roller 91R and the fixed-side guide roller.

[0100] The control device 110A controls the nip state of the left cross guide 90CL and the right cross guide 90CR by controlling the cross guide 90C (actuators 92L, 92R) so that the width of the prepreg m2 (UD substrate m1 immediately after the resin powder has been welded) being transported, as detected by the substrate width sensor 100, becomes a predetermined target width.

[0101] Next, we will describe an example of the operation of a prepreg manufacturing apparatus using the Cross Guider 90C configured as described above.

[0102] Figure 16 is a flowchart showing an example of the operation of a prepreg manufacturing apparatus using the Cross Guider 90C (prepreg width control process 3).

[0103] The following assumes that the prepreg m2 (UD base material m1 immediately after the resin powder has been welded) is being transported with the operating side guide roller 91L and the operating side guide roller 91R each in a non-nip position.

[0104] First, the width of the prepreg m2 is detected (step S30). This is achieved by the substrate width sensor 100. The substrate width sensor 100 detects the width W2 of the prepreg m2 after it has passed through the cross guider 90C (see Figure 14).

[0105] Next, it is determined whether the width of the prepreg m2 detected in step S30 is the target width (step S31). This is achieved by the control device 110 executing program 121. In this case, the target width used is the target width 122 stored in the storage unit 120.

[0106] In step S31, if it is determined that the width of the prepreg m2 detected in step S30 is the target width (step S31: YES), the process in step S30 is repeated.

[0107] On the other hand, in step S31, if it is determined that the width of the prepreg m2 detected in step S30 is not the target width (step S31: NO), the nip state of the cross guides 90C (left cross guide 90CL and right cross guide 90CR) is controlled so that the width of the prepreg m2 becomes the target width (step S32). This is achieved by the control device 110C executing program 121. For example, if the width W2 of the prepreg m2 detected in step S30 is smaller than the target width 122, the control device 110C controls the actuators 92L and 92R to move the operating side guide rollers 91L and 91R to the nip position, respectively (nip on). As a result, the left and right ends of the prepreg m2 are nipped, creating a widening effect, which brings the width W2 of the prepreg m2 after passing the cross guide 90C closer to the target width 122.

[0108] Thereafter, the processes described in steps S30 to S32 above will be executed repeatedly.

[0109] Subsequently, if the width W2 of the prepreg detected in step S30 becomes larger than the target width 122, the control device 110 controls the actuators 92L and 92R to move the operating side guide rollers 91L and 91R, respectively, to the non-nip position (nip off). As a result, the nips at the left and right ends of the prepreg m2 are released, eliminating the widening effect, and the width W2 of the prepreg m2 after passing the cross guider 90C can be brought closer to the target width 122.

[0110] As a result, it is possible to manufacture prepreg m2 with a stable width (target width or approximately target width).

[0111] As explained above, this modified example 3 also makes it possible to manufacture prepregs with a stable width (target width or approximately target width).

[0112] In this modified example 3, an example of controlling the nip state of the cross guide 90C (left cross guide 90CL and right cross guide 90CR) was described in which the operating side guide rollers 91L and 91R are moved to the nip position or the non-nip position, respectively, but the method is not limited to this. For example, the inclination angle (V-shaped inclination angle) of the cross guide 90C (left cross guide 90CL and right cross guide 90CR) may be controlled, or the force (pressing force) at which the cross guide 90C (left cross guide 90CL and right cross guide 90CR) nip the prepreg m2 during transport may be controlled by controlling the actuators 92L and 92R.

[0113] The present inventors have described the invention in detail based on embodiments, but it goes without saying that this disclosure is not limited to the embodiments already described, and various modifications are possible without departing from the spirit of the invention. [Explanation of Symbols]

[0114] 11 Inlet 12 Accelerator 13 brushes 14 Compression section 15 Storage Box 16 tubes 17 Powder 18 holes 19 Chambers 20 Carbon fiber fabric 30 Resin powder 31, 32 chambers 31a,32a Outer shell 31b,32b inner shell 33,34 Opening (resin powder discharge outlet) 35,36 Outlet 37,38 Supply pipe 39,40 Compressor 41,42 Flat-type air nozzle 41a, 42a Main body 43,44 Powder resin charging part 45,46 channel 47,48 Inlet pipe 47a,48a Inlet 50 Sheet-like fiber base material 51, 52 High Voltage Plate 53, 54 Dust collector T Air Multiplier 60 Resin welding heater 70 High-voltage power supply 80 feeders 90 Expander Roll 90A Spiral Roll 90B Crown Roll 90C Cross Guider 110, 110A, 110C control devices

Claims

1. A prepreg manufacturing apparatus for producing a prepreg by heating and welding the resin powder to a sheet-like fibrous substrate to which resin powder is attached during transport, A width detection sensor detects the width of the heated sheet-like fiber substrate, which is the sheet-like fiber substrate to which the resin powder is attached, during transport after the resin powder has been heated and welded. A prepreg manufacturing apparatus comprising: width control means for controlling the width of the heated sheet-like fibrous substrate during transport so that the width of the heated sheet-like fibrous substrate during transport, as detected by the width detection sensor, becomes a predetermined target width.

2. The prepreg manufacturing apparatus according to claim 1, wherein the width control means is a control device that controls the amount of bending of the expander roll so that the width of the heated sheet-like fiber substrate being transported, as detected by the expander roll and the width detection sensor, becomes a predetermined target width.

3. The prepreg manufacturing apparatus according to claim 1, wherein the width control means is a control device that controls the tension of the heated sheet-like fiber substrate during transport so that the width of the heated sheet-like fiber substrate during transport, as detected by the spiral roll in which the heated sheet-like fiber substrate during transport contacts the heated sheet-like fiber substrate within a predetermined gripping angle range and by the width detection sensor, becomes a predetermined target width.

4. The prepreg manufacturing apparatus according to claim 1, wherein the width control means is a control device that controls the tension of the heated sheet-like fiber substrate during transport so that the width of the heated sheet-like fiber substrate during transport, as detected by the crown roll in which the heated sheet-like fiber substrate during transport contacts the heated sheet-like fiber substrate within a predetermined gripping angle range and by the width detection sensor, becomes a predetermined target width.

5. The prepreg manufacturing apparatus according to claim 1, wherein the width control means is a control device that controls the tension of the heated sheet-like fiber substrate during transport so that the width of the heated sheet-like fiber substrate during transport, as detected by the inverted crown roll in which the heated sheet-like fiber substrate during transport contacts the heated sheet-like fiber substrate within a predetermined gripping angle range and by the width detection sensor, becomes a predetermined target width.

6. The prepreg manufacturing apparatus according to claim 1, wherein the width control means is a first cross guide that nips one end of the heated sheet-like fibrous substrate in the width direction during transport, a second cross guide that nips the other end, and a control device that controls the nip state of the first cross guide and the second cross guide so that the width of the heated sheet-like fibrous substrate during transport, as detected by the width detection sensor, becomes a predetermined target width.

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