JP4273187B2 - Manufacturing method of mixed fiber bundle using tape-like fiber bundle and manufacturing apparatus thereof - Google Patents

Description

The present invention relates to a mixed fiber bundle in which a plurality of fiber bundles are uniformly mixed. Specifically, a round fiber in which a reinforcing fiber bundle and a reinforcing fiber bundle or a reinforcing fiber bundle and a thermoplastic resin fiber bundle are continuously mixed uniformly. The present invention relates to a method for producing a mixed fiber bundle having a cross-sectional form or a tape-like form and a production apparatus thereof.

Conventionally, carbon fibers, glass fibers, aramid fibers, and the like have been used as reinforcing materials for composite materials. Since each fiber has different mechanical properties, thermal properties, material costs, and the like, they are properly used according to the properties required for the composite material molded product. However, depending on the required properties of the molded product, it may be desired to use two or more types of reinforcing materials. For example, when a composite material having both high elastic properties and impact resistance properties is required, the carbon fiber and the aramid fiber may be required to be combined because the impact resistance properties are poor with carbon fibers alone.

In such a case, at present, a carbon fiber prepreg sheet and an aramid fiber prepreg sheet are sequentially laminated to obtain a molded product, and the carbon fiber bundle and the aramid fiber bundle are arranged in the order of the carbon fiber bundle and the aramid fiber bundle. A method of using, as a reinforcing sheet, a woven fabric in which weaving and weaving in order as wefts is performed.

  In addition, a mixed fiber bundle in which a continuous reinforcing fiber bundle and a continuous thermoplastic resin fiber bundle are mixed may be used as one of intermediate materials for obtaining a composite material molded product. In obtaining a composite material molded product, it is very important that the reinforcing fiber and the thermoplastic resin fiber are uniformly mixed in the mixed fiber bundle in order to sufficiently exhibit the mechanical characteristics.

As a method for uniformly mixing a continuous reinforcing fiber bundle and a continuous thermoplastic resin fiber bundle, Japanese Patent Application Laid-Open No. 60-209034 discloses a method in which gas (air) is collided with a mixed fiber and mixed. JP-A-308824 discloses a method of imparting crimpability to a thermoplastic resin fiber bundle, and JP-A-3-33237 discloses a method of specifying a sizing agent application amount in each fiber bundle. ing. JP-A-2-282219 and JP-A-4-73227 disclose a method of opening a fiber bundle in a liquid in order to suppress the occurrence of single fiber breakage. JP-A-9-324331 Discloses a method in which a suction air flow is applied to a bent fiber bundle to widely open the fiber bundle, and then the open fiber bundle is combined to be mixed.
Japanese Unexamined Patent Publication No. 60-209034 JP-A-2-308824 JP-A-3-33237 JP-A-2-28219 Japanese Unexamined Patent Publication No. 4-73227 JP-A-9-324331

  However, in a molding material in which different types of reinforcing prepreg sheets are alternately laminated, or a molding material in which an unwoven fabric made of different types of reinforcing fiber bundles is used as a reinforcing material, the same type of fiber bundles exist in a bundled state. The characteristic of one of the fibers will appear, and the characteristics of the different types of fibers cannot be utilized uniformly. Therefore, there is a problem that the characteristics required as a composite material molded product are not sufficiently satisfied.

  Further, in any of the above conventional methods in which continuous reinforcing fiber bundles and thermoplastic resin fiber bundles are mixed, it is difficult to uniformly mix continuous reinforcing fiber bundles and thermoplastic resin fiber bundles. When trying to obtain the state, single fiber breakage tends to occur, and there is a problem that the original mechanical properties of the fiber cannot be obtained. When trying to prevent single fiber breakage, a sufficiently mixed state cannot be obtained, and a problem has arisen that sufficient mechanical properties cannot be obtained when a composite material molded product is obtained.

  In addition, the method of mixing fibers in a liquid has a problem that an extra step of removing the liquid is required. Further, in the method of mixing fibers by combining widely opened fiber bundles, the spread fiber bundles are combined. However, although a uniform mixed fiber can be obtained at the combined portion, a sufficient mixed state cannot be obtained as a whole.

The present invention has been made in view of the above-mentioned problems, and the object thereof is the same type of fiber bundles, for example, a reinforcing fiber bundle and a reinforcing fiber bundle, and a thermoplastic resin fiber bundle and a thermoplastic resin fiber bundle, or different kinds of fibers. A bundle, for example, a reinforcing fiber bundle and a thermoplastic resin fiber bundle, in which these fiber bundles are continuously and uniformly mixed to produce a mixed fiber bundle having a round cross-sectional shape or a tape-like shape, and It is to provide a manufacturing apparatus for that purpose.

The manufacturing method of the mixed fiber bundle of the present invention made to achieve the above object is a method of producing a folded fiber bundle in which the folded fiber bundle is folded at least once along the longitudinal direction. After that, there is a feature that the spread folding fiber bundle is subjected to fiber opening processing.

By adopting the above method, it is possible to obtain a mixed fiber bundle having a tape-like shape in which a plurality of fiber bundles are mixed. And the method of performing the fiber opening process after performing the folding along the longitudinal direction of the mixed fiber bundle in the tape-like form obtained by the method at least once and repeatedly folding it is repeated once or a plurality of times. By adopting the method to be performed, it is possible to obtain a mixed fiber bundle in a tape form in which a plurality of fiber bundles are mixed more uniformly.

Furthermore, it becomes possible to obtain a mixed fiber bundle having a round cross-sectional shape in which a plurality of fiber bundles are mixed by adopting a method of twisting a mixed fiber bundle in a tape form. .

  Next, as an apparatus for producing a mixed fiber bundle having a round cross section according to the present invention, a tape having a fiber bundle width / fiber bundle thickness ratio of 10 or more, a fiber bundle width of 2 mm or more. A tape-like fiber bundle supply mechanism for continuously supplying a fiber bundle; a superposition mechanism that forms a superposition fiber bundle in which a plurality of the tape-like fiber bundles are laminated in the thickness direction; and the superposition fiber It is characterized in that it has a twisting mechanism for twisting the bundle.

As another apparatus for producing a mixed fiber bundle having a round cross-section, a tape-like fiber having a fiber bundle width / fiber bundle thickness ratio of 10 or more and a fiber bundle width of 2 mm or more is used. A tape-like fiber bundle supply mechanism that continuously feeds the bundle; an overlapping mechanism that forms a stacked fiber bundle in which a plurality of the tape-like fiber bundles are stacked in the thickness direction; and On the other hand, it is characterized in that it has a fiber opening mechanism that opens a wide and thin state; and a twisting mechanism that twists the opened fiber bundle.

  Moreover, as an apparatus for producing a mixed fiber bundle in the form of a tape according to the present invention, a tape having a fiber bundle width / fiber bundle thickness ratio of 10 or more, a fiber bundle width of 2 mm or more. A tape-like fiber bundle supply mechanism for continuously supplying a fiber bundle; a superposition mechanism that forms a superposition fiber bundle in which a plurality of the tape-like fiber bundles are laminated in the thickness direction; and the superposition fiber It is characterized in that it has a folding mechanism that folds the bundle along the longitudinal direction and folds it; and a spreading mechanism that opens the bundle of folded fibers in a wide and thin state.

  Furthermore, as an apparatus for producing a mixed fiber bundle having a round cross section from a mixed fiber bundle in the form of a tape, the fiber bundle width is in a tape form with a ratio of fiber bundle width / fiber bundle thickness of 10 or more. A tape-like fiber bundle supply mechanism that continuously supplies a tape-like fiber bundle having a thickness of 2 mm or more; a superposition mechanism that forms a superposition fiber bundle in which a plurality of the tape-like fiber bundles are laminated in the thickness direction; A folding mechanism that folds the folded fiber bundle along the longitudinal direction and folds it; a spreading mechanism that opens the folded fiber bundle in a wide and thin state; and a spread folded fiber that has been opened. It is characterized in that it has a twisting mechanism for twisting the bundle.

  According to the present invention, first, a tape-like fiber bundle having a fiber bundle width / fiber bundle thickness ratio of 10 or more and a fiber bundle width of 2 mm or more is used. Since this method adopts a method in which a twisted yarn processing is applied to the overlapped fiber bundle after the overlapped fiber bundle is continuously overlapped and laminated in the thickness direction, a mixed fiber bundle having a round cross section is used. Obtainable.

Here, the tape-like fiber bundle is a fiber bundle having a tape-like form with a ratio of fiber bundle width / fiber bundle thickness of 10 or more. When the ratio of the fiber bundle width / fiber bundle thickness is approximately 1, it can be said that the cross section of the fiber bundle is a round cross-section fiber bundle having a substantially round shape. When the ratio of the fiber bundle width / fiber bundle thickness is in the range of 2 to 10, it can be said that the cross section of the fiber bundle is an elliptical cross-section fiber bundle.

From the form of the round cross-section fiber bundle and the elliptic cross-section fiber bundle, it is difficult to stably stack the fiber bundles in the thickness direction. In addition, when twisting is performed after the round cross-section fiber bundle and the elliptical cross-section fiber bundle are aligned, the fiber bundles are not mixed uniformly, and the fiber bundles are twisted together in a bundled state. Only a bundle of fibers.

  On the other hand, the tape-shaped fiber bundle can easily and continuously overlap the fiber bundle in the thickness direction from its form. Furthermore, when the fiber bundle width is 2 mm or more, a plurality of fiber bundles can be easily stacked in the thickness direction. Conversely, when the fiber bundle width is 2 mm or less, even if the fiber bundle width / fiber bundle thickness ratio is a tape-like fiber bundle having a ratio of 10 or more, a plurality of fiber bundles are continuously and stably disposed in the thickness direction. It will be difficult to overlap.

  Then, after the tape-shaped fiber bundles are overlapped in the thickness direction, a plurality of fiber bundles are overlapped from the center of the fiber bundle toward the outer side in the cross section of the fiber bundle after twisting by performing twisting processing. As a result, a plurality of fiber bundles are mixed.

  As the fiber bundle thickness decreases and the ratio of fiber bundle thickness / single fiber diameter decreases, the number of fibers arranged in the thickness direction decreases, resulting in a tape-shaped fiber bundle. Ultimately, when the ratio of the fiber bundle thickness / single fiber diameter is 1, a tape-like fiber bundle in which single fibers are arranged in a row in the width direction is obtained. When such a tape-like fiber bundle having a small fiber bundle thickness / single fiber diameter ratio is used, fiber mixing at a single fiber level is performed.

By opening the fiber bundle, the fiber bundle can be made wide and thin, and a tape-like fiber bundle having a small ratio of fiber bundle thickness / single fiber diameter can be obtained. Therefore, using the fiber bundle that has been subjected to the fiber opening process makes it possible to obtain a mixed fiber bundle in which a plurality of fiber bundles are mixed more uniformly in the method for manufacturing the mixed fiber bundle.

Next, according to the present invention, a round in which a plurality of fiber bundles are mixed more uniformly by adopting a method of performing twisting processing after performing fiber opening processing on the overlapped fiber bundle. A mixed fiber bundle having a cross-sectional shape is obtained.

By performing the opening process on the overlapped fiber bundle, the overlapped fiber bundle becomes a fiber bundle in a tape-like form opened in a wider and thin state, and the fiber bundle and the fiber bundle overlap each other. In the part, fiber mixing at the single fiber level is performed. By applying twist processing to the overlapped fiber bundle in such a state, it becomes possible to obtain a mixed fiber bundle having a round cross-sectional shape in which a plurality of fiber bundles are mixed more uniformly. is there.

Further, according to another manufacturing method of the present invention, the overlapped fiber bundle is folded at least once along the longitudinal direction to form an overlapped fiber bundle that is overlapped and then folded into the overlapped fiber bundle. On the other hand, by performing the fiber opening process, it is possible to obtain a mixed fiber bundle in a tape form in which a plurality of fiber bundles are mixed.

Bending along the longitudinal direction of the overlapped fiber bundle and performing the overlap fold increases the number of overlapping surfaces of the fiber bundle and the fiber bundle. When the fiber bundle in this state, that is, the overlap-folded fiber bundle is subjected to fiber opening processing, the overlap-folded fiber bundle becomes a fiber bundle in a tape-like form opened in a wider and thin state, and the fiber bundle Fiber mixing at the single fiber level is performed on each surface where the fiber bundles overlap. Since the overlapping folded fiber bundle has many overlapping surfaces of the fiber bundle and the fiber bundle in the thickness direction, fiber mixing at the single fiber level is performed on each overlapping surface, and as a result, a plurality of fiber bundles It becomes a mixed fiber bundle in a tape-like form in which the fiber is further mixed.

And by repeating the method of performing the fiber opening process after folding along the longitudinal direction and repeatedly folding the mixed fiber bundle in the tape-like form, the mixed fiber at the single fiber level on the overlapping surface As a result, a mixed fiber bundle in the form of a tape in which a plurality of fiber bundles are mixed more uniformly is obtained.

  Furthermore, by adopting a method of performing twisting using a mixed fiber bundle in a tape-like form obtained by the above method, a mixed fiber having a round cross-sectional shape in which a plurality of fiber bundles are mixed more uniformly. A fiber bundle can be obtained.

Note that the overlap fiber bundle can be obtained by overlapping a plurality of tape-like fiber bundles in the thickness direction. At this time, when the tape-like fiber bundle is in a wider and thin state due to fiber opening processing or the like, The laminated fiber bundle is also wide and becomes a thin fiber bundle. The overlapped fiber bundle in such a state can be easily bent in the longitudinal direction, and therefore can be easily bent a plurality of times.

In addition, the fiber bundle width narrowed as a result of repeated folding is applied to the fiber bundle width before overlapped folding again after folding along the longitudinal direction. It can be spread to.

According to the present invention, a method of superimposing and twisting using a fiber bundle in a plurality of tape-like forms, a method of superimposing and opening and twisting, a method of overlapping and folding and opening Further, in order to perform fiber mixing using a method such as overfolding, opening, twisting, etc., a mixed fiber bundle having a round cross-sectional shape in which a plurality of fiber bundles are uniformly mixed at a single fiber level or A mixed fiber bundle in the form of a tape can be obtained.

  Hereinafter, the content of the present invention will be described in more detail with reference to the accompanying drawings which exemplarily show preferred forms when the present invention is specifically implemented.

[ Reference Example 1 ]
As a reference example 1, “a method for producing a mixed fiber bundle” will be described based on an apparatus example illustrated in FIGS. 1 to 3. The present invention relates to a method for obtaining a mixed fiber bundle having a round cross section using a plurality of tape-like fiber bundles . FIG. 1 and FIG. 2 are examples of an apparatus for carrying out a method of performing twisting processing after superimposing tape-like fiber bundles, and FIG. It is an example of an apparatus which implements the method of performing twisting processing.

The tape-like fiber bundle Ta or the tape-like fiber bundle Tb is pulled out from the yarn supply reel 11a or 11b in FIGS. 1 and 3 and from the yarn supply bobbin 11a 'or 11b' in FIG. In the apparatus example of FIG. 2, the tape-like fiber bundle is traversed and wound around the yarn feeding bobbin, so that the yarn feeding bobbin is traversed so that the tape-like fiber bundle is fed from a certain position. Is adopted.

Here, the tape-shaped fiber bundle is a fiber bundle having a fiber bundle width / fiber bundle thickness ratio of 10 or more and a fiber bundle width of 2 mm or more. An opened fiber bundle having a fiber bundle width / fiber bundle thickness ratio of 20 or more and a fiber bundle width of 4 mm or more may be used.

The fiber bundles used include reinforcing fiber bundles such as carbon fiber bundles, glass fiber bundles, aramid fiber bundles, ceramic fiber bundles, polyethylene, polypropylene, nylon 6, nylon 66, nylon 12, polyethylene terephthalate, polyphenylene sulfide, poly There are bundles of fibers made of thermoplastic resins such as ether ether ketone, that is, thermoplastic resin fiber bundles.

Combinations for fiber blending include carbon fiber bundles and carbon fiber bundles, polypropylene resin fiber bundles and polypropylene resin fiber bundles, and the like, carbon fiber bundles and glass fiber bundles, and carbon fiber bundles and aramid fiber bundles. And a combination of a reinforcing fiber bundle such as a carbon fiber bundle and a polypropylene fiber bundle, a glass fiber bundle and a nylon 6 resin fiber bundle, and a thermoplastic resin fiber bundle.

Further, the figure shows a case where two tape-like fiber bundles are used, but any number of tape-like fiber bundles used can be used by increasing the number of tape-like fiber bundle supply mechanisms even if three or four tape-like fiber bundles are used. be able to.

Then, the drawn tape-shaped fiber bundle Ta and the tape-shaped fiber bundle Tb are formed into a superimposed fiber bundle W that is continuously overlapped in the thickness direction by the overlapping mechanism 2, and is sent out to the next process at a constant speed.

As the superposition mechanism 2, a mechanism in which two superposition rolls 21 are combined so as to contact each other as shown in FIGS. 1 to 3 can be used. The superposition roll 21 is made of, for example, a urethane rubber roll having a hardness of 80, and has a mechanism in which one superposition roll 21 is rotationally driven by a take-up motor 22. In the superposition mechanism 2, a mechanism for controlling the contact pressure between the two superposition rolls 21 can be added. With this mechanism, it is possible to reduce the load caused by the contact pressure between the rolls on the overlapped fiber bundle, thereby preventing single fiber breakage.

  The superposition mechanism 2 is not limited to a mechanism in which two superposition rolls 21 shown in the figure are combined, but a plurality of tape-like fiber bundles such as a mechanism in which several rolls are combined and a mechanism in which a belt is incorporated. Any mechanism may be used as long as it can continuously overlap in the thickness direction.

  Thereafter, in the apparatus example of FIGS. 1 and 2, the overlapped fiber bundle W is twisted by the twisting mechanism 3 to obtain a mixed fiber bundle C having a round cross-sectional shape in which a plurality of tape-shaped fiber bundles are mixed.

  As the twisting mechanism 3, a ring-type twisting mechanism as shown in the figure can be used. The overlapped fiber bundle W is passed through the guide 31 and then passed through the traveler 32 that slides on the ring 33 and wound around the winding bobbin 34.

  The twisting is performed by rotating the spindle 35 by the spindle belt 36 and rotating the winding bobbin 34 set up on the spindle 35. Further, when the ring 33 moves up and down, the mixed fiber bundle C is wound up while traversing on the winding bobbin 34.

  The number of twisted yarns is determined by the rotational speed of the take-up motor 22, that is, the speed at which the superposed fiber bundle W is sent out and the rotational speed of the spindle 35. The number of twisting yarns is preferably 200 times / m or less in order to obtain a more uniform mixed fiber state, but the number of twisting yarns from 50 times / m to 100 times / m is more desirable in order to prevent single fiber breakage.

  The twisting mechanism 3 is not limited to the ring-type twisting mechanism shown in the figure, but may be any mechanism that can twist the fiber bundle, such as a double twister.

  In the example of the apparatus shown in FIG. 3, a fiber opening mechanism 4 is provided between the overlapping mechanism 2 and the twisting mechanism 3, and the twisting process is performed after the overlapping fiber bundle W is opened, so that a mixed fiber having a round cross-sectional shape is obtained. A fiber bundle C is obtained.

  As the fiber opening mechanism 4, the present inventor has already filed a "multifilament fiber sheet manufacturing method and apparatus (Patent No. 3064019)" and a ventilation-type fiber opening device equipped with an assembly fiber deflection level control mechanism ( The opening device shown by Unexamined-Japanese-Patent No. 2002-053266) is used.

  The superposed fiber bundle W fed from the superposition mechanism 2 is subjected to speed control so that a constant overfeed state is formed by the take-up motor 22 and the take-up motor 46, and the two guide rolls 31 Into the wind tunnel 42 sandwiched between the two. A suction air flow having a certain flow velocity is generated in the wind tunnel 42 by the air suction device 43. Therefore, the overlapped fiber bundle W sent to the wind tunnel 42 is bent in a bow shape and simultaneously opened in the width direction by the action of the suction air flow. The speed of the take-up motor 22 is controlled by a signal output from the deflection detection sensor 44 so that the deflection position of the overlapped fiber bundle W is always constant. The take-up motor 46 rotates at a constant speed.

  As the opening mechanism 4, not only the opening device shown in the figure, but also a roll-type opening device using multiple rolls, an ultrasonic-type opening device using ultrasonic waves, etc. Any mechanism may be used.

[ First Embodiment ]
A “mixed fiber bundle manufacturing method” according to the first embodiment of the present invention will be described with reference to FIGS. The first embodiment relates to a method for obtaining a mixed fiber bundle in a tape form in which a plurality of fiber bundles are mixed using a plurality of tape-like fiber bundles.

In the example of the apparatus of FIG. 4, a plurality of tape-shaped fiber bundles are made into a superposed fiber bundle, and then the superposed fiber bundle is bent along the longitudinal direction once to form a superfolded fiber bundle. An apparatus for obtaining a mixed fiber bundle in a tape form by performing a fiber opening process on a fiber bundle is shown.

  The configurations of the tape-shaped fiber bundle supply mechanism 1 and the superposition mechanism 2 are the same as the configurations of the apparatus examples in FIGS. 1 and 3. An overlapped fiber bundle V is obtained by the overlap folding mechanism 5 with respect to the overlapped fiber bundle W sent out from the overlap mechanism 2.

  The fold folding mechanism 2 employed in the apparatus example of FIG. 4 will be described with reference to FIG. The overlapping folding mechanism 2 uses the folding rolls 52a and 52b and the folding and holding rolls 51a and 51b to bend the overlapping fiber bundle W gradually in the longitudinal direction, and finally completely folds it with the folding and holding roll 51c. It is made into the state folded and folded in the longitudinal direction. In FIG. 5, two pairs of folding rolls and folding holding rolls are employed, and both ends of the overlapping fiber bundle W are raised about 30 degrees by the folding roll 52a and the two folding holding rolls 51a. The folded fiber bundle W is bent in a state where both ends of the overlapped fiber bundle W are raised by about 60 degrees by the folding roll 52b and the two folding holding rolls 51b. Note that the number of combinations of folding rolls and folding holding rolls may be increased, the folding angle may be made finer, and the folding may be gradually performed.

  In addition, as shown in FIG. 6, the overlapping fiber bundle W can be bent a plurality of times by using a configuration in which a plurality of the overlapping folding mechanisms 5 are continued. In the illustrated folding mechanism, when the number of times of folding is an odd number, the width direction of the folded fiber bundle V is a direction rotated by 90 degrees with respect to the width direction of the folded fiber bundle W, but the number of folding times is an even number. In this case, the width direction of the overlap-folded fiber bundle V is the same direction as the overlap-folded fiber bundle W.

  When the width direction of the stacked folded fiber bundle V is the direction rotated by 90 degrees with respect to the width direction of the folded folded fiber bundle W, it is necessary to return the width direction of the folded folded fiber bundle V by 90 degrees from the relationship of the next step. As a mechanism example for rotating the width direction of the folded fiber bundle V by 90 degrees, there is a width direction maintaining mechanism 6 shown in FIGS. The width direction maintaining mechanism 6 uses the width direction rotating rolls 61a and 61b to gradually rotate the width direction of the overlapping folded fiber bundle V, and finally the width of the overlapping folded fiber bundle V by the width direction rotating roll 61c. The direction is the same as the width direction of the overlapping fiber bundle W. In addition, the number of rotation rolls for width direction may be increased and a rotation angle may be made finer.

  As the overlap folding mechanism and the width direction maintaining mechanism, not only the mechanism shown in the figure but also a mechanism for folding and folding the overlap fiber bundle W and a mechanism for rotating the overlap direction fiber bundle V in the width direction by 90 degrees may be used. .

  The opening mechanism 4 illustrated in FIG. 4 has the same configuration as the opening mechanism employed in the apparatus example of FIG. The folded fiber bundle V is opened widely and thinly by the opening mechanism 4. The speed control of the rotation control motor 62 is performed by a signal output from the deflection detection sensor 44 so that the deflection position of the folded fiber bundle V is always constant. The take-up motor 46 rotates at a constant speed.

By opening the folded fiber bundle V, a mixed fiber bundle TC in a tape form in which a plurality of fiber bundles are mixed is obtained. The tape-shaped mixed fiber bundle TC is wound around the winding reel 71 by the winding mechanism 7.

  Depending on how the overlapped fiber bundle W is folded and overlapped, the configuration of the overlapped fiber bundle V changes. This will be described with reference to the folding examples shown in FIGS. In FIG. 8, tape-shaped fiber bundles Ta and Tb having substantially the same width are used to align both ends in the width direction to form a laminated fiber bundle W, and then folded at the center in the width direction of the laminated fiber bundle W. As the fiber bundle V, a mixed fiber bundle TC in a tape form is obtained by opening process. The laminated fiber bundle V has a configuration in which the upper and lower ends in the thickness direction are the same fiber bundle, in FIG. 8, the tape-like fiber bundle Tb, and the central portion in the thickness direction is the same fiber bundle, in FIG. 8, the tape-like fiber bundle Ta. ing.

  FIG. 9 shows a method of performing the bending process twice. As in FIG. 8, the tape-like fiber bundles Ta and Tb having substantially the same width are used to bend the bundled fiber bundle W with both ends in the width direction aligned. The first folding is performed at approximately the center of the overlapped fiber bundle W in the width direction, and then the second bending is performed at approximately the center of the obtained overlapped fiber bundle V in the width direction. The obtained double folded fiber bundle V is a fiber bundle having the same thickness and both ends and a central part, in FIG. 9, becomes a tape-like fiber bundle Tb, and in the meantime, the other fiber bundle, in FIG. 9, becomes a tape-like fiber bundle Ta. It is configured.

  FIG. 10 shows a method of folding twice, as in FIG. 9, but the way of folding is different. Similar to FIGS. 8 and 9, the tape-shaped fiber bundles Ta and Tb having substantially the same width are used to bend the folded fiber bundle W with both ends aligned in the width direction. The first folding is performed at approximately one-third of the width direction of the overlapped fiber bundle W, and then the second bending is performed in the opposite direction at approximately the center in the width direction of the overlapped fiber bundle V obtained. The obtained overlap-folded fiber bundle V obtains the overlap-folded fiber bundle V having a configuration different from that shown in FIG.

  In FIG. 11, unlike FIGS. 8 to 10, the configuration of the overlapping fiber bundle W is different. Tape-like fiber bundles Ta and Tb having substantially the same width are superposed to each other in the middle to form a superposed fiber bundle W. Then, the first folding is performed at approximately one-third of the overlapped fiber bundle W, and then the second bending is performed in the opposite direction at approximately the center in the width direction of the obtained overlapped fiber bundle V. The obtained overlap-folded fiber bundle V provides an overlap-folded fiber bundle V having a configuration different from that shown in FIGS. The width of the folded fiber bundle V is ¼ of the tape-like fiber bundles Ta and Tb in FIG. 9, whereas it is 3 in FIG. 10 and ½ in FIG. 11.

  By bending the overlapped fiber bundle W into the overlapped fiber bundle V, a plurality of tape-like fiber bundles are stacked in various orders in the thickness direction. As the number of overlap folding increases, a plurality of tape-shaped fiber bundles are more alternately stacked. Then, by opening the fiber bundle in such a state, a mixed fiber bundle in a tape-like form in which a plurality of fiber bundles are more mixed is obtained.

  In addition, although the case where the two tape-shaped fiber bundles were used was employ | adopted in the figure, the tape-shaped fiber bundle mixed may be three or more. The widths of the tape-shaped fiber bundles are preferably substantially the same, but the stacked fiber bundles W may be formed using tape-shaped fiber bundles having different widths. In addition, the number of folding, the direction of folding, the order of folding, etc. are determined in consideration of the type and form of the tape-shaped fiber bundle and the form of the laminated fiber bundle, and the optimal number of times, the optimal folding direction, and the optimal folding order. Adopt it.

The apparatus example of FIG. 12 is an apparatus example of a configuration in which the configuration in which the overlap folding mechanism 5, the width direction maintaining mechanism 6, and the fiber opening mechanism 4 are combined with the apparatus example of FIG. As a result, the mixed fiber bundle TC in the form of a tape obtained by performing the fiber opening process on the overlap-folded fiber bundle V can be again folded and subjected to the fiber opening process. It is possible to obtain a mixed fiber bundle TC in the form of a tape in which is further mixed.

FIG. 13 shows an example of a cross-sectional state of the overlapping fiber bundle W, the overlapping folded fiber bundle V, and the mixed fiber bundle TC in a tape form. As can be seen from this cross-sectional state example, after the folded fiber bundle V is made into a mixed fiber bundle TC in the form of a tape by opening processing, a plurality of fiber bundles are obtained by overlapping and folding again. Can be mixed evenly. In addition, the method of performing the fiber opening process by overlapping and folding the mixed fiber bundle TC in a tape form may be repeated twice or more.

[ Second Embodiment ]
A “mixed fiber bundle manufacturing method” according to the second embodiment of the present invention will be described with reference to FIG. In the second embodiment , a tape-shaped mixed fiber bundle obtained by mixing a plurality of fiber bundles using a plurality of tape-shaped fiber bundles and then twisted to give a round cross-section mixed fiber. The present invention relates to a method for obtaining a fiber bundle.

The apparatus example of FIG. 14 is an apparatus example in which the winding mechanism 7 is removed from the apparatus example of FIG. 4 and the twisting mechanism 3 is adopted after the fiber opening mechanism 4. The example of the apparatus of FIG. 14 can obtain a mixed fiber bundle C having a round cross-sectional shape in which a plurality of tape-shaped fiber bundles are mixed by twisting the mixed fiber bundle TC having a tape shape. It becomes like this.

Since the mixed fiber bundle C having a round cross section obtained by the apparatus example of FIG. 14 is obtained by using the mixed fiber bundle TC having a tape-like form, the overlapping fiber bundle is obtained by using the apparatus example of FIGS. Compared with the mixed fiber bundle having a round cross section obtained from W, a plurality of fiber bundles become a mixed fiber bundle in which fibers are mixed more uniformly.

[ Reference Example 2 ]
As Reference Example 2, “a method for producing a mixed fiber bundle” will be described with reference to FIG. The present invention relates to a method for obtaining a mixed fiber bundle by opening a plurality of fiber bundles to form a tape-like fiber bundle, and subsequently performing a superposition process, a twisting process and the like.

The raw yarn Fa or Fb is pulled out from the bobbin 11a '' or 11b '' for the raw yarn of the fiber bundle supply mechanism 1 ', and a wide and thin fiber bundle, that is, a tape-like fiber bundle Ta or Tb is obtained by the opening mechanism, respectively. . Then, the mixed fiber bundle C having a round cross-sectional shape is obtained by twisting by the twisting mechanism 3 as a superposed fiber bundle W by the superposing mechanism 2. In FIG. 15, since the raw yarn is traversed and wound around the bobbin for raw yarn, a mechanism for traversing the bobbin for raw yarn is employed so that the raw yarn is fed from a certain position.

  The raw yarn used here is a fiber bundle that has been processed so that a large number of fibers are bundled together and are not separated by a sizing agent. The cross-sectional form varies depending on the number of converging lines, the aligned state, the amount of sizing agent applied, and the like, and there are various forms such as a round shape, an elliptical shape, and a wide shape.

  In FIG. 15, only two sets of the combination of the fiber bundle supply mechanism 1 ′ and the fiber opening mechanism 4 are adopted, but three or more sets are adopted according to the number of fibers to be mixed, and each is formed into a tape-like fiber bundle. It is possible to obtain a superposed fiber bundle by processing. 15 shows an example of an apparatus that employs the twisting mechanism 3 after the overlapping mechanism 2. However, an example of an apparatus that configures the twisting mechanism after the opening mechanism is adopted after the overlapping mechanism 2, or An example of an apparatus configured with an overlap folding mechanism, a width direction maintaining mechanism, and a fiber opening mechanism may be employed.

  Next, specific examples will be described.

" Reference Example 1 "
A mixed fiber bundle having a round cross-sectional shape in which carbon fibers and glass fibers were mixed was manufactured using the apparatus example shown in FIG. Carbon fiber bundle 12K (Pyrofil TR50S, manufactured by Mitsubishi Rayon Co., Ltd.) with 12000 single fibers with a single yarn diameter of 7μm as a carbon fiber bundle, and glass with 4000 single fibers with a single yarn diameter of 13μm as a glass fiber bundle. Roving (manufactured by Nippon Electric Glass Co., Ltd.) was used. The carbon fiber bundle and the glass fiber bundle were each opened to a width of 20 mm by the method disclosed in Japanese Patent No. 3064019, and the opened yarn was used as the tape-like fiber bundles Ta and Tb.

  A tape-like fiber bundle Ta with a carbon fiber bundle width of 20 mm and a thickness of 0.05 mm and a tape-like fiber bundle Tb with a glass roving width of 20 mm and a thickness of 0.08 mm are aligned at both ends in the width direction by the overlay mechanism 2. After superposing in the thickness direction to form a superposed fiber bundle W, the superposed fiber bundle W was twisted by the twisting mechanism 3. The speed fed from the superposition mechanism 2 was 20 m / min, and the rotational speed of the spindle 35 in the twisting mechanism 3 was 1000 times / min.

  The obtained mixed fiber bundle C had a round cross-sectional shape with a diameter of 2 mm to which a twist of 50 turns / m was added. Further, from the cross-sectional observation of the mixed fiber bundle C, it was confirmed that the carbon fiber and the glass fiber were mixed from the inside to the outside of the mixed fiber bundle.

" Reference Example 2 "
A mixed fiber bundle having a round cross-sectional shape in which carbon fibers and glass fibers were mixed was manufactured using the apparatus example shown in FIG. The same carbon fiber bundle and glass fiber bundle as in Reference Example 1 were used. Further, as in Reference Example 1 , the carbon fiber bundle and the glass fiber bundle were each opened to a width of 20 mm by the method of Japanese Patent No. 3064019, and the opened yarn was used as tape-like fiber bundles Ta and Tb. .

In the same manner as in Reference Example 1 , a tape-like fiber bundle Ta having a carbon fiber bundle having a width of 20 mm and a thickness of 0.05 mm and a tape-like fiber bundle Tb having a glass roving having a width of 20 mm and a thickness of 0.08 mm are An overlapped fiber bundle W having a width of 20 mm was obtained. Thereafter, the spread fiber bundle W was opened to a width of 30 mm by the fiber opening mechanism 4, and the twisted fiber mechanism SW was twisted with respect to the opened fiber bundle SW. In the opening mechanism 4, an apparatus example of Japanese Patent No. 3064019 was adopted. A wind tunnel having a width of 32 mm and a length of 26 mm was used as the wind tunnel tube 42, and a suction air flow having a flow rate of 30 m / sec was applied in the wind tunnel tube without a fiber bundle. Then, the take-up motor 22 was controlled so that the overlapped fiber bundle W traveled in the wind tunnel with a deflection amount of 8 mm. The take-up motor 46 was rotating at a constant speed, and the opened fiber bundle SW was taken up at 20 m / min. Further, the rotational speed of the spindle 35 in the twisting mechanism 3 was 1000 times / min as in Reference Example 1 .

The obtained mixed fiber bundle C had a round cross-sectional shape with a diameter of 2 mm to which a twist of 50 turns / m was added. Further, from the cross-sectional observation of the mixed fiber bundle C, it was confirmed that the carbon fiber and the glass fiber were mixed from the inside to the outside of the mixed fiber bundle. In addition, compared with the reference example 1 , it was confirmed that the carbon fiber and the glass fiber are in a more mixed state.

" Example 1 "
A mixed fiber bundle in the form of a tape in which carbon fibers and glass fibers were mixed was manufactured using the apparatus example shown in FIG. The carbon fiber bundle and the glass fiber bundle were the same as those in Reference Examples 1 and 2 . Further, as in Reference Examples 1 and 2 , the carbon fiber bundle and the glass fiber bundle were each opened to a width of 20 mm by the method of Japanese Patent No. 3064019, and the opened yarn was used as tape-like fiber bundles Ta and Tb. used.

  The opened carbon fiber bundle is changed to a tape-like fiber bundle Ta, and the opened glass roving is changed to a tape-like fiber bundle Tb. 5, the folded fiber bundle V having a width of 10 mm was formed by bending at approximately the center of the laminated fiber bundle W as shown in FIG. Then, the width direction maintaining mechanism 6 rotates the width direction of the folded folded fiber bundle V by 90 degrees, and then the opening folded mechanism 4 opens the folded folded fiber V to a width of 20 mm to obtain a tape-shaped mixed fiber bundle. Got TC.

The opening mechanism 4 employs the same mechanism as in Reference Example 2 . However, the speed of the suction air acting in the wind tunnel is set so that the flow rate is 20 m / sec in the absence of fiber bundles, and the rotation control motor 62 is controlled so that the deflection of the folded fiber bundle V is 6 mm. I did it. The take-up motor 46 is rotating at a constant speed, and is set so that the tape-shaped mixed fiber bundle TC is sent to the winding mechanism 7 at 10 m / min. Then, a tape-shaped mixed fiber bundle TC having a width of 20 mm was wound around the winding reel 71.

  The obtained tape-shaped mixed fiber bundle TC was a mixed fiber bundle in a tape-like form having a width of 20 mm and a thickness of 0.12 mm. In addition, from the cross-sectional observation of the tape-shaped mixed fiber bundle TC, it was confirmed that the carbon fiber and the glass fiber were mixed in any part.

" Example 2 "
Using the apparatus example shown in FIG. 12, a mixed fiber bundle in the form of a tape in which carbon fibers and glass fibers were mixed together was manufactured. The carbon fiber bundle and the glass fiber bundle were the same as those in Reference Examples 1, 2 and Example 1 . Similarly to Reference Examples 1, 2 and 1 , the carbon fiber bundle and the glass fiber bundle were each opened to a width of 20 mm by the method of Japanese Patent No. 3064019, and the opened fiber bundle was taped. The fiber bundles Ta and Tb were used.

In Example 2 , the tape-shaped mixed fiber bundle TC having a width of 20 mm obtained by the same method as in Example 1 is again folded at the approximate center of the tape-shaped mixed fiber bundle TC by the overlap folding mechanism 5. Then, after forming a folded fiber bundle V having a width of 10 mm, the width direction is rotated 90 degrees by the width direction maintaining mechanism 6, and then opened to a width of 20 mm by the opening mechanism 4. Obtained.

In the example of the apparatus in FIG. 12, two opening mechanisms 4 are employed, and in both opening mechanisms, the suction air flow rate acting in the wind tunnel tube is set so that the flow rate is 20 m / sec without any fiber bundle. Then, the rotation control motor 62 was controlled so that the deflection amount of the folded fiber bundle V was 6 mm. Then, the finally obtained tape-shaped mixed fiber bundle TC was sent out to the winding mechanism 7 at a speed of 10 m / min, and wound around the winding reel 71 with a width of 20 mm.

  The obtained tape-shaped mixed fiber bundle TC was a mixed fiber bundle in a tape-like form having a width of 20 mm and a thickness of 0.12 mm. Further, from the cross-sectional observation of the tape-shaped mixed fiber bundle TC, it was confirmed that the carbon fiber and the glass fiber were mixed more by repeatedly performing the method of folding and opening the fiber.

" Example 3 "
Using a device example shown in FIG. 14, a mixed fiber bundle having a round shape in which carbon fibers and glass fibers were mixed together was manufactured. The carbon fiber bundle and the glass fiber bundle were the same as those in Reference Examples 1 and 2 and Examples 1 and 2 . Similarly to Reference Examples 1 and 2 and Examples 1 and 2 , the carbon fiber bundle and the glass fiber bundle were each opened to a width of 20 mm by the method of Japanese Patent No. 3064019, and this spread fiber bundle was taped. The fiber bundles Ta and Tb were used.

In Example 3 , twisting was performed by the twisting mechanism 3 on a tape-shaped mixed fiber bundle TC having a width of 20 mm and a thickness of 0.12 mm obtained by the same method as in Example 1 . The take-up motor 46 in the opening mechanism 4 is rotating at a constant speed, and the tape-like mixed fiber bundle TC is taken up at a speed of 10 m / min. The rotation speed of the spindle 35 in the twisting mechanism 3 was 500 times / min.

The obtained mixed fiber bundle C had a round cross-sectional shape with a diameter of 2 mm to which a twist of 50 turns / m was added. Further, from the cross-sectional observation of the mixed fiber bundle C, it was confirmed that the carbon fiber and the glass fiber were mixed from the inside to the outside of the mixed fiber bundle. In addition, compared with Reference Examples 1 and 2 , it was confirmed that the carbon fiber and the glass fiber were in a more mixed state.

[Industrial applicability]
The mixed fiber bundle having a round cross section obtained by the present invention or the mixed fiber bundle having a tape shape can be used as a reinforcing material for a composite material having different reinforcing characteristics. Further, a mixed fiber bundle of a reinforcing material and a thermoplastic resin fiber can be used as an intermediate material of a molded article for a composite material. And in any case, since each fiber is mixed uniformly, the composite material molded article in which the characteristic of each fiber was fully utilized can be obtained.

It is a figure regarding the example of an apparatus which superimposes two tape-like fiber bundles, performs twisting process, and obtains the mixed fiber bundle of a round cross-section form. A bobbin traverse mechanism that feeds a tape-shaped fiber bundle from a certain position is employed in a method for obtaining a mixed fiber bundle having a round cross-section after two tape-shaped fiber bundles are overlapped. FIG. It is a figure regarding the example of an apparatus which performs a twisting process after superposing two tape-like fiber bundles and performing a fiber opening process, and obtaining the mixed fiber bundle of a round cross-section form. It is a figure regarding the example of an apparatus which superimposes two tape-like fiber bundles, performs overlap folding by the bending along a longitudinal direction, and obtains a mixed fiber bundle of a tape-like form by performing a fiber opening process. It is explanatory drawing regarding an overfolding mechanism. It is explanatory drawing regarding the mechanism in which two sets of overlap folding mechanisms continue. It is explanatory drawing regarding the mechanism in which the overlap folding mechanism and the width direction maintenance mechanism were made continuous. It is the figure which imaged the fiber bundle cross-section state in the method of performing one time folding with respect to an overlap fiber bundle, opening the overlap folding fiber bundle, and obtaining a tape-form mixed fiber bundle. It is the figure which imaged the fiber bundle cross-section state in the method of performing two times folding with respect to an overlap fiber bundle, opening the overlap folding fiber bundle, and obtaining a tape-form mixed fiber bundle. FIG. 10 is a diagram illustrating an image of a fiber bundle cross-sectional state in a method of performing double folding different from FIG. 9 on an overlapped fiber bundle, opening the overlapped fiber bundle, and obtaining a tape-shaped mixed fiber bundle. . FIG. 9 and FIG. 10 show a fiber bundle cross-sectional state in a method for performing a double fold on a laminated fiber bundle having a different configuration from that of FIG. 9 and opening the folded fiber bundle to obtain a tape-shaped mixed fiber bundle. FIG. After the two tape-like fiber bundles are overlaid, a tape-like mixed fiber bundle is obtained that employs a mechanism that performs a method of performing fiber opening processing after being folded along the longitudinal direction and then folded twice. It is a figure regarding the example of an apparatus. It is the figure which imaged the fiber bundle cross-sectional state in the method of performing the fiber opening method after performing double folding twice, and obtaining a tape-shaped mixed fiber bundle. Two tape-shaped fiber bundles are overlapped, and after folding and folding along the longitudinal direction, twisted yarn processing is performed on the mixed fiber bundle in the tape-like form obtained by performing the fiber opening process. It is a figure regarding the example of an apparatus which obtains the mixed fiber bundle of a cross-sectional form. It is a figure regarding the example of an apparatus which obtains the mixed fiber bundle of a round section form by opening two raw yarns, making a tape-like fiber bundle, performing superposition, and performing twisting processing.

Explanation of symbols

1 Tape-like fiber bundle supply mechanism
11a, 11b Yarn supply reel
11a ', 11b' bobbin for yarn feeding
1 'Fiber bundle supply mechanism
11a ”, 11b” bobbin for raw yarn
2 Overlay mechanism
21 Overlap roll
22 Pick-up motor
3 Twisting mechanism
31 Guide
32 Traveler
33 rings
34 Winding bobbin
35 spindle
36 Spindle belt
4 Opening mechanism
41 Guide roll
42 Wind tunnel
43 Air suction device
44 Deflection detection sensor
45 Take-up roll
46 Pick-up motor
5 Layer folding mechanism
51a, 51b, 51c Bending roll
52a, 52b Bending roll
51a ', 51b', 51c 'Second-stage bending holding roll
52a ', 52b' Second stage folding roll
6 Width maintaining mechanism
61a, 61b, 61c Roll for width direction rotation
62 Motor for rotation control
7 Winding mechanism
71 Reel for take-up
72 Winding motor
Ta tape fiber bundle
Tb Tape-like fiber bundle
Fa yarn
Fb raw yarn
W superposed fiber bundle
V Folded fiber bundle
SW unfolded fiber bundle
C Mixed fiber bundle
TC tape-shaped mixed fiber bundle or tape-shaped mixed fiber bundle

Claims (14)

As the fiber bundle, a tape-shaped fiber bundle having a fiber bundle width of 2 mm or more in which the ratio of the fiber bundle width / fiber bundle thickness is 10 or more is used, and a plurality of the tape-shaped fiber bundles are continuously provided in the thickness direction. After forming a superposed fiber bundle that is superposed and laminated, it is subjected to folding along the longitudinal direction at least once to form a superfolded fiber bundle that is overfolded. A method for producing a mixed fiber bundle, characterized in that a plurality of fiber bundles are mixed to form a tape-like form . One or a plurality of methods for subjecting the mixed fiber bundle in the form of a tape obtained by the method according to claim 1 to a fiber opening process after performing folding along the longitudinal direction at least once and performing repeated folding. A method for producing a mixed fiber bundle, characterized in that a plurality of fiber bundles are mixed into a tape-like form by repeating the process repeatedly. A mixed fiber, wherein a plurality of fiber bundles are mixed by twisting a mixed fiber bundle in a tape-like form obtained by the method according to claim 1 or 2. A method of manufacturing a bundle. The spread fiber bundle used is a fiber bundle width / fiber bundle thickness ratio of 20 or more and a fiber bundle width of 4 mm or more as the tape-like fiber bundle. The manufacturing method of the mixed fiber bundle as described in one. The fiber bundle is opened to obtain a fiber bundle having a fiber bundle width / fiber bundle thickness ratio of 20 or more and a fiber bundle width of 4 mm or more, and the spread fiber bundle is a tape-like fiber bundle. A method for producing a mixed fiber bundle, wherein the mixed fiber is mixed by the method according to any one of. In the fiber opening process, the fiber bundle is caused to travel while being controlled so that a constant overfeed state is generated, while a fluid is passed in a direction substantially perpendicular to the traveling direction of the fiber bundle, and the fiber bundle is allowed to pass through the fluid. The method for producing a mixed fiber bundle according to any one of claims 1 to 5, wherein the fiber bundle is opened by bending it in a bowing direction. The method for producing a mixed fiber bundle according to any one of claims 1 to 6, wherein the same type of fiber bundle is used as the fiber bundle. The method for producing a mixed fiber bundle according to any one of claims 1 to 6, wherein different types of fiber bundles are used for the fiber bundle. The method for producing a mixed fiber bundle according to claim 8, wherein the different types of fiber bundles are a reinforcing fiber bundle and a thermoplastic resin fiber bundle. The carbon fiber bundle, the glass fiber bundle, the aramid fiber bundle, or the ceramic fiber bundle in which the single yarn is finely attached to each other with a required sizing agent is used for the fiber bundle. The manufacturing method of the mixed fiber bundle described in 2. A tape-like fiber bundle supply mechanism for continuously supplying a tape-like fiber bundle having a fiber bundle width / fiber bundle thickness ratio of 10 or more and a fiber bundle width of 2 mm or more; A superposition mechanism that forms a superposed fiber bundle in which a plurality of bundles are superposed in the thickness direction; a superposition folding mechanism that performs folding along the longitudinal direction of the superposition fiber bundle and then superimposes; An apparatus for producing a mixed fiber bundle having a fiber opening mechanism that opens the folded fiber bundle in a wide and thin state. A tape-like fiber bundle supply mechanism for continuously supplying a tape-like fiber bundle having a fiber bundle width / fiber bundle thickness ratio of 10 or more and a fiber bundle width of 2 mm or more; A superposition mechanism that forms a superposed fiber bundle in which a plurality of bundles are superposed in the thickness direction; a superposition folding mechanism that performs folding along the longitudinal direction of the superposition fiber bundle and then superimposes; An apparatus for producing a mixed fiber bundle, comprising: a spread mechanism that opens the folded fiber bundle in a wide and thin state; and a twist mechanism that twists the opened folded fiber bundle. The mixed fiber according to claim 11 or 12, further comprising a width direction maintaining mechanism that continuously rotates the folded folded fiber bundle so that the width direction of the folded folded fiber bundle coincides with the width direction. Bundle manufacturing equipment. 14. A fiber bundle supply mechanism that continuously supplies fiber bundles; and a fiber opening mechanism that opens the fiber bundles into a wide and thin state to form a tape-like fiber bundle. The manufacturing apparatus of the mixed fiber bundle as described in any one.

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