JP2010031088A - Partially impregnated tow prepreg and apparatus for producing the same - Google Patents

Abstract

Provided is a partially impregnated tow prepreg that can ensure a degassing path during molding and can be quickly and easily degassed.
A partially impregnated tow prepreg 1 has an arrangement configuration in which an impregnated portion 4 impregnated with a matrix resin and an unimpregnated portion 3 not impregnated with a matrix resin are arranged in the width direction of a tow 2. When the fabric 5 is formed using the partially impregnated tow prepreg 1 and a plurality of fabrics 5 are laminated to form a laminate 6, an unimpregnated portion 3 overlaps to form an air passage that communicates in the stacking direction. be able to. Accordingly, a degassing path can be reliably ensured in the stacking direction of the stacked body 6, and degassing can be performed quickly and easily.
[Selection] Figure 1

Description

  The present invention relates to a partially-impregnated tow prepreg in which a matrix resin is partially impregnated into a tow which is a reinforcing fiber bundle, and an apparatus for manufacturing the same.

  Fiber reinforced composite materials are made by integrating a thermosetting resin or a thermoplastic resin matrix resin into a reinforced fiber substrate made of carbon fiber, glass fiber, etc. Used in the field.

  One method for forming a fiber reinforced composite material is to use a prepreg that is an intermediate in which a reinforcing fiber is impregnated with a matrix resin. Examples of the prepreg include a sheet prepreg obtained by impregnating a matrix resin into a sheet-like reinforcing fiber base material, and a tow prepreg obtained by impregnating a matrix resin into a tow which is a reinforcing fiber bundle. When forming a fiber-reinforced composite material by laminating such prepregs, an autoclave method has been performed in which the pressure is sufficiently reduced in advance using an autoclave or the like and then heated and pressurized to form.

  Patent Document 1 discloses a technique of a partially impregnated prepreg in which a vent hole 110 is provided in a matrix resin layer 101 (see FIGS. 11 and 12) to ensure a degassing path during molding. In the case of a prepreg in which the matrix resin is completely impregnated in the reinforcing fiber, the air confined between the layers of the prepreg where multiple sheets are laminated and the air confined inside the prepreg are pushed out to the outside and completely deaerated It was difficult to reduce the void ratio of the molded product.

  According to the publication, as shown in FIG. 11 which is a schematic cross-sectional view of a prepreg 100 and FIG. 12 which is a plan view of a matrix resin layer 101, a sheet is provided with vent holes 110 provided in a film-like matrix resin layer 101. It describes that the air inside the prepreg 100 is deaerated by partially covering the fibrous reinforcing fiber layer 102 and using the vent hole 110 as a vent path in the thickness direction.

No. 2002-249605

  However, if the prepreg 100 having the structure shown in Patent Document 1 is a single unit, a ventilation path can be secured by the ventilation holes 110, but in general, a plurality of prepregs 100 are randomly stacked and laminated. There is a possibility that the air holes 110 are completely blocked by the other prepregs 100 and a ventilation path communicating in the stacking direction cannot be secured.

  Further, it is necessary to impregnate the unimpregnated portion of the reinforcing fiber 102 with the matrix resin at the time of molding, and the size, number and arrangement position of the ventilation path are limited, so that a sufficiently large deaeration route can be secured. It was difficult to reduce the void ratio of the molded product.

  The present invention has been made in view of the above points, and an object of the present invention is to provide a partially impregnated tow prepreg that can reliably ensure a degassing path during molding and can be quickly and easily degassed. .

  The partially impregnated tow prepreg of the present invention that solves the above problems is a partially impregnated tow prepreg in which a matrix resin is partially impregnated in a tow composed of a reinforcing fiber bundle, the impregnated part impregnated with the matrix resin, and the matrix resin The non-impregnated portion that is not impregnated with is arranged in the width direction of the tow.

  When a woven fabric is formed using the partially impregnated tow prepreg of the present invention and a laminate is formed by laminating a plurality of woven fabrics, the unimpregnated portions of the partially impregnated tow prepreg overlap and communicate with the air passageway in the stacking direction. It can form, and a deaeration path | route can be ensured reliably in the lamination direction of a laminated body.

  And by the unimpregnated part of each partially impregnated tow prepreg, an air passage can be formed also in the surface direction in which the woven fabric extends, and a degassing path can be ensured in the surface direction of the laminate. Therefore, it can deaerate from both the lamination direction and surface direction of a laminated body at the time of vacuum forming, it can deaerate quickly and easily, and the void ratio of the molded product formed can be reduced.

  As an example of a specific configuration, the tow may have an impregnated portion on one side in the width direction and an unimpregnated portion on the other side in the width direction of the tow.

  The production apparatus for producing a partially impregnated tow prepreg according to the present invention is a production apparatus for producing a partially impregnated tow prepreg in which a matrix resin is partially impregnated in a tow comprising reinforcing fiber bundles. A resin impregnating unit that partially abuts in the width direction of the resin and impregnates the matrix resin into the abutting part, and a resin drying unit that heats and drys the matrix resin partially impregnated in the tow by the resin impregnating unit. It is characterized by that.

  The resin impregnation means may include a pulley having a pulley surface that partially contacts the tow in the width direction of the tow and a resin supply means that applies a liquid matrix resin to the pulley surface.

  According to the present invention, when a woven fabric is formed using a partially impregnated tow prepreg and a laminate is formed by laminating a plurality of woven fabrics, the non-impregnated portions of the partially impregnated tow prepreg overlap and communicate with each other in the stacking direction. A passage can be formed, and a degassing path can be reliably ensured in the stacking direction of the stacked body. And by the unimpregnated part of each partially impregnated tow prepreg, an air passage can be formed also in the surface direction in which the woven fabric extends, and a degassing path can be ensured in the surface direction of the laminate. Therefore, it can deaerate from both the lamination direction and surface direction of a laminated body at the time of vacuum forming, it can deaerate quickly and easily, and the void ratio of the molded product formed can be reduced.

Next, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view schematically showing a configuration of a partially impregnated tow prepreg 1 in the present embodiment, and FIG. 2 is a view schematically showing a cross section of the partially impregnated tow prepreg 1.

  As shown in FIGS. 1 and 2, the partially impregnated tow prepreg 1 in this embodiment includes a tow 2 made of a reinforcing fiber bundle, and an impregnated portion 4 impregnated with a matrix resin and an impregnated matrix resin. The non-impregnated portion 3 that has not been arranged is arranged in the width direction of the tow 2. More specifically, one side in the width direction of the tow 2 is an impregnated portion 4 and the other side in the width direction of the tow 2 is an unimpregnated portion 3 so that the tow 2 is divided in the width direction.

  The tow 2 is formed by bundling a plurality of filaments F of reinforcing fibers, such as 12000 or 24000, and has a flat shape with a larger width than a thickness. And it has the tape shape extended by substantially constant width and constant thickness.

  As the reinforcing fiber constituting the tow 2, carbon fiber, glass fiber, aramid fiber, boron fiber, metal fiber, etc. can be used. Among them, the mechanical properties after molding are good and lightweight. Carbon fiber is preferably used.

  The type of the matrix resin is not particularly limited, and is a thermosetting resin such as an epoxy resin, a polyester resin, a vinyl ester resin, a phenol resin, a maleimide resin, a polyimide resin, or a BT resin in which a cyanate ester and a bismaleimide resin are combined. And thermoplastic resins such as acrylic resins and polyether ketones. In particular, a thermosetting resin is preferable because it leads to an improvement in strength of the obtained FRP. Among them, an epoxy resin is excellent in adhesiveness with reinforcing fibers, and the mechanical properties of the obtained FRP are improved. Can be mentioned.

  Examples of the epoxy resin include bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, biphenyl type epoxy resin, naphthalene type epoxy resin, dicyclopentadiene type epoxy resin, and fluorene type epoxy resin which are bifunctional resins. Or a modified resin using these, a phenol novolac type epoxy resin that is a polyfunctional epoxy resin having three or more functions, a cresol type epoxy resin, tetraglycidyldiaminodiphenylmethane, triglycidylaminophenol, tetraglycidylamine, and the like. Type epoxy resin, glycidyl ether type epoxy resin such as tetrakis (glycidyloxyphenyl) ethane or tris (glycidyloxymethane), or these were used RESIN, and it may be applied to the resin composition in combination at least one or more of these resins.

  In addition, these epoxy resin compositions include diphenylmethane, diaminodiphenylsulfone, aliphatic amine, imidazole derivatives, dicyandiamide, tetramethylguanidine, thiourea-added amine, carboxylic acid hydrazide, carboxylic acid amide, polyphenol compound, polymercaptan, trifluoride. A curing agent such as boron ethylamine complex, or an epoxy resin and a part of the curing agent that has been subjected to a reaction can be blended in the resin composition.

  Furthermore, the thermosetting resin in the present invention preferably has a minimum viscosity of 1000 poise or less. Use of a resin composition having a high viscosity such that the minimum viscosity exceeds 1000 poise is not preferable because the fluidity of the resin composition is deteriorated.

  The partially impregnated tow prepreg 1 of the present invention is filled with the resin composition that has exuded from the impregnated part 4 in the non-impregnated part 3 that has served as a degassing path during vacuum forming. If the flowability of the product is poor, the molding may be completed before the filling is completed, and the remaining unimpregnated portion 3 may become a void, and the resin basis weight must be increased, which is costly. It is not preferable. Therefore, it is better that the minimum viscosity is small, and it is particularly preferably 500 poise or less.

  The amount of the matrix resin impregnated is 30% or more with respect to the fiber volume, and if it exceeds 40%, the fiber deposition content (Vf) increases, and the properties of the heat-cured fiber reinforced resin decrease. In the present embodiment, it is set between 35 percent and 40 percent.

  The partially impregnated tow prepreg 1 described above is manufactured using, for example, the following manufacturing apparatus 10.

  3 is a configuration diagram of the manufacturing apparatus 10 for the partially impregnated tow prepreg 1 according to the present embodiment, FIG. 4 is a view taken along the line AA in FIG. 3, and FIG. 5 is an enlarged view of a portion B in FIG. 6 is an enlarged view of a portion C in FIG.

  As shown in FIG. 3, the manufacturing apparatus 10 includes unwinding means 11 for unwinding the tow, resin impregnation means 21, resin drying means 31, and winding means 41 for winding the partially impregnated tow prepreg.

  The unwinding means 11 includes a creel stand 12. A bobbin 13 is mounted on the creel stand 12, and a flat tow 2 made of an unimpregnated reinforcing fiber bundle not impregnated with a matrix resin is wound around the bobbin 13. The creel stand 12 has a configuration capable of being unwound in a state where a tension is applied to the tow 2 by applying a back tension to each bobbin 13.

  A plurality of bobbins 13 can be mounted on the creel stand 12, and in this embodiment, seven bobbins 13 are mounted and the tow 2 can be unwound from each bobbin 13.

  The resin impregnation means 21 has a configuration in which the tow 2 supplied from the unwinding means 11 is partially abutted in the width direction of the tow 2 and the abutting portion is impregnated with a liquid resin serving as a matrix resin. . The resin impregnation means 21 includes a groove pulley (pulley) 22, a resin supply device 24, and a doctor knife 25. As shown in FIG. 3, the groove pulley 22 is rotatably supported so that the tow 2 supplied from the unwinding means 11 can be passed through the lower part and supplied to the resin drying means 31.

  As shown in FIGS. 4 and 6, the groove pulley 22 has a concave groove 23 having a groove width slightly larger than the lateral width of the tow 2, and a large diameter is provided in the concave groove 23 through a step. A surface (pulley surface) 23a and a small diameter surface 23b are formed. And the tow | toe 2 can be passed in the state which contact | abutted the width direction one side part of the tow | toe 2 to the large diameter surface 23a.

  The resin supply means 24 includes a nozzle 24 a that can drop liquid resin onto the groove pulley 22. As shown in FIG. 5, the nozzle 24a is disposed above the groove pulley 22 and at a position facing the large-diameter surface 23a, and drops a predetermined amount of liquid resin at a predetermined speed to drop the large-diameter surface 23a. It has the structure applied to. In the present embodiment, as the liquid resin dropped from the nozzle 24a, a thermosetting liquid resin using a bisphenol-based liquid resin as a main agent and an amine-based curing agent as a curing agent is used.

  The doctor knife 25 smoothes the liquid resin dripped onto the large-diameter surface 23 a to a certain thickness and adjusts the amount of resin impregnated in the tow 2, and approaches or separates from the large-diameter surface 23 a of the groove pulley 22. The thickness of the liquid resin can be adjusted according to the clearance.

  Therefore, the liquid resin on the large-diameter surface 23a of the groove pulley 22 can be impregnated into the tow 2 passed through the concave groove 23 at the lower part of the groove pulley 22, and the impregnated portion 4 (FIGS. 1 and 2). The amount of the liquid resin impregnated in (1) can be made uniform and appropriate.

  In the present embodiment, the groove pulley 22 has seven concave grooves 23, and the nozzle 24 a and the doctor knife 25 of the resin supply unit 24 are respectively arranged in each concave groove 23. Have.

  When the liquid resin is partially impregnated by the resin impregnation means 21, the tow 2 is supplied to the resin drying means 31. In the resin drying means 31, a process of heating and drying the liquid resin partially impregnated in the tow 2 is performed, and the B-stage (prepreg) of the matrix resin is performed.

  The resin drying means 31 includes a heater 32 using far infrared rays. The heater 32 is disposed over a predetermined distance along the moving direction of the tow 2 so as to face the tow 2 partially impregnated with the liquid resin.

  Then, the liquid resin impregnated in the tow 2 is heated at a preset condition such as 10 minutes at 100 ° C., for example, to increase its viscosity, thereby forming a prepreg. Thereby, the partially impregnated tow prepreg 1 in which one side in the width direction of the tow 2 is the impregnated portion 4 and the other side in the width direction is the non-impregnated portion 3 is manufactured. The partially impregnated tow prepreg 1 is not sticky and has high handleability by being dried by the resin drying means 31 by increasing the viscosity of the liquid resin.

  The winding means 41 includes a creel stand 42. A bobbin 43 is attached to the creel stand 42, and the partially impregnated tow prepreg 1 supplied from the resin drying means 31 is wound around the bobbin 43. A plurality of bobbins 43 can be mounted on the creel stand 42. In the present embodiment, seven bobbins 43 can be mounted and the partially impregnated tow prepreg 1 can be wound around each bobbin 43. Yes.

  Next, the fabric 5 and the laminate 6 using the above partially impregnated tow prepreg will be described. The fabric 5 is formed by using a plurality of partially impregnated tow prepregs 1 so that the surfaces of the partially impregnated tow prepregs 1 overlap each other. Examples of the form of the fabric 5 include plain weave, twill weave, satin weave, multiaxial fabric, and weave. Further, a partially impregnated tow prepreg 1 having different reinforcing fibers for warp and weft may be used.

As the woven fabric 5, a fabric having a basis weight of 1500 kg / m ² or less is preferably used. When the fiber basis weight exceeds 1500 kg / m ² , the density of the reinforcing fibers is too high, and it becomes difficult to obtain a product having excellent mechanical properties, which is not preferable. More preferably, it is preferably 1000 kg / m ² or less. The lower limit of the fiber basis weight is not particularly limited, but is preferably 100 g / m ² or more. If it is less than 100 g / m ^2, it is necessary to increase the number of laminated layers, which may lead to an increase in cost, which is not preferable.

  FIG. 7 is a schematic plan view of a biaxial stitch base material 5 which is an example of a fabric 5 using the partially impregnated tow prepreg 1, and FIG. 8 is a laminate 6 in which a plurality of the biaxial stitch base materials 5 of FIG. FIG.

  As shown in FIG. 7, the biaxial stitch base material 5 is a sheet in which a plurality of (only two are shown) partially impregnated tow prepregs 1 are arranged in the width direction, and the upper and lower partially impregnated tow prepregs 1 are orthogonal to each other. Thus, two sheets are laminated and integrated by stitch yarn (not shown). In the present embodiment, the orientation of the upper and lower partially impregnated tow prepregs 1 is inclined to the left and right by an angle of 45 degrees with respect to the longitudinal direction of the biaxial stitch base material 5. Material 5 is used.

  As shown by a thick arrow in FIG. 7, the biaxial stitch base 5 has the non-impregnated portion 3 of the partially impregnated tow prepreg 1 as an air passage in the surface direction, and the unimpregnated portion 3 of the partially impregnated tow prepreg 1 The overlapping portion K (the portion surrounded by the two-dot chain line in FIG. 7) can be used as an air passage communicating in the stacking direction.

  The laminate 6 is configured by cutting the biaxial stitch base 5 into a desired shape and laminating a plurality of sheets. In the present embodiment, as shown in FIG. 8, four biaxial stitch base materials 5 are laminated.

  When a plurality of biaxial stitch base materials 5 are laminated, the unimpregnated portions 3 of the partially impregnated tow prepregs 1 are overlapped with each other, and an air passage communicating in the lamination direction of the biaxial stitch base materials 5 is formed. The air passage communicating in the laminating direction is not blocked even when the biaxial stitch bases 5 are randomly stacked. Accordingly, it is possible to reliably ensure a degassing path communicating with the stacking direction of the stacked body 6.

  An air passage is also formed in the surface direction in which the biaxial stitch base material 5 extends by the non-impregnated portion 3 of the partially impregnated tow prepreg 1. Accordingly, a degassing path can be secured also in the surface direction of the stacked body 6. Therefore, as shown by the thick arrows in FIG. 8, many degassing paths can always be secured, and the inside of the laminate 6 can be quickly and easily efficiently degassed during vacuum forming.

  In vacuum forming, the laminated body 6 is sealed with, for example, a vacuum bag, the inside of the vacuum bag is sufficiently depressurized, and the inside of the laminated body 6 is deaerated. And it heats and pressurizes on a predetermined condition, and shape | molds in a desired shape. Then, the non-impregnated portion is impregnated and filled with the matrix resin liquefied by heating and exuded from the impregnated portion, and cured after the filling is completed.

  Since the delamination path is secured in both the laminating direction and the plane direction by the non-impregnated portion 3 of the partially impregnated tow prepreg 1, the laminate 6 can be quickly and easily degassed during vacuum forming. Can be obtained.

  Further, since the partially impregnated tow prepreg 1 is formed by arranging the unimpregnated portion 3 and the impregnated portion 4 of the tow 2 side by side, even if air is included in the impregnated portion 4, 4 can be easily discharged to the non-impregnated portion 3, and the void ratio of the molded product can be reduced.

  FIG. 9 is a graph showing a comparative example of intensity characteristics. The conventional product shown in FIG. 9 is a fiber reinforced resin member formed by vacuum forming a laminate composed of a conventional tow prepreg completely impregnated with a matrix resin. It is a fiber reinforced resin member formed by vacuum forming a laminate 6 composed of the partially impregnated tow prepreg 1 of the invention.

  As shown in FIG. 9, the product of the present invention has a tensile strength of 1350 MPa, whereas the conventional product has only 900 MPa, and the product of the present invention has a higher tensile strength. The void ratio of the present product is 2% or less, whereas the conventional product is 3 to 5%, and the present product is reduced more than the conventional product.

  In the above-described embodiment, the case where the flat tow 2 is divided into the non-impregnated portion 3 and the impregnated portion 4 in the width direction has been described as an example. As long as it has an arrangement configuration aligned in the width direction.

  FIG. 10 is a view showing a modification of the partially impregnated tow prepreg 1 of the present invention. FIG. 10A shows an arrangement configuration in which the non-impregnated portion 3 and the impregnated portion 4 are alternately arranged so that the flat tape-like tow 2 is divided into four in the width direction, and FIG. The non-impregnated portion 3 and the impregnated portion 4 are alternately arranged so that the flat tape-like tow 2 is divided into seven in the width direction.

  10 (c) shows an arrangement in which the center in the width direction is an unimpregnated portion 3 and both sides in the width direction of the flat tow 2 are arranged as an impregnated portion 4. FIG. 10 (d) is a flat configuration. The tape-shaped tow 2 has an arrangement configuration in which both sides in the width direction are arranged as non-impregnated portions 3 and the center in the width direction is arranged as an impregnated portion 4.

  As described above, the partially impregnated tow prepreg 1 of the present invention may have a configuration in which at least one of the non-impregnated portion 3 and the impregnated portion 4 is arranged in the width direction of the tow 2. Even if it is set as this structure, the unimpregnated part 3 can be piled up in the lamination direction in the laminated state, and a deaeration path | route can be ensured reliably in the lamination direction.

  As mentioned above, although embodiment of this invention has been explained in full detail using drawing, a concrete structure is not limited to the above-mentioned embodiment, and the design change etc. in the range which does not deviate from the gist of the present invention are carried out. If so, they are included in the present invention.

The perspective view which shows typically the structure of the partially impregnated tow prepreg in this Embodiment. It is a schematic diagram of the cross section of a partially impregnated tow prepreg. The block diagram of the manufacturing apparatus of a partially impregnated tow prepreg. FIG. 4 is a view taken along line AA in FIG. 3. The B section enlarged view of FIG. The C section enlarged view of FIG. The top view which shows typically the deaeration path | route of the textile fabric using a partially impregnated tow prepreg. Sectional drawing which shows typically the deaeration path | route of the textile fabric using a partially impregnated tow prepreg. The graph which shows the comparative example of an intensity | strength characteristic. The schematic diagram of the cross section which shows the modification of the partially impregnated tow prepreg of this invention. The figure explaining a prior art. The figure explaining a prior art.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Partially impregnated tow prepreg 2 Tow 3 Unimpregnated part 4 Impregnated part 5 Fabric 6 Laminate 10 Manufacturing apparatus 11 Unwinding means 21 Resin impregnating means 22 Groove pulley (pulley)
23 Groove 23 Large diameter surface (pulley surface)
24 Resin supply means 25 Doctor knife 31 Resin drying means 41 Winding means

Claims (6)

A partially impregnated tow prepreg in which a matrix resin is partially impregnated into a tow comprising a reinforcing fiber bundle,
A partially impregnated tow prepreg comprising an arrangement in which an impregnated part impregnated with the matrix resin and an unimpregnated part not impregnated with the matrix resin are arranged in the width direction of the tow.   The partially impregnated tow prepreg according to claim 1, wherein one side in the width direction of the tow is the impregnated portion, and the other side in the width direction of the tow is the unimpregnated portion.   A laminate comprising the partially impregnated tow prepreg according to claim 1 or 2.   The laminate according to claim 3, wherein the laminate is formed by forming a fabric using the partially impregnated tow prepreg and laminating a plurality of the fabrics. In a production apparatus for producing a partially impregnated tow prepreg in which a matrix resin is partially impregnated in a tow comprising a reinforcing fiber bundle,
A resin impregnation means for partially abutting in the width direction of the tow against the surface of the tow, and impregnating a matrix resin into the contact portion;
Resin drying means for heating and drying the matrix resin partially impregnated in the tow by the resin impregnation means;
A partially impregnated tow prepreg manufacturing apparatus comprising:   The resin impregnation means includes a pulley having a pulley surface that partially contacts the tow in the width direction of the tow, and a resin supply means for applying a liquid matrix resin to the pulley surface. An apparatus for producing a partially impregnated tow prepreg according to claim 5.

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