HK1168394B

HK1168394B - Method for spreading fiber bundles and method for manufacturing a fiber-reinforced sheet

Info

Publication number: HK1168394B
Application number: HK12109103.1A
Authority: HK
Inventors: 川边和正
Original assignee: 福井县
Priority date: 2009-05-25
Filing date: 2010-05-21
Publication date: 2014-12-12

Description

Method for opening fiber bundle and method for manufacturing fiber reinforced plate

Technical Field

The present invention relates to a fiber bundle spreading method for spreading a fiber bundle composed of a plurality of fibers by conveying the fiber bundle in a fiber length direction and moving the fibers in a width direction while bending the fibers by passing a fluid through the fiber bundle, a spread fiber sheet obtained by spreading the fiber bundle, and a fiber reinforced sheet obtained by attaching or impregnating a resin material to the spread fiber sheet.

Background

Fiber-reinforced composite materials comprising reinforcing fibers such as carbon fibers, glass fibers, and aramid fibers and a matrix resin such as an epoxy resin are being developed, and such reinforcing fibers can provide a reliable high-strength composite material molded product by laminating thin split yarn sheets combed in one direction in a plurality of directions. Further, from the viewpoint of the advantages of recyclability, short-time moldability, improvement in impact resistance of molded articles, and the like, it is considered that in the future, molded articles of composite materials using thermoplastic resins such as polyamide 6 resin, polyetherimide resin, and polyether ether ketone resin as matrix resins will be increased.

In recent years, carbon fiber composite materials have attracted attention as materials for aircrafts and automobiles. Various carbon fibers exist, but mainly: a tensile modulus of elasticity of about 24ton/mm²Carbon fibers having a strand diameter of about 7 μm, which are used for industrial and sports applications and are called general-purpose carbon fibers; a tensile modulus of elasticity of about 30ton/mm²A type having a single wire diameter of about 5 μm, and is called high-strength medium-elastic carbon fiber or the like for aircraft use.

Carbon fibers are commercially available as carbon fiber bundles, but there are many carbon fiber bundles. In terms of superiority in price and product quality (straightness of fibers, carding state of fibers, etc.) and ease of handling, carbon fiber bundles having 12000 and 15000 bundles (fineness of about 800 to 1100g/1000m) are mainly used as general-purpose carbon fiber bundles, and carbon fiber bundles having 12000 and 24000 bundles (fineness of about 400 to 1000g/1000m) are mainly used as high-strength, middle-elastic carbon fiber bundles.

In general-purpose carbon fiber bundles, there are types in which the number of carbon fibers bundled is increased in order to achieve a lower price, and general-purpose carbon fiber bundles having the number of bundled fibers of 24000 (fineness of about 1600g/1000m), 48000 (fineness of about 3200g/1000m), or more are commercially available. The fiber bundle has a large fineness and is therefore called a large-fineness carbon fiber bundle. However, the carbon fiber bundle having an increased number of bundles has a drawback that the number of bundles increases, which increases the number of twists, kinks, and the like of the fibers.

In order to develop a sheet and improve impregnation with a high-viscosity resin such as a thermoplastic resin, a step called spreading is required to widen and thin a fiber bundle. In particular, in bundling a large number of fiber bundles, the opening step becomes important. As a fiber opening technique, for example, patent document 1 describes a method for manufacturing a multifilament fiber opening sheet in which a multifilament is transported from a yarn feeding section to a winding section, and an air flow is passed through the multifilament a plurality of times in a cross direction, thereby bending the multifilament in a bow shape in a downwind direction, and thereby decomposing filaments constituting the multifilament in a width direction to open the multifilament. Patent document 2 describes a fiber opening device including a delivery roller around which a gathered fiber is wound, an opening section for opening the gathered fiber by flowing a fluid in a direction orthogonal to a moving direction of the gathered fiber with respect to the gathered fiber delivered from the delivery roller, and a winding roller for winding a fiber opening plate opened by the opening section, wherein the opening section is arranged in multiple stages along the moving direction. Patent document 3 describes a fiber spreading device that feeds a fiber bundle by being drawn out from each of a plurality of wire feeders, causes the fed fiber bundle to travel in an air flow in a plurality of fluid flow-through portions, and spreads the fiber bundle in the width direction while bending the fiber bundle by the action of the air flow.

Prior art documents

Patent document

Patent document 1: japanese patent No. 3064019

Patent document 2: japanese patent No. 3907660

Patent document 3: japanese Kokai publication No. 2007-518890

The above-mentioned patent documents describe a fiber opening technique for expanding a fiber bundle into a predetermined width by passing a fluid through the transported fiber bundle. In such a spreading technique, it is necessary to spread fibers constituting a fiber bundle uniformly and to increase the spreading width as much as possible, and to form the thickness of the spread fiber bundle as uniform and thin as possible.

In addition, since the material cost of the thick fiber bundle, which is a fiber bundle having an increased number of fibers bundled, is lower than that of the thin fiber bundle, which is a fiber bundle having a small number of fibers bundled, the production cost can be reduced by spreading the thick fiber bundle. Further, since the spreading using the large-fineness fiber bundle can obtain a wider spread yarn sheet by one spreading process, the production efficiency can be further improved.

In patent document 1, in order to widen the opening width of the fiber bundle, the fiber bundle is subjected to the opening operation a plurality of times (twice in the example), but since it is necessary to provide devices for adjusting the amount of bending of the fiber, such as a feedforward device, a feedback device, and a bending measurement sensor, at a plurality of locations (two locations in the example), it is inevitable to increase the size of the apparatus and increase the cost burden of the devices. Further, it is difficult to arrange the devices in the width direction, and it is difficult to obtain a plate-like spread fiber sheet in which a plurality of fiber bundles are simultaneously spread with high quality.

In patent documents 2 and 3, the fiber bundle is continuously expanded in the opening width each time the fiber bundle passes through each opening part by providing the opening parts in a plurality of stages in series. If the opening width is enlarged by continuing the opening portion in this way, the fibers constituting the fiber bundle are not uniformly dispersed, and a coarse density or a gap may occur in the density of the fibers after opening.

The present inventors have conducted experiments with reference to examples of patent documents 2 and 3, and as a result, when a general-purpose carbon fiber bundle having 12000 or 15000 bundled carbon fibers or a high-strength medium-elastic carbon fiber bundle having 12000 or 24000 bundled carbon fibers is used, carbon fibers are substantially uniformly dispersed in 1 carbon fiber bundle and the opening width is about 20 to 25mm (the basis weight is about 40 g/m)²Left and right) to continuously form a uniform thickness, but if continuous spreading is performed, the spreading width is 25mm or more (the weight per unit area is about 30 g/m)²Hereinafter), a portion where a crack is generated is formed in the opened yarn sheet.

In the case of using 24000 thick carbon fiber bundles, the carbon fibers are substantially uniformly dispersed in 1 carbon fiber bundle having an opening width of 3About 0to 35mm (weight per unit area of about 50 g/m)²Left and right) of a uniform thickness, but if the continuous spreading is performed, the spreading width is about 40mm or more (the basis weight is about 40 g/m)²Hereinafter), a portion such as a break, a bundle caused by a fiber kink, or a local twist is formed in the opened yarn sheet.

In addition, in the case of using thick-fineness carbon fiber bundles having a number of bundled fibers of 48000 and 60000, it was confirmed that when 1 carbon fiber bundle was opened with an opening width of about 40mm or more, bundling, local twisting, and the like due to fiber kinking occurred, and continuous opening was difficult.

When the cause of such uneven dispersion of the fibers in the opening step was investigated, the following was concluded. In the methods of patent documents 2 and 3, since the portions of the fiber bundle in the curved state to which the air flow is applied are continuous, if the number of continuous fiber-opened portions is increased or the air flow rate is increased in order to perform wider fiber opening, the fibers are likely to move in the width direction and are continuously subjected to a force to expand in the width direction. The fiber bundle is not always aligned in a straight state and is slightly entangled, and the adhesive of the fiber bundle is unevenly adhered. Therefore, if the fiber bundle is continuously opened in a wider and thinner width by the methods of patent documents 2 and 3, a portion that is required to be increased in force to expand the fiber bundle in the width direction is formed in each fiber, and as a result, the fiber bundle moves in the width direction in a state where the fibers are gathered, the entanglement of the fibers becomes large, the dispersibility of the fibers deteriorates, and the fiber bundle moves in the width direction from a portion where the amount of adhesive is small, so that a portion in an unstable state where a gap or an opening width is likely to occur in an opened state of the fiber bundle is formed. That is, it is found that continuous opening is difficult in a state where the fibers constituting the fiber bundle are uniformly dispersed.

In addition, in the fiber bundle (thick fiber bundle) having an increased number of bundles, uneven adhesion of the adhesive and kinking of the fibers are more likely to occur. Therefore, if the large-fineness fiber bundle is opened by the methods of patent documents 2 and 3, the gap and the opening width in the opened yarn sheet are more likely to be unstable.

Therefore, in the conventional spreading technique, it is difficult to spread a wider width (in the case of the general-purpose carbon fiber bundles having 12000 or 15000 bundled members and the high-strength medium-elasticity carbon fiber bundles having 12000 or 24000 bundled members, the spreading width of 1 carbon fiber bundle reaches 25mm or more) and to spread a wider width having good fiber dispersibility in the coarse fiber bundle (in the case of the coarse fiber bundle having 24000 or more bundled members, the spreading width of 1 carbon fiber bundle reaches 40mm or more).

Disclosure of Invention

Therefore, an object of the present invention is to provide a spreading method which can be applied to a fiber bundle having an increased number of bundles and can continuously form a spread fiber sheet having a wide spread width and a uniform thickness by uniformly dispersing fibers, a spread fiber sheet using a carbon fiber bundle, and a method for manufacturing a fiber-reinforced sheet having excellent mechanical properties by adhering or impregnating a spread fiber sheet obtained by the spreading method with a resin material.

In a fiber bundle opening method according to the present invention, a fiber bundle composed of a plurality of fibers is conveyed in a fiber length direction, and the fibers are bent and moved in a width direction by passing a fluid through the fiber bundle in a movable region set so that the fibers can move in the width direction, and the fiber bundle opening method is characterized in that n (n.gtoreq.2) fiber-opening regions A are arranged in the movable region in the conveying direction of the fiber bundle_i(i-1, …, n) and an expanded region B_i(i-1, …, n) paired region group S_i(i-1, …, n) to sequentially pass through the zone group S_iThe fiber bundle is conveyed and opened, and the opening area A is_i(i-1, …, n) by passing a fluid through the fibersThe bundle is opened to an opening width W by bending and moving the fibers in the width direction_i(i-1, …, n), the expanded region B_i(i-1, …, n) and the splitting region A_iCorrespondingly arranged at the upstream side of the conveying direction and along with the fiber opening area A_iThe widthwise movement of the fiber, the expansion region B_iThe width of the fiber bundle in (1) is expanded in a manner that the end is enlarged. The method for opening a fiber bundle according to the present invention is characterized in that the group S of the first regions is₁In the above-mentioned fiber opening region A₁The opening width W of the fiber bundle₁Relative to the original width W of the fiber bundle₀Is set to

1＜(W₁/W₀)≤5，

In the remaining of said regional groups S_j(j-2, …, n), and (d) subjecting the opened region a to a chemical vapor deposition_j-1Opening width W of_j-1The opening area A_jOpening width W of_jAnd the expanded region B_jLength L of the fiber bundle in the conveying direction_jIs set to satisfy

0＜(W_j-W_j-1)/2L_jTan is less than or equal to 30 degrees. The method for opening a fiber bundle according to the present invention is characterized in that the opening region a is formed in a fiber bundle₁The opening width W of the fiber bundle₁Is set to

2≤(W₁/W₀)≤4。

In the fiber bundle opening method according to the present invention, the fibers are moved in the width direction while being bent by passing a fluid through the fiber bundle in a plurality of divided regions in at least a part of the opening region. In the fiber bundle opening method according to the present invention, at least one contact roller that is arranged in the width direction of the fiber bundle and comes into contact with the fiber bundle is provided in at least a part of the expanded region, and the fiber bundle is conveyed while coming into contact with the contact roller. In the fiber bundle opening method according to the present invention, the contact roller is configured to reciprocate in a width direction of the fiber bundle. The method for spreading a fiber bundle according to the present invention is characterized in that the fiber bundle is heated in at least a part of the expanded region and/or the spreading region. The method for spreading a fiber bundle according to the present invention is characterized in that the amount of bending of the fiber bundle is changed with time in at least a part of the spreading region. The method for spreading a fiber bundle according to the present invention is characterized in that the fiber bundle is spread while securing a predetermined amount of bending of the fiber bundle by a bending securing roller in at least a part of the spreading region. The fiber bundle opening method according to the present invention is characterized in that the fiber bundle is vibrated in a direction orthogonal to a conveyance direction by at least one of the bend ensuring rollers. The fiber bundle opening method according to the present invention is characterized in that the fiber bundle is conveyed while preventing the fiber bundle from being pulled back on the upstream side of the movable region. The method for spreading a fiber bundle according to the present invention is characterized in that vibration is applied in the width direction to a spread sheet obtained by spreading the fiber bundle. The fiber bundle opening method according to the present invention is characterized in that the fiber bundles are simultaneously opened while being conveyed. The method for spreading a fiber bundle according to the present invention is characterized in that a plurality of spreading thread plates formed by spreading a plurality of fiber bundles in parallel are vibrated in a width direction, and are formed in a plate state uniform as a whole.

The disclosed split thread sheet is characterized in that a carbon fiber bundle having a number of fiber bundles of 12000 to 24000 and a fineness of 400g/1000m to 1100g/1000m is split, whereby the carbon fiber bundle is formed to have a width of 25mm or more and a thickness of 0.04mm or less. The split thread sheet according to the present invention is characterized in that the carbon fiber bundle having a number of fiber bundles of 24000 or more and a fineness of 1600g/1000m or more is split, thereby forming the carbon fiber bundle to have a width of 40mm or more and a thickness of 0.2mm or less.

The method for manufacturing a fiber-reinforced panel according to the present invention is characterized by manufacturing a fiber-reinforced panel by forming a resin layer on one surface or both surfaces of a split thread sheet obtained by any one of the methods for splitting a fiber bundle. The method for manufacturing a fiber-reinforced panel according to the present invention is characterized in that the resin layer is formed using a resin sheet. The method for manufacturing a fiber-reinforced board according to the present invention is characterized in that a fiber-opened thread sheet obtained by any one of the methods for opening a fiber bundle is attached to both surfaces of a resin sheet to manufacture a fiber-reinforced board. The method for manufacturing a fiber-reinforced board according to the present invention is characterized by manufacturing a fiber-reinforced board by impregnating a split yarn sheet obtained by any one of the methods for splitting a fiber bundle with a resin material.

Effects of the invention

In the present invention, the fiber bundle is arranged in the fiber opening region a in the movable region set so that the fibers of the fiber bundle can move in the width direction_i(i-1, …, n) and an expanded region B_i(i-1, …, n) paired region group S_i(i-1, …, n) in the splitting region a_i(i-1, …, n), the fiber is opened to an opening width W by passing a fluid through the fiber bundle to move the fiber in the width direction while bending the fiber_i(i-1, …, n), the expanded region B_i(i-1, …, n) and the splitting region A_iCorrespondingly arranged at the upstream side of the conveying direction and following the fiber opening area A_iThe widthwise movement of the fiber, the expansion region B_iThe width of the fiber bundle in (a) is expanded in a manner that the end is enlarged, and thus, by passing through the opening area A_iThe generated widthwise shift phenomenon due to the dispersion of the fibers of the fiber bundle affects the expansion region B on the upstream side_iThe fibers can be continuously opened in the opening region a by gradually moving the fibers in the width direction to perform pre-opening_iThe fiber bundle can be spread into a wide width with good fiber dispersibility by uniformly dispersing the fiber bundle and expanding the spread width to a predetermined width to make the thickness uniform.

When the wide opening is performed by the method of continuously setting the opening regions as in the prior art document described above, the fiber is directly opened in a state affected by the uneven adhesion or the kinking of the fiber, and therefore the uneven adhesion or the kinking of the fiber prevents the uniform fiber distribution_iIs set as an expansion region B_iOf the region group S_iTherefore, the fiber bundle can be opened slowly while being unwound.

That is, since no member that is nipped by the feed back roller or the like and that interferes with the movement of the fibers in the width direction is provided in the movable region, the movable region is a region in which the fibers of the fiber bundle can move in the width direction. By arranging a plurality of pairs of expanded regions B in pairs in the region_iAnd an opening region A_iTherefore, even when the fiber bundle has uneven adhesion of the adhesive or kinks in the fibers, the fiber bundle can be opened so that the fibers gradually move in the width direction and are untied. That is, in the movable region, the fiber bundle is uniformly dispersed in a state where the fibers are not bent and are good in straightness, and the opening width is gradually increased.

By performing the opening by such area setting, even when carbon fiber bundles having 12000 to 24000 bundled carbon fiber bundles are used, the opening width of 1 carbon fiber bundle can be set to 25mm or more (the basis weight is about 30 g/m)²Below) are uniformly dispersed to form a thin and uniform-thickness spread yarn sheet. In addition, in the case of using a thick carbon fiber bundle having 24000 or more bundled members, the number of the regional groups S is increased_iThe number of the arrays of (2) can be stably spread into a spread sheet having a wide spread width and a uniform thickness. That is, even when the width of the fiber bundle before continuous opening is 4to 5 times or more wide, the fiber bundle is not adhered with the adhesiveThe fibers are gradually moved in the width direction due to the influence of the unevenness and the kinks of the fibers, and the fiber can be opened with good fiber dispersibility, and the width and the fiber dispersibility in the opened state can be remarkably continued and stabilized as compared with the conventional opening method.

By means of an initial set S of regions₁In the area A to be opened₁The opening width W of the fiber bundle₁Relative to the original width W of the fiber bundle₀Is set to

1＜(W₁/W₀)≤5，

Thus, when the fiber bundle is initially expanded, the fiber bundle can be opened without causing breakage in the fiber bundle while untwisting the fiber bundle generated when the fiber bundle is unwound from the bobbin or partial twist in the fiber bundle that may be generated in the process of manufacturing the fiber bundle.

In addition, by grouping S in the remaining regions_j(j-2, …, n), the splitting region a_j-1Opening width W of_j-1Opening area A_jOpening width W of_jAnd an expanded region B_jLength L of fiber bundle in conveying direction_jIs set to satisfy

0＜(W_j-W_j-1)/2L_j≤tan30°，

The adhesive irregularity of the adhesive locally generated in the fiber bundle or the kink of the fiber can be passed through the expansion region B_jThe pre-splitting is gradually loosened in the splitting area A_jThe fibers are uniformly dispersed without causing unevenness in density of the fibers, and are opened.

In addition, the expansion region B is based on the expansion region B as shown in the above equation_jLength L in the conveying direction of_jAssociated with the opening area A_jOpening width W of_jThereby, the fiber opening area A can be set_jOpening width W of_jWill not be opposite to the expansion area B_jLength L in the conveying direction of_jOver-enlargement without generation of fiber bundlesCracking, etc.

The split thread sheet obtained by the splitting method is a split thread sheet having excellent fiber straightness and fiber dispersibility and a small number of fibers in the thickness direction, and is a sheet in which a matrix material such as a resin is easily impregnated and which can sufficiently exhibit the original mechanical properties (tensile properties) of fibers.

Further, according to the manufacturing method of attaching or impregnating the resin material to the spread sheet having excellent fiber straightness and fiber dispersibility obtained by the present spreading method, it is possible to obtain a fiber-reinforced sheet having uniform width and thickness directions with few defects that cause stress concentration and the like while sufficiently exhibiting mechanical properties (for example, tensile properties, compressive properties and the like) inherent to fibers.

Further, by the manufacturing method in which the resin material is attached to or impregnated into the spread sheet having a small number of fibers in the thickness direction, that is, a thin layer obtained by the present spreading method, a fiber-reinforced plate having excellent moldability, that is, drapability can be obtained.

Drawings

Fig. 1 is a schematic plan view of an example of an apparatus for carrying out the fiber opening method according to the present invention.

Fig. 2 is a schematic side view of the apparatus shown in fig. 1.

FIG. 3 shows a plurality of zone groups S in the movable zone M_iThe arrangement of (i ═ 1, …, n) is a generalized pattern diagram.

FIG. 4 relates to a zone group S_j-1And region group S_jThe description of the drawings.

FIG. 5 is a view of the opening area A_jMiddle opening width W_jThe description of the drawings.

FIG. 6 is a view of the opening area A_jMiddle opening width W_jAnother explanatory view of (1).

Fig. 7 is a schematic plan view of another example of the device for carrying out the fiber opening method according to the present invention.

Fig. 8 is a schematic side view of the apparatus shown in fig. 7.

Fig. 9 is a schematic plan view of still another example of the apparatus for carrying out the fiber opening method according to the present invention.

Fig. 10 is a schematic side view of the device example shown in fig. 9.

Fig. 11 is a schematic plan view of still another example of an apparatus for carrying out the fiber opening method according to the present invention.

Fig. 12 is a schematic side view of the device example shown in fig. 11.

Fig. 13 is a schematic side view of another example of the apparatus for carrying out the fiber opening method according to the present invention.

Fig. 14 is a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention.

Fig. 15 is a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention.

Fig. 16 is a schematic plan view of still another example of the apparatus for carrying out the fiber opening method according to the present invention.

Fig. 17 is a schematic side view of the device example shown in fig. 16.

Fig. 18 is a schematic plan view of still another example of an apparatus for carrying out the fiber opening method according to the present invention.

Fig. 19 is a schematic side view of the device example shown in fig. 18.

Fig. 20 is a schematic side view of another example of the apparatus for carrying out the fiber opening method according to the present invention.

Fig. 21 is a schematic side view of an example of an apparatus for manufacturing a fiber-reinforced board according to the present invention.

Fig. 22 is a schematic side view of another example of an apparatus for manufacturing a fiber-reinforced panel according to the present invention.

Detailed Description

Hereinafter, embodiments according to the present invention will be described in detail. The embodiments described below are specific examples preferred for carrying out the present invention, and therefore, various technical limitations are imposed on the embodiments, but the present invention is not limited to these embodiments unless the content of the limitations of the present invention is specifically and explicitly described in the following description.

Fig. 1 and 2 are a schematic plan view and a schematic side view of an example of an apparatus for carrying out the fiber opening method according to the present invention. A fiber bundle Tm formed by bundling a plurality of long fibers is wound around a bobbin-shaped yarn feeder 11, and the yarn feeder 11 is rotated by a yarn feeder motor 12 to release the fiber bundle Tm.

Examples of the fiber material used for the fiber bundle Tm include a reinforcing fiber bundle composed of high-strength fibers such as a carbon fiber bundle, a glass fiber bundle, an aramid fiber bundle, a ceramic fiber bundle, and the like; thermoplastic resin fiber bundles obtained by carding thermoplastic synthetic fibers such as polyethylene, polypropylene, nylon 6, nylon 66, nylon 12, polyethylene terephthalate, polyphenylene sulfide, and polyether ether ketone. In the case of using carbon fiber bundles, carbon fiber bundles having a bundling number of 12000 to 24000 fiber bundles are often distributed on the market, but fiber bundles having a bundling number of more than 24000 (for example, 48000 or 60000) may be used in the present invention.

In addition, as the form of the fiber bundle Tm, a fiber bundle in which a plurality of fibers are combed and bundled by a glue or the like so as not to be separated is preferable. The adhesive agent is attached to the opened yarn sheet, whereby the shape of the opened yarn sheet is also stable. The fiber bundle twisted by forced twisting is not preferable to be used in the opening method of the present invention because it is difficult to obtain a continuous opened state.

The fiber bundle Tm fed out from the yarn feeder 11 is drawn out in a drawing direction in a predetermined direction by a guide roller 21 rotatably supported at a predetermined position. The drawn fiber bundle Tm is nipped by the feed roller 22 and the backup roller 23 and conveyed by a predetermined feed amount. The feeding amount of the fiber bundle Tm is adjusted by controlling the rotation operation of the feeding motor 24 that rotates the feeding roller 22.

The fiber bundle Tm conveyed by the feed roller 22 is supported and conveyed by a pair of support rollers 25 arranged at a predetermined interval in the conveyance direction of the fiber bundle Tm. Between the support rollers 25, the tension applying roller 26 is provided so as to be able to move up and down, and the fiber bundle Tm is provided so as to wind from the upper side of the support rollers 25 to the lower side of the tension applying roller 26. The fiber bundle Tm passing between the backup rolls 25 is given a tension within a predetermined range by the tension-giving roll 26. Then, the tension applying roller 26 is moved up and down according to the feeding amount of the fiber bundle Tm fed by the feeding roller 22. The vertical movement of the tension applying roller 26 is detected by an upper limit position detecting sensor 27 and a lower limit position detecting sensor 28.

The tension applying roller 26 operates so as to rise when the fiber bundle Tm is opened and the feed amount becomes smaller than the amount (conveyance amount) of the fiber bundle Tm being conveyed, and to fall when the feed amount becomes larger than the conveyance amount of the fiber bundle Tm. Therefore, when the tension applying roller 26 rises and the upper limit position detection sensor 27 detects the tension applying roller 26, the rotation of the feed roller 22 is increased to increase the feed amount of the fiber bundle Tm. When the tension applying roller 26 is lowered and the lower limit position detection sensor 28 detects the tension applying roller 26, the rotation of the feed roller 22 is slowed down to reduce the feed amount of the fiber bundle Tm.

In this way, the feed amount of the fiber bundle Tm is adjusted so that the tension applying roller 26 is positioned within the predetermined range based on the detection signals from the upper limit position detecting sensor 27 and the lower limit position detecting sensor 28, and the tension of the fiber bundle Tm is stabilized within the predetermined range.

It should be noted that a method other than this mechanism may be adopted as long as the mechanism is a mechanism that draws out the fiber bundle from the bobbin and continuously stabilizes the tension of the fiber bundle within a certain range.

A pinch roller 29 is provided downstream of the support roller 25, and the fiber bundle Tm is nipped by the pinch roller 29 and conveyed to the fiber opening section. The nip roller 29 is provided with a one-way clutch, not shown, and is configured to rotate only in a direction of feeding the fiber bundle Tm and not to rotate in a direction of pulling back.

The fiber bundle Tm set to a predetermined range of tension by the nip roller 29 passes through a plurality of fiber opening sections arranged in the conveyance direction. Each fiber opening section supports the fiber bundle Tm by a pair of guide rollers 31 arranged in the conveyance direction. An air duct 32 is provided between the guide rollers 31, and an upper opening of the air duct 32 is formed with a predetermined width between the guide rollers 31. A flow rate adjustment valve 33 and an air suction pump 34 are attached to the lower side of the air tunnel 32, and by operating the air suction pump 34, air in the air tunnel 32 is sucked, so that an air flow generated by the suction is generated in an upper opening portion between the guide rollers 31.

When the suction airflow passes through the fiber bundle Tm being conveyed between the guide rollers 31, the fiber bundle Tm is bent due to the relationship between the tension of the fiber bundle Tm and the flow velocity of the airflow. In such a state, when the air flow passes between the fibers of the fiber bundle Tm, a force that moves the fibers in the width direction of the fiber bundle Tm acts, and the fiber bundle Tm is opened due to the effect of fiber bending. Such a splitting action is known.

When the fiber bundle Tm is bent, the magnitude of the bending thereof can be represented by a bending amount t. The bending amount t may be represented by a distance from the upper surface of the guide roller 31 to the lowermost position at which the fiber bundle is bent.

By providing the nip roller 29, the fiber bundle Tm cannot be pulled back in the direction opposite to the conveyance direction, and is easily bent in the air duct.

A pair of guide members 35 are provided along the conveying direction on both sides of the upper opening of the air tunnel 32, and when the fiber bundle Tm being conveyed between the guide rollers 31 is opened by passing the suction airflow, the opening width is defined by the guide members 35.

The guide member 35 may be formed such that the upper opening of the air tunnel 32 is rectangular and the side wall of the opening is used as it is. Further, a plurality of wires or the like may be erected inside the wind tunnel 32 to serve as a guide member.

The fiber bundle Tm is split a plurality of times by the splitting unit to form a thin split line sheet Ts in which fibers are uniformly dispersed. The filament-opened wire plate Ts is held by a pulling roller 41 and conveyed. The pulling roller 41 is rotated by a pulling motor 42 to pull in the slit sheet Ts and convey the slit sheet Ts. Therefore, the conveying speed of the fiber bundle Tm can be adjusted by the rotation speed of the traction motor 42.

The spread sheet Ts fed out by the take-up roll 41 is wound by a winding device not shown. Or continuously conveyed to a device for adhering or impregnating the resin material.

In the above-described apparatus, the fiber bundle Tm is nipped by the nip roller 29, the split wire plate Ts is nipped by the pulling roller 41, and the fiber bundle Tm is not nipped between these roller pairs. Therefore, the fiber that becomes the fiber bundle Tm between the two roller pairs is conveyed in the movable region M in a state of being movable in the width direction.

The fiber bundle Tm is conveyed at a predetermined conveyance speed by the drawing roll 41, and the tension thereof is adjusted to a predetermined range by the tension applying roll 26. Therefore, the fiber bundle Tm is conveyed in a state of being bent by the suction airflow in the plurality of fiber opening portions arranged in the movable region M.

The guide rollers 31 of the fiber opening part are set to be fiber opening areas A₁～A₃. The opening width W of each opening region₁～W₃Is set according to the interval between the pair of guide members of each fiber opening part. The width of the fiber bundle Tm before entering the movable region M is the original width W₀。

The upstream side of each fiber opening region is set as a fiber bundleExpanded region B in which Tm is expanded in a manner that the end is expanded₁～B₃. In the example shown in fig. 1 and 2, the expansion region B₁Is set from the pinch roller 29 to the opening area A₁The guide roller on the upstream side of (B), the expansion area B₂～B₃Is set from the downstream end of the guide member 35 to the guide roller on the upstream side of the fiber opening region. The length L in the transport direction of the fiber bundle Tm in the expansion region set upstream of each fiber opening region is set₂And L₃The length of the region where the fiber bundle Tm actually expands so as to expand the end thereof is the length from the downstream end of the guide member 35 as the start position thereof to the guide roller on the upstream side of the fiber opening region. In the example shown in fig. 1, the guide member 35 is set at a position such that a space is left between the upstream side of the expansion region and the fiber opening region, but the position may be adjusted so that the fiber opening region and the expansion region are continuous.

The upstream side of each fiber opening region is set as an expansion region B in which the Tm of the fiber bundle is expanded so as to expand the end₁～B₃. Length L in the conveyance direction of fiber bundle Tm in the expansion region between the fiber-opening regions₂And L₃The interval between the guide rollers as the adjacent fiber opening regions is set. Expanded region B₁Is set from the pinch roller 29 to the opening area A₁。

And a group S of the opened region and the expanded region formed in a pair₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

FIG. 3 shows a plurality of zone groups S in the movable zone M_iThe arrangement of (i ═ 1, …, n) is a generalized pattern diagram. In fig. 3, the respective block groups are arranged continuously, but may be arranged with a space between the block groups as shown in fig. 1 and 2. Zone group S_iHas an opening region A_iAnd an expanded region B_iIn the splitting area A_iIn which the fibres are caused to pass through the fibre bundle by means of a suction air stream as a fluidThe fiber is bent and moved in the width direction to be opened to an opening width W_i(ii) a Expanded region B_iAnd the opening area A_iCorrespondingly arranged at the upstream side of the conveying direction and along with the fiber opening area A_iThe fiber width direction of (A) expands the region (B)_iThe width of the fiber bundle in (1) is expanded in a manner that the end is enlarged.

In the present invention, in the opening region A_iThe phenomenon that each fiber of the generated fiber bundle moves in the width direction is applied to the expansion region B on the upstream side_iThe fibers are expanded so that the ends thereof are enlarged, and thus the fibers are opened so that the adhesion unevenness of the adhesive and the kinks between the fibers are gradually eliminated and the fibers are untied. That is, the fibers can be opened while suppressing the influence of the uneven adhesion of the adhesive and the kinks between the fibers. In addition, even when the respective zone groups are arranged continuously or when there is a space between the respective zone groups, the respective fibers can move in the width direction in the movable zone, and therefore the fiber bundle can be opened so that the respective fibers are unwound.

Due to the fact that in the fiber opening area A_iThe thickness of the opened fiber bundle is gradually reduced because the opening width is increased as the fiber bundle is fed downstream. When the fiber bundle is thick, the adhesive unevenness of the adhesive and the kinks between the fibers are present inside, but as the fibers gradually move in the width direction, the thickness is gradually reduced to cause the adhesive unevenness of the adhesive and the kinks between the fibers to be present inside the expanded region B_iGradually eliminated. Therefore, compared to the case where the opening width is enlarged at once by opening, the influence of the uneven adhesion of the sizing agent and the entanglement of the fibers can be suppressed, and the fibers can be opened while being uniformly dispersed by being unwound.

The adhesion unevenness of the glue in the fiber bundle and the kink between the fibers are most affected when the fiber is first opened. In addition, since the entire fiber bundle is twisted at the stage of manufacturing the fiber bundle and at the time of winding the bobbin, a continuous and stable fiber opening width cannot be obtained at the time of opening the fiber bundle, and breakage or the like occurs between the fiber bundles during opening.

In the present invention, in the first region group S₁In (2), passing through the original width W relative to the Tm of the fiber bundle₀To open the fiber area A₁Opening width W of₁Is set as

1＜(W₁/W₀)≤5，

Accordingly, the fibers can be uniformly dispersed and the initial fiber opening can be stably performed while suppressing the influence of the twist between the fibers in the fiber bundle and the twist of the entire fiber bundle. When opening width W₁Expanded to exceed the original width W₀When the amount is 5 times the amount of the fiber bundle, the twist of the fibers in the fiber bundle and the twist of the entire fiber bundle are rather increased at the time of opening, and a continuous and stable opening width cannot be obtained or a crack is easily generated between the fiber bundles due to the influence. Further preferably set to

2≤(W₁/W₀)≤4。

If the width W of the split fiber is made₁To the original width W₀The opening efficiency can be improved by more than 2 times. Further, by dividing the width W of the fiber₁Is set as the original width W₀Within 4 times of the total fiber length, fiber spreading with good fiber dispersibility can be achieved while further suppressing the influence of fiber kinking in the fiber bundle and twisting of the entire fiber bundle.

Next, for the first regional group S₁The following segment group Sj (j ═ 2, …, n) will be explained. FIG. 4 relates to a zone group S_j-1And region group S_jThe description of the drawings. Zone group S_j-1Comprises an opening area A_j-1And an expanded region B_j-1Opening area A_j-1Set to the opening width W_j-1Expanding region B_j-1Set as the length L of the fiber bundle in the conveying direction_j-1. Likewise, region group S_jComprises an opening area A_jAnd an expanded region B_jOpening area A_jSet to the opening width W_jExpanding, expandingSheet region B_jSet to the length L of the fiber bundle in the conveying direction_j。

Expanded region B_jThe opening width W is enlarged toward the downstream end_jSpecific splitting width W_j-1And (4) wide. And, the expanded region B_jThe distance between the two sides is set to be equal to the distance between the two sides

ΔW＝(W_j-W_j-1)/2。

And, when in the expanded region B_jWhen the angle of both sides of (A) with respect to the conveying direction is theta, the condition is satisfied

tanθ＝ΔW/L_j＝(W_j-W_j-1)/2L_j。

Here, the expansion region B is preferred_jSet to expand at equal distances on both sides. If the expansion method is set to be biased, the fibers are biased in the movement in the width direction by the opening, and it is difficult to perform the opening with uniform fiber dispersion.

In the region group S_jBy expanding the region B_jThe widening angle theta of (A) is set to 30 DEG or less, and the fiber can be opened in the fiber opening region (A)_jIn the fiber opening step, the fibers are uniformly dispersed and opened to an opening width W_j. If the angle theta is greater than 30 deg., in the expansion region B_jIn the case of (1), the fiber is opened without sufficiently eliminating the uneven adhesion of the sizing agent and the kinking of the fibers, and it is difficult to continuously and uniformly disperse the sizing agent by generating gaps between the fibers or by forming a coarse density in the density of the fibers.

Thereby, the opening area A is set_j-1Opening width W of_j-1Opening area A_jOpening width W of_jAnd an expanded region B_jLength L of fiber bundle in conveying direction_jSatisfy the requirement of

0＜(W_j-W_j-1)/2L_j≤tan30°，

Thus, the fibers of the fiber bundle can be continuously and uniformly spread.

It is preferable in terms of fiber dispersibility that the smaller θ is, the slower each fiber moves, but the longer the distance L is, the larger the apparatus becomes. Conversely, the distance L becomes shorter as θ becomes larger, and the device becomes smaller, but the amount of movement of each fiber becomes larger, and the fiber dispersibility is easily affected. Thus, θ is preferably an angle of 5 ° ≦ θ ≦ 20 °.

By setting in the above manner, in the expanded region B_iThe pre-opening can be performed by untwisting the fibers while eliminating the uneven adhesion of the adhesive and the kinking of the fibers, thereby enabling the pre-opening to be performed in the opening area A_iThe fiber is uniformly dispersed, and the opening width is enlarged to a predetermined width to make the thickness uniform. And, by setting a plurality of secondary opening regions A_iAnd an expanded region B_iFormed region group S_iThe split yarn board can be processed to have a wider split width and a thinner thickness than conventional split yarn boards.

For example, in the case of collecting 12000 carbon fiber bundles, the fiber opening width is about 27mm (the basis weight is about 30 g/m)²) Even an open width of about 40mm (weight per unit area of about 20 g/m)²) The split yarn of (2) can form a split yarn sheet in which fibers are uniformly dispersed.

According to the present invention, it is possible to open a wide-width fiber sheet having an extremely small thickness as compared with the case of continuous opening as in the conventional art, and it is possible to open a wide-width fiber sheet having a high fiber dispersibility even for a fiber bundle having a large number of bundles which is difficult to open a wide-width fiber in the related art.

FIGS. 5 and 6 relate to the opening region A_jMiddle opening width W_jThe description of the drawings. As can be seen from, for example, the schematic explanatory view of fig. 1, a pair of guide members 35 are attached to both sides of the upper opening of the wind tunnel 32 along the fiber bundle conveyance direction, and the fiber opening region a is defined by the guide members 35_jMiddle opening width W_j。

When the upper opening of the air tunnel 32 has a rectangular shape as shown in fig. 1 and 5, the guide member 35 is attached in parallel to the conveyance direction. The fiber opening width W, which is the length of the wind tunnel 32 on the upstream side and the downstream side in the fiber bundle conveyance direction (wind tunnel width)_jAre of equal length.

For example, as shown in fig. 6, the wind tunnel 32 may have a shape in which the length on the downstream side in the fiber bundle conveyance direction is longer than the length on the upstream side. That is, a wind tunnel tube having a shape expanding in the transport direction may be used. At this time, the pair of guide members 35 are attached to both sides of the opening of the wind tunnel pipe so as to be enlarged in the transport direction.

In the case of fig. 6, the width WB of the tow on the downstream side in the conveying direction may be set_jIs an opening area A_jMiddle opening width W_j. However, in the calculation in the expansion region B_jAngle theta of both sides of (1) with respect to the conveying direction

tanθ＝ΔW/L_j＝(W_j-W_j-1)/2L_j

Can be the width W_jSuitable for the fiber opening area A_jWidth WP on the upstream side in the fiber bundle conveying direction_jAs the width W_j-1Suitable for the fiber opening area A_j-1Width WB of downstream side in fiber bundle conveying direction_j-1。

Fig. 7 and 8 are a schematic plan view and a schematic side view of another example of the device for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus example shown in fig. 1 and 2 are denoted by the same reference numerals, and the description thereof will be omitted.

In this apparatus example, a longitudinal vibration applying mechanism is provided downstream of the fiber opening section. The longitudinal vibration applying mechanism has a pressing roller 53 arranged between a pair of support rollers 51. The pressing roller 53 is attached to the lower end of the lifting rod 52, and the upper end of the lifting rod 52 is connected to one end of the crank 54. The other end of the crank 54 is coupled to an output shaft of a crank motor 55, and the elevating rod 52 repeats elevating operation by driving the crank motor 55 to rotate. Therefore, the pressing roller 53 moves up and down to collide with the upper surface of the opened yarn plate Ts after the upper opening of the supporting roller 51 at a predetermined cycle.

When the pressing roller 53 collides with the spread sheet Ts and the spread sheet Ts is pushed in between the support rollers 51, the tension of the spread sheet Ts is temporarily increased to generate a tension state, and when the pressing roller 53 is lifted and separated from the spread sheet Ts, the tension of the spread sheet Ts is decreased to generate a relaxation state.

The repetition of the tension state and the relaxation state of the spread sheet Ts is also transmitted to the fiber bundle Tm at the spreading portion, and the bending amount of the fiber bundle Tm at the spreading portion is changed with time. That is, in the opening section, when the fiber bundle Tm is tensioned, the bending amount of the fiber bundle Tm changes in a direction in which the bending amount decreases, and when the fiber bundle Tm relaxes, the bending amount of the fiber bundle Tm changes in a direction in which the bending amount increases. In the opening action, if the action of the fluid is periodically repeated in the direction in which the amount of bending of the fiber bundle increases and in the direction in which the amount of bending of the fiber bundle decreases, the fibers are more straight and gradually move in the width direction, and therefore, opening with a wider width and good fiber dispersibility is easily performed. That is, the fiber opening efficiency can be improved. In each opening section, if the fiber bundle is tensioned and the bending of the fiber bundle Tm disappears, the fiber bundle is easily bundled, and the opening width becomes unstable. Therefore, it is important to ensure the bending of the fiber bundle at each fiber-opening portion and stabilize the fiber-opening width by adjusting the vertical movement speed of the pressing roller 53 corresponding to the fiber bundle conveyance speed to adjust the tension state and the relaxation state of the fiber-opening sheet Ts.

The vibration applied to the split sheet Ts is also transmitted to the upstream side of the pinch roller 29. In this device example, a mechanism for removing the transmitted vibration is provided between the backup roller 25 and the pinch roller 29. As an example of the mechanism, a pair of support rollers 201 and a tension roller 202 are provided, and the tension roller 202 is arranged between the pair of support rollers 201, and is set so that the fiber bundle Tm passing through the lower side of the support rollers 201 passes through the upper side of the tension roller 202. The tension roller 202 is attached to the spring member 203, and the tension roller 202 also vibrates up and down in response to the vibration of the fiber bundle, thereby removing the vibration of the fiber bundle.

By providing the pinch roller 29, the fiber bundle is reversed due to the influence of the vibration of the tension roller 202 without affecting the fiber opening portion, and the fiber bundle is stably bent in each air tunnel.

In this apparatus example, a region from the nip roller 29 to the pulling roller 41 is set as a movable region M. The guide rollers 31 of the fiber opening part are set to be fiber opening areas A₁～A₃. The upstream side of each fiber opening region is set as an expansion region B in which the Tm of the fiber bundle is expanded so as to expand the end₁～B₃. Expanded region B₁Is set from the pinch roller 29 to the opening area A₁。

And a region group S formed by the pair of the fiber opening region and the expanding region₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

The longitudinal vibration applying mechanism may be disposed at any position as long as it is within the range of the movable region M. For example, it may be disposed in the expanded region B₁～B₃Or a splitting region A₁～A₃Any one of (1).

In this apparatus example, the longitudinal vibration applying mechanism changes the amount of bending of the fiber bundle with time in the fiber opening region. By making the rotation of the crank motor 55 constant, the amount of curvature can be changed periodically. Further, if the control is performed such that the rotation of the crank motor 55 is changed with time, the amount of curvature can be changed irregularly. The control can be correspondingly carried out according to the opening state of the fiber bundle.

As another method of changing the amount of bending of the fiber bundle in the opening region with time, for example, the amount of bending of the fiber bundle in the opening region can be changed with time by bringing an elliptical rotating body into contact with the fiber bundle Tm or the opening plate Ts and rotating the elliptical rotating body. Further, a method may be used in which the amount of bending of the fiber bundle in the fiber opening region is changed with time by changing the magnitude of the fluid flowing in each fiber opening portion with time by controlling the opening/closing amount of each flow rate adjustment valve 33 with time.

By setting the opening width of each opening region and the length of each expanded region in the transport direction in each region group as described above, the fibers are unwound and pre-opened while eliminating the uneven adhesion of the adhesive and the kinking of the fibers in the expanded regions, and the fibers can be uniformly dispersed in the opening regions, so that the opening width can be increased to a predetermined width and the thickness can be made uniform. Further, by arranging a plurality of region groups each including the splitting region and the expanding region, a splitting yarn sheet having a wider splitting width and a smaller thickness than those of the conventional art can be processed.

Fig. 9 and 10 are a schematic plan view and a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus examples shown in fig. 7 and 8 are denoted by the same reference numerals, and the description thereof will be omitted.

In this device example, a bend ensuring roller 36 is provided in an upper opening portion of the wind tunnel 32 of the fiber opening portion. The fiber bundle Tm passing through the upper side of the guide roller 31 is conveyed so as to pass through the lower side of the bend ensuring roller 36. Even if the amount of bending of the fiber bundle Tm is reduced by the longitudinal vibration applying mechanism, the fiber bundle Tm is set to be bent to a predetermined magnitude by the bending ensuring roller 36. Therefore, the fiber bundle Tm does not become linear in each split portion, and the split width of the fiber bundle is prevented from contracting. Further, if the longitudinal vibration applying mechanism reduces the amount of bending of the fiber bundle Tm and instantaneously contacts the bending ensuring roller 36, the dispersibility and straightness of the fibers in the fiber bundle are improved, and a high-quality opened state can be obtained. That is, by repeating 2 states of bending by separating the bending ensuring roller 36 when the fiber bundle Tm is in a relaxed state and bending by momentarily contacting the bending ensuring roller 36 when it is in a tensioned state, it is possible to perform opening with a wide fiber bundle and excellent fiber dispersibility.

In this device example, the opening part a is provided₃The longitudinal vibration applying means is disposed on the downstream side of the expansion region B, but the longitudinal vibration applying means may be disposed on the expansion region B₁～B₃Any one of the above.

In this device example, similarly to the device example shown in fig. 7, a group S of regions in which the opened region and the expanded region are paired is formed₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

In addition, by setting the opening width of each opening region and the length of each expanded region in the conveyance direction in each region group as described above, the fibers are unwound in the expanded regions to be subjected to pre-opening, and the fibers are uniformly dispersed in the opening regions to expand the opening width to a predetermined width and make the thickness uniform. Further, by arranging a plurality of region groups each including the splitting region and the expanding region, a splitting yarn sheet having a wider splitting width and a smaller thickness than those of the conventional art can be processed.

Fig. 11 and 12 are a schematic plan view and a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus examples shown in fig. 9 and 10 are denoted by the same reference numerals, and the description thereof will be omitted.

In this apparatus example, a longitudinal vibration applying mechanism is disposed in the fiber opening section on the most downstream side, and a pressing roller 53 is provided as the bend ensuring roller 36. That is, the bending ensuring roller 36 is vibrated in a direction orthogonal to the feeding direction of the fiber bundle, preferably in the bending direction of the fiber bundle. Thus, the fiber bundle Tm is repeatedly periodically given a tensioned state and a relaxed state in the fiber opening portion. With this action, the fiber bundle Tm can be positively bent, that is, the magnitude of the bend can be positively changed, and the fiber opening efficiency can be improved.

In this apparatus example, the pressing roller 53 of the longitudinal vibration applying mechanism is disposed in the most downstream side fiber opening portion, but the pressing roller 53 of the longitudinal vibration applying mechanism may be disposed in any other fiber opening portion. Further, the fiber may be arranged in a plurality of fiber opening portions.

In this device example as well, similarly to the device example shown in fig. 7, the group S of the opened region and the expanded region is formed as a pair₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

Fig. 13 is a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus example shown in fig. 10 are denoted by the same reference numerals, and the description thereof will be omitted.

In this apparatus example, three guide rollers 31 are provided in the fiber opening section, and the bend ensuring rollers 36 are provided between the guide rollers 31. Thus, the fiber bundle Tm is bent within 2 sections in the opening portion, and the opening is performed.

In this apparatus example, the guide rollers 31 on the most upstream side and the most downstream side are set to have the fiber opening regions therebetween, and similarly to the apparatus example shown in fig. 7, the group S of regions in which the fiber opening region and the expanding region are paired is set as the group S of regions₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

In this apparatus example, the longitudinal vibration applying mechanism is disposed downstream of the fiber opening section a3, but the longitudinal vibration applying mechanism may be disposed in any one of the expanded regions B1 to B3. As in the apparatus example of fig. 12, at least one of the bending ensuring rollers 36 in the fiber opening portion may be moved up and down by the longitudinal vibration applying mechanism, and the amount of bending of the fiber bundle in the fiber opening region may be changed with time by repeatedly applying tension and relaxation to the fiber bundle Tm.

Fig. 14 is a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus example shown in fig. 13 are denoted by the same reference numerals, and the description thereof will be omitted.

In this apparatus example, a heating mechanism 61 for ejecting hot air to and heating the fiber bundle Tm is provided corresponding to the fiber opening section. The adhesive attached to the fiber bundle Tm can be softened by heating the opened fiber bundle Tm. Therefore, the fibers are easily disentangled in the expansion region, and the fibers are uniformly dispersed in the opening region.

In this device example as well, similarly to the device example shown in fig. 13, the group S of the opened region and the expanded region which are paired is formed₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

In addition, by setting the opening width of each opening region and the length of each expanded region in the conveyance direction in each region group as described above, the fibers are unwound and pre-opened in the expanded regions, and the fibers can be uniformly dispersed in the opening regions, so that the opening width can be expanded to a predetermined width and the thickness can be made uniform. Further, by arranging a plurality of region groups each including the splitting region and the expanding region, a splitting yarn sheet having a wider splitting width and a smaller thickness than those of the conventional art can be processed.

Fig. 15 is a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus example shown in fig. 14 are denoted by the same reference numerals, and the description thereof will be omitted.

In this apparatus example, in the expansion region, a pair of contact rollers 71 are disposed along the width direction of the fiber bundle Tm on the upper side of the fiber bundle Tm, and a backup roller 72 is disposed between the contact rollers 71 on the lower side. In this apparatus example, 2 contact rollers and 1 support roller are used, but the number of the contact rollers may be arbitrary.

The contact roller 71 and the backup roller 71 may be rotatable or may be fixed. By bringing the fiber bundle Tm into contact with each roller and conveying the fiber bundle, the fiber bundle is easily broken from the fixing by the glue while being collapsed in the width direction and moved in the width direction, and as a result, pre-splitting is performed with good fiber dispersibility.

The contact roller 71 may be configured to reciprocate in the width direction of the fiber bundle Tm by a crank mechanism, not shown. When the fiber bundle Tm passes between the touch roller 71 and the backup roller 72 while contacting, the fibers of the fiber bundle Tm move in the width direction by the reciprocating movement of the touch roller 71, and thus the fibers are uniformly dispersed more efficiently.

Fig. 16 and 17 are a schematic plan view and a schematic side view of another example of the apparatus for carrying out the fiber opening method according to the present invention. In this apparatus example, a plurality of apparatus examples shown in fig. 9 and 10 are arranged in parallel, and a plurality of fiber bundles Tm are opened in parallel, whereby a plurality of opened wire plates Ts can be formed simultaneously. The same components as those of the apparatus examples shown in fig. 9 and 10 are denoted by the same reference numerals, and the description thereof will be omitted.

The fiber bundle Tm fed out from each wire feeder 11 is fed out by the nip roller 29 and is conveyed toward the aligning roller 205 by the guide roller 204. The aligning roller 205 collectively holds the plurality of fiber bundles Tm being conveyed, aligns the plurality of fiber bundles Tm on the same plane at equal intervals, and outputs the aligned fiber bundles.

The plurality of fiber bundles Tm to be output are split at 3 splitting portions in the same manner as in the apparatus examples shown in fig. 9 and 10, but the splitting portion on the most downstream side forms an upper opening portion over the entire width, and the plurality of fiber bundles Tm are collectively split. The collectively split thread plates Ts formed by the collective splitting are collectively vibrated by the pressing roller 53 of the longitudinal vibration applying mechanism and output by the take-up roller 41.

In this apparatus example, the region from the aligning roller 205 to the pulling roller 41 is set as the movable region M. The guide rollers 31 of the fiber opening part are set to be fiber opening areas A₁～A₃. The upstream side of each fiber opening region is set as an expansion region B in which the Tm of the fiber bundle is expanded so as to expand the end₁～B₃. Expanded region B₁Is set from the aligning roller 205 to the opening area A₁。

The opening on the most downstream sideAn opening region A of each fiber bundle Tm of the fiber part₃Middle opening width W₃The length of the opening section in the width direction is divided by the number of fiber bundles passing through the opening section.

And a region group S formed by the pair of the open region and the expanded region₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

Fig. 18 and 19 are a schematic plan view and a schematic side view of another example of an apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus examples shown in fig. 16 and 17 are denoted by the same reference numerals, and the description thereof will be omitted.

In this apparatus example, a widthwise vibration applying mechanism which is in sliding contact with the fibers of the spread sheet Ts in the widthwise direction is provided downstream of the longitudinal vibration applying mechanism. The widthwise vibration applying mechanism has a pair of bow bars (bow bars) 81 arranged over the entire width on the upper side of the spread sheet Ts, and a support roller 82 arranged on the lower side of the spread sheet Ts. The bow bar 81 is coupled to a crank mechanism 84, and the crank mechanism 84 is driven by a crank motor 83 to move the bow bar 81 forward and backward in the width direction of the spread sheet Ts. The arcuate strips 81 move forward and backward to come into sliding contact with the fibers of the filament-opened wire plate Ts, whereby the portions where the fibers adhere to each other can be softened and loosened, and the filament-opened wire plate Ts as a whole can be processed into a state of one sheet in which the fibers are uniformly dispersed.

At the position ofIn the device example, similarly to the device example shown in fig. 16, the group S of the opened region and the expanded region is formed as a pair₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

In addition, by setting the opening width of each opening region and the length of each expanded region in the conveyance direction in the three region groups as described above, the fibers are unwound in the expanded regions to be subjected to pre-opening, and the fibers are uniformly dispersed in the opening regions to expand the opening width to a predetermined width and make the thickness uniform. Further, by arranging a plurality of region groups each including the splitting region and the expanding region, a splitting yarn sheet having a wider splitting width and a smaller thickness than those of the conventional art can be processed.

In this apparatus example, the widthwise vibration applying mechanism is applied to a plurality of spread sheet Ts, thereby obtaining a single-width spread sheet Ts. The widthwise vibration applying mechanism may be applied to one split thread sheet Ts, and a split thread sheet Ts having excellent fiber dispersibility can be obtained.

Fig. 20 is a schematic side view of another example of the apparatus for carrying out the fiber opening method according to the present invention. The same components as those of the apparatus example shown in fig. 19 are denoted by the same reference numerals, and the description thereof will be omitted.

In this device example as well, similarly to the device example shown in fig. 18, the group S of the opened region and the expanded region which are paired is formed₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

By any of the above-described spreading methods, a spread yarn sheet having a wide and thin fiber bundle and excellent fiber dispersibility can be continuously obtained.

In the carbon fiber bundle, the number of the carbon fiber bundles is 12000 to 24000, and the fineness is 400g/1000m to 1100g/1000m, so that the spread sheet having a width of 25mm or more and a thickness of 0.04mm or less and excellent fiber dispersibility can be formed. In this case, the weight per unit area of the split cord sheet can be about 30g/m²The following.

Further, a large-fineness carbon fiber bundle having 24000 or more bundled filaments and a fineness of 1600g/1000m or more can be formed into an open fiber sheet having a width of 40mm or more and a thickness of 0.2mm or less and excellent fiber dispersibility. For example, in the case of bundling a carbon fiber bundle having 48000 carbon fibers and a fineness of 3200g/1000m, if the spreading width is 40mm, the weight per unit area of the obtained spread yarn sheet is about 80g/m². In the case of carbon fiber bundles having a number of 60000 and a fineness of 4000g/1000m, if the spreading width is set to 40mm, the weight per unit area of the obtained spread sheet is about 100g/m²。

The maximum width and the minimum thickness of the split thread sheet obtained by splitting are the same as those in the case where the fibers bundled are aligned in a row in the width direction. In the present spreading method, since the fiber bundle is gradually spread in the width direction, the spread of the fiber bundle in which the fibers are aligned in a row in the width direction can be performed as long as the fibers constituting the fiber bundle are well combed and the fibers are not twisted.

For example, in the case of a carbon fiber bundle having a single wire diameter of 0.007mm and a bundled number of 12000, an open fiber sheet having an open width of 84mm and a thickness of 0.007mm can be obtained by the present opening method.

The opening method can be applied to a fiber bundle having an increased number of bundled fibers, and therefore, in the case of a large-fineness carbon fiber bundle having a number of bundled fibers of 60000 or more, opening of a width of 40mm or more is possible, and at present, a carbon fiber bundle having a number of bundled fibers of 12000 to 24000 and having a weight per unit area of 120 to 160g/m can be obtained²The split thread board of (1).

Here, the width and thickness of the opened fiber bundle are measured in such a manner that the opened fiber bundle is in a natural state. The fiber opening width was measured using a length meter capable of measuring 1mm at the minimum, and the thickness was measured by an outside micrometer having a minimum indicated amount of 0.001mm as specified in JIS B7502 (corresponding to international standard ISO 3611).

In the measurement of the width and thickness of the split thread sheet, the measurement is not performed at only one point but performed at a plurality of points in order to confirm the continuous stability of the split thread. For example, measurement is performed at 10 sites every 10cm, 10 sites every 1m, 10 sites every 10m, or the like in the longitudinal direction. In the thickness measurement, the outer micrometer measures the thickness variation in the width direction from the end to the end in the width direction of the measured portion. For example, the thickness of a position equally divided from the end to the end a in the width direction of the measured portion is measured using a value a obtained by dividing the width of the split thread plate by the diameter of the measurement surface of the outside micrometer (a value obtained by carrying a decimal point one digit later is used if the division is not complete).

In the fiber dispersion of the opened yarn sheet, if the fibers are uniformly dispersed, the variation in thickness in the width direction is reduced. In the carbon fiber bundle, when the carbon fiber bundle with the number of bundles ranging from 12000 to 24000 and the fineness ranging from 400g/1000m to 1100g/1000m is formed into an open fiber board with the width of more than 25mm and the thickness of less than 0.04mm and good fiber dispersibility, the deviation is less than +/-0.01 mm of the average thickness. The single line diameter of the carbon fiber is 0.005-0.007 mm, so the deviation is about 1-2 carbon fibers.

In addition, when the number of the thick-fineness carbon fiber bundles with the number of the bundles being 24000 or more and the fineness being 1600g/1000m or more are formed into the open fiber sheet with the width of 40mm or more and the thickness of 0.2mm or less and the fiber dispersibility being good, the deviation is + -0.02 mm or less of the average thickness. The single line diameter of the carbon fiber is 0.005-0.007 mm, so the deviation is about 3-4.

If the splitting is performed gradually and stably, the variation in width and thickness of the split thread sheet becomes small. In the carbon fiber bundle, when the number of the carbon fiber bundles is 12000 to 24000 and the fineness is 400g/1000m to 1100g/1000m, the width is within + -10% of the average opening width and the thickness is within + -0.01 mm of the average thickness when the fiber-opening sheet with the width of more than 25mm and the thickness of less than 0.04mm is formed.

When a large-fineness carbon fiber bundle having 24000 or more bundled filaments and a fineness of 1600g/1000m or more is formed into an open fiber sheet having a fiber dispersibility of 40mm or more and 0.2mm or less in width, the width is within. + -. 10% of the average open width and the thickness is. + -. 0.02mm or less of the average thickness.

Fig. 21 is a schematic side view of a manufacturing process of the fiber-reinforced panel Ps according to the present invention. The present embodiment is an explanatory view of a process of manufacturing a fiber-reinforced sheet Ps by continuously bonding a resin adhesion stripper JRs to one surface of a wide spread-out yarn sheet Ts obtained by the apparatus example of fig. 20 and heating and pressing the sheet.

The resin adhesion stripper JRs is continuously supplied from the resin adhesion stripper supply mechanism 902 to one surface of the fiber-cut sheet Ts so that the resin surface adheres to the fiber-cut sheet Ts, and the stripper Rs is continuously supplied from the stripper supply mechanism 901 to the other surface of the fiber-cut sheet Ts, and travels over the heat and pressure roller 905, the heat and pressure plate 907, the heat and pressure roller 905, the cooling plate 908, and the cooling roller 906, thereby obtaining the fiber-reinforced sheet Ps in which the fiber-cut sheet Ts adheres to the resin or the fiber bundles of the fiber-cut sheet Ts are impregnated with the resin. In fig. 21, after traveling on the cooling roll 906, the stripper plates Rs bonded to the upper and lower surfaces of the fiber-reinforced sheet Ps are respectively wound up by the stripper plate winding mechanism 903, and the fiber-reinforced sheet Ps is bonded to the stripper plate Rs supplied from the new stripper plate supply mechanism 902 and wound up by the product winding mechanism 904.

The resin adhesion release sheet JRs is a sheet in which a resin is adhered to one surface of the release sheet Rs, and a thermosetting resin or a thermoplastic resin can be used as the adhered resin. Examples of the thermosetting resin include epoxy resins, unsaturated polyester resins, and phenol resins, and examples of the thermoplastic resin include polypropylene, polyethylene, polystyrene, polyamides (e.g., polyamide 6, polyamide 66, and polyamide 12), polyacetal, polycarbonate, acrylonitrile-butadiene-styrene copolymer (ABS), polyethylene terephthalate, polybutylene terephthalate, polyetherimide, polyethersulfone, polyphenylene sulfide, polyetherketone, and polyetheretherketone. In the case of a thermoplastic resin, two or more of the thermoplastic resins described above may be mixed and a resin forming a polymer alloy may be used.

As the release sheet Rs, release paper that is release-treated paper, a fluororesin sheet, a thermosetting polyimide resin sheet, or the like can be used.

As the adhesion state of the resin to the stripper plate Rs, there are a state in which the resin is applied to one surface of the stripper plate Rs and adheres in a plate shape, a state in which the resin in a powder form is dispersed and adhered to one surface of the stripper plate Rs, and the like.

By controlling the heating temperature of the heating and pressing roller 905, the heating plate 907, or the pressing force of the heating and pressing roller 905, a state in which resin adheres to one surface of the slit sheet Ts or a state in which the slit sheet Ts is impregnated with resin can be formed.

Here, the adhesion of the resin to the spread sheet Ts means that the spread sheet is bonded and integrated with the resin by thermally melting the resin on the entire surface or a plurality of portions of one surface or both surfaces of the spread sheet, or thinly applying and bonding an adhesive or the like which does not affect the mechanical properties or the like when the spread sheet is formed into a molded product. When the resin is thermally melted on the split thread sheet, the surface layer portion of the split thread sheet may be impregnated with a small amount of the resin, and in this case, the split thread sheet may be said to be in a state of adhesion.

Here, the impregnation of the resin into the spread sheet Ts means that the resin enters the space between the fibers constituting the spread sheet, and the fibers are integrated with the resin. The state where the resin enters substantially the entire space of the spread sheet is often referred to as impregnation, but in the present invention, the resin may be treated as impregnation even in a half-impregnated state where there is a space left.

The number of the heat pressure roller 905, the cooling roller 906, the heat flat plate 907, and the cooling flat plate 908 may be arbitrarily determined depending on the processing speed and the like. In fig. 21, the resin adhesion stripper JRs is supplied to only one surface of the spread sheet Ts, but the resin adhesion stripper JRs may be supplied to both the upper and lower surfaces, so that the fiber-reinforced board Ps having resin adhered to both the upper and lower surfaces of the spread sheet Ts, or the fiber-reinforced board Ps impregnated with resin from both the upper and lower surfaces of the spread sheet Ts, is obtained.

In this apparatus example, a region from the alignment roller 205 to the first heat pressure roller 905 is set as the movable region M. Further, similarly to the device example shown in fig. 20, a region group S in which the fiber-opening region and the expansion region are paired is formed₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

A wide-open-width thin-thickness open fiber sheet Ts having excellent fiber dispersibility obtained by the present opening method in which a plurality of open fiber sheets are arranged in a group of regions including an expanded region and an open fiber region is adhered or impregnated with a resin, thereby forming a fiber-reinforced sheet Ps having excellent drapability, i.e., uniform moldability in the width direction and thickness direction, and having few defects that cause stress concentration or the like while sufficiently exhibiting the original mechanical properties of fibers.

Fig. 22 is another schematic side view of the manufacturing process of the fiber-reinforced panel Ps according to the present invention. The present invention is an explanatory view of a process of manufacturing a fiber-reinforced sheet Ps by continuously laminating a resin sheet Js on one surface of a wide spread-out sheet Ts obtained by the apparatus example of fig. 20 and heating and pressing the laminate.

The spread sheet Ts obtained by the present spreading device travels on the reversing roller 909, is supplied to the heating and pressing roller 905, is overlapped with the resin sheet Js supplied from the resin extruding means 910, travels on two consecutive heating and pressing rollers 905 and two consecutive cooling rollers 906, and is bonded to the resin sheet Js, or a fiber-reinforced sheet Ps in which the resin sheet Js is impregnated in the fiber bundle of the spread sheet Ts is obtained. In fig. 22, the stripper plate Rs is continuously supplied from the first heating and pressing roll 905 from both sides thereof by the stripper plate supply mechanism 901, and after traveling on the last cooling roll 906, the stripper plates Rs attached to both surfaces of the fiber-reinforced plate Ps are respectively wound by the stripper plate winding mechanism 903, and the fiber-reinforced plate Ps is wound by the product winding mechanism 904.

The resin sheet Js is a sheet-like resin extruded from the resin extrusion mechanism 910, and a thermoplastic resin or the like can be used. The resin to be extruded may be a single thermoplastic resin, or may be a resin obtained by adding two or more resins and polymer-alloying them.

As the release sheet Rs, as in fig. 21, release paper that is release-treated paper, a fluororesin sheet, a thermosetting polyimide resin sheet, or the like can be used. Depending on the heating temperature conditions, the fiber-reinforced sheet Ps may be manufactured without supplying the stripper plate Rs and without the stripper plate.

By controlling the heating temperature or the pressing force of the heating and pressing roller 905, the resin sheet Js can be adhered to, i.e., bonded to, one surface of the slit sheet Ts, or the slit sheet Ts can be impregnated or semi-impregnated with resin.

The number of the heat pressure roller 905 and the cooling roller 906 may be arbitrarily determined according to the processing speed and the like.

Further, a single set of the present fiber-opening device may be provided on the opposite side of the heat and pressure roller 905 to obtain the fiber-reinforced sheet Ps in which the fiber-opening sheet Ts is adhered or impregnated on both sides of the resin sheet Js.

In this apparatus example, a region from the aligning roller 205 to the reversing roller 909 is set as a movable region M. Further, similarly to the device example shown in fig. 20, a region group S in which the fiber-opening region and the expansion region are paired is formed₁～S₃Arranged in the moving region M along the conveying direction of the fiber bundle Tm.

In the device example of fig. 21, the movable region is set by pinching the fiber bundle or the opened yarn sheet by a pair of rollers, but in the device example of fig. 22, the movable region is set by a pinch roller (a pair of rollers) and a reverse roller. The movement of the fibers of the spread sheet Ts in the width direction is restricted by making the reverse roller a roller made of an elastic material such as rubber, increasing the roller diameter to increase the contact length between the spread sheet Ts and the roller, or making the reverse roller contact the heating and pressing roller. This allows the region up to the reversing roller to be set as a movable region.

By bonding or impregnating a resin sheet to the spread sheet Ts having a wide spread width and a small thickness and having excellent fiber dispersibility obtained by the spreading method, a fiber-reinforced sheet Ps having a uniform width direction and thickness direction and excellent moldability, i.e., drapability, is formed which sufficiently exhibits the original mechanical properties of fibers and has few defects which cause stress concentration and the like.

Examples

[ example 1]

The apparatus shown in FIGS. 11 and 12 is configured such that two fiber-opening units are arranged, a longitudinal vibration applying mechanism is provided in the downstream fiber-opening unit, and a weight shown in FIG. 14 is providedThe thermal mechanism 61 is constituted by a device. Carbon fibers (トレカ T700SC-12K, manufactured by DONG レ Co., Ltd.; fiber diameter about 7 μm, number of bundles 12000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 7 mm.

Splitting area A₁Opening width W of₁Set to 16mm, opening area A₂Opening width W of₂Set to 27mm, expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 10 ° at 30 mm. The length between the guide rolls in each fiber-opening area was 20mm, the diameter of the guide roll was 6mm, and the surface was subjected to pear texturing (satin processing). The bending ensures that the roller has a diameter of 10mm and the surface is textured. The bending ensuring roller is set to be positioned at a position of 5mm below with respect to the guide roller.

The initial tension applied to the fiber bundle was set at 150g, and the fiber bundle was conveyed at a conveying speed of 5 m/min. The flow rate of the suction air flow in the fiber opening section (open state without fiber bundle) was 20 m/sec, and the temperature of the hot air blown out from the heating mechanism was 100 ℃. The number of vibrations of the longitudinal vibration applying mechanism was set to 600rpm and the stroke amount of the pressing roller was set to 10 mm. The press roll had a diameter of 10mm, and had a surface on which a pear ground pattern was formed.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split cord, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split cord is about 30g/m²。

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 25 to 27mm, and the average spreading width was about 26.5 mm. There is a deviation of-5.7% to 1.9% from the average opening width. The thickness is within the range of 0.028-0.038 mm, and the average thickness is 0.034 mm. There is a deviation of-0.006 to 0.004mm from the average thickness.

[ example 2]

According to the followingThe lower apparatus is constructed by arranging two fiber-opening units in the apparatus shown in fig. 11 and 12, providing a longitudinal vibration applying mechanism in the fiber-opening unit on the downstream side, and providing a heating mechanism 61 shown in fig. 14. Carbon fibers (パイロフイル TR50S-15K, manufactured by Mitsubishi レイヨン K., fiber diameter of about 7 μm, and number of bundles of 15000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 6 mm.

Splitting area A₁Opening width W of₁Set to 25mm, opening area A₂Opening width W of₂Set to 48mm, expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 21 ° at 30 mm. The length between the guide rolls in each fiber opening region was 20mm, the diameter of the guide roll was 6mm, and the surface of the guide roll was textured. The bending ensures that the roller has a diameter of 10mm and the surface is textured. The bending ensuring roller is set to be positioned at a position of 5mm below with respect to the guide roller.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 21g/m²。

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 44 to 48mm, and the average spreading width was about 46.6 mm. There is a deviation of-5.6% to 3.0% from the average opening width. The thickness is in the range of 0.020-0.028 mm, and the average thickness is 0.023 mm. The deviation from the average thickness is-0.003 to 0.005 mm.

[ example 3]

In example 3, the same apparatus configuration and the same carbon fiber bundle as in example 2 were used.

Splitting area A₁Opening width W of₁And an opening area A₂Opening width W of₂The same as in example 2. Expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 30 ° at 20 mm. The length between the guide rollers, the diameter of the guide rollers and the surface treatment, the diameter of the bend ensuring rollers and the surface treatment, and the position of the bend ensuring rollers in each fiber opening region were the same as in example 2.

The initial tension applied to the fiber bundle, the fiber bundle conveyance speed, the flow rate of the suction air flow in the fiber opening section, the temperature of the hot air from the heating means, the number of times of vibration by the longitudinal vibration applying means, the diameter of the press roll, the surface treatment, and the stroke amount were the same as in example 2.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 21g/m². Even when the expansion angle θ is 30 °, an open fiber sheet having excellent fiber dispersibility can be obtained.

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 42 to 48mm, and the average spreading width was about 45.7 mm. There is a deviation of-8.1% to 5.0% from the average opening width. The thickness is within the range of 0.019-0.029 m, and the average thickness is 0.024 mm. The deviation from the average thickness is-0.005 to 0.005 mm.

[ example 4]

The apparatus shown in FIG. 1 is configured such that two fiber-opening units are arranged and a heater shown in FIG. 14 is providedThe structure 61 is constructed as a device. Carbon fibers (パイロフイル TR50S-15K, manufactured by Mitsubishi レイヨン K., fiber diameter of about 7 μm, and number of bundles of 15000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 6 mm.

Splitting area A₁Opening width W of₁Set to 20mm, opening area A₂Opening width W of₂Set to 40mm, expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 11 ° at 50 mm. The length between the guide rolls in each fiber opening region was 20mm, the diameter of the guide roll was 6mm, and the surface of the guide roll was textured.

The initial tension applied to the fiber bundle was set to 100g, and the fiber bundle was conveyed at a conveying speed of 3 m/min. The flow rate of the suction air flow in the fiber opening section (open state without fiber bundle) was 30 m/sec, and the temperature of the hot air blown out from the heating mechanism was 100 ℃.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 26g/m²。

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 36 to 40mm, and the average spreading width was about 37.8 mm. There is a deviation of-4.8% to 5.8% from the average opening width. The thickness is within the range of 0.024-0.031 mm, and the average thickness is 0.028 mm. There is a deviation of-0.004 to 0.003mm from the average thickness.

[ example 5]

The apparatus shown in fig. 9 and 10 is configured by arranging two fiber opening units, providing a longitudinal vibration applying mechanism in the fiber opening unit on the downstream side, and providing a heating mechanism 61 shown in fig. 14. Carbon fibers (トレカ T700SC-24K, manufactured by DONG レ Co., Ltd.) having a fiber diameter of about 7 μm and the number of bundles24000 roots). Original width W of fiber bundle₀Is about 12 mm.

Splitting area A₁Opening width W of₁Set to 25mm, opening area A₂Opening width W of₂Set to 45mm, expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 11 ° at 50 mm. The length between the guide rolls in each fiber opening region was 20mm, the diameter of the guide roll was 6mm, and the surface of the guide roll was textured. The bending ensures that the roller has a diameter of 10mm and the surface is textured. The bending ensuring roller is set to be positioned at a position of 5mm below with respect to the guide roller.

The initial tension applied to the fiber bundle was set to 200g, and the fiber bundle was conveyed at a conveying speed of 5 m/min. The flow rate of the suction air flow in the fiber opening section (open state without fiber bundle) was 20 m/sec, and the temperature of the hot air blown out from the heating mechanism was 100 ℃. The number of vibrations of the longitudinal vibration applying mechanism was set to 600rpm and the stroke amount of the pressing roller was set to 10 mm. The press roll had a diameter of 10mm, and had a surface on which a pear ground pattern was formed.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 37g/m²。

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was 40 to 45mm, and the average spreading width was about 42.9 mm. There is a deviation of-6.8% to 4.9% from the average opening width. The thickness is within the range of 0.034-0.046 mm, and the average thickness is 0.041 mm. There is a deviation of-0.007 to 0.005mm from the average thickness.

[ example 6]

The apparatus shown in FIGS. 11 and 12 is configured such that three fiber-opening sections are arranged, and a longitudinal vibration applying mechanism is provided at the fiber-opening section on the most downstream sideThe heating means 61 shown in FIG. 14 is provided. Carbon fibers (トレカ T700SC-24K, manufactured by DONG レ Co., Ltd.; fiber diameter about 7 μm, number of bundles 24000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 12 mm.

Splitting area A₁Opening width W of₁Set to 25mm, opening area A₂Opening width W of₂Set to 45mm, opening area A₃Opening width W of₃Set to 65mm, expanded region B₂Length L in the conveying direction of₂Set to 50mm (the expansion angle theta is set to about 11 DEG), and expanded region B₃Length L in the conveying direction of₃Set to 50mm (the enlargement angle θ is set to about 11 °). The length between the guide rolls in each fiber opening region was 20mm, the diameter of the guide roll was 6mm, and the surface of the guide roll was textured. The bending ensured that the roller had a diameter of 10mm and had a pear texture on the surface. The bending ensuring roller is set to be positioned at a position of 5mm below with respect to the guide roller.

The initial tension applied to the fiber bundle was set to 200g, and the fiber bundle was conveyed at a conveying speed of 7 m/min. The flow rate of the suction air flow in the fiber opening section (open state without fiber bundle) was 20 m/sec, and the temperature of the hot air blown out from the heating mechanism was 100 ℃. The number of vibrations of the longitudinal vibration applying means was set to 800rpm and the stroke amount of the pressing roller was set to 10 mm. The press roll had a diameter of 10mm, and had a surface on which a pear ground pattern was formed.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 25g/m²。

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 58 to 65mm, and the average spreading width was about 62.3 mm. There is a deviation of-6.9% to 4.3% from the average opening width. The thickness is in the range of 0.023-0.034 mm, and the average thickness is 0.027 mm. There is a deviation of-0.004 to 0.006mm from the average thickness.

[ example 7]

The apparatus shown in fig. 11 and 12 is configured by arranging two fiber-opening sections, providing a longitudinal vibration applying mechanism in the fiber-opening section on the downstream side, and providing a heating mechanism 61 shown in fig. 14. Carbon fibers (model 50-60K, manufactured by グラフイル Co., Ltd.; fiber diameter about 7 μm, number of bundles 60000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 14 mm.

Splitting area A₁Opening width W of₁Set to 30mm, opening area A₂Opening width W of₂Set to 50mm, expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 11 ° at 50 mm. The length between the guide rolls in each fiber opening region was 20mm, the diameter of the guide roll was 6mm, and the surface of the guide roll was textured. The bending ensures that the roller has a diameter of 10mm and the surface is textured. The bending ensuring roller is set to be positioned at a position of 5mm below with respect to the guide roller.

The initial tension applied to the fiber bundle was set at 400g, and the fiber bundle was conveyed at a conveying speed of 5 m/min. The flow rate of the suction air flow in the fiber opening section (open state without fiber bundle) was 20 m/sec, and the temperature of the hot air blown out from the heating mechanism was 100 ℃. The number of vibrations of the longitudinal vibration applying mechanism was set to 600rpm and the stroke amount of the pressing roller was set to 10 mm. The press roll had a diameter of 10mm, and had a surface on which a pear ground pattern was formed.

The fiber bundle is set and fed as described above to continuously form the opened yarn sheet. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 83g/m²。

In order to confirm the continuity of the opening, the opening width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 44 to 50mm, and the average spreading width was about 47.8 mm. There is a deviation of-7.9% to 4.6% from the average opening width. The thickness is in the range of 0.081-0.102 mm, and the average thickness is 0.089 mm. There is a deviation of-0.009 to 0.013mm from the average thickness.

[ example 8]

The apparatus shown in fig. 20 is configured such that two fiber-opening units are arranged and a longitudinal vibration applying mechanism is provided at the downstream fiber-opening unit. Carbon fibers (パイロフイル TR50S-15K, manufactured by Mitsubishi レイヨン K., fiber diameter of about 7 μm, and number of bundles of 15000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 6 mm. The number of the fiber bundles was 7, and the interval between the fiber bundles was set to 48 mm.

Splitting area A₁Opening width W of₁Set to 24mm, opening area A₂Opening width W of₂Set to 48mm, expanded region B₂Length L in the conveying direction of₂The angle of enlargement θ was set to about 13 ° at 50 mm. The length between the guide rolls in each fiber opening region was 20mm, the diameter of the guide roll was 10mm, and the surface of the guide roll was textured. The bending ensures that the roller has a diameter of 10mm and the surface is textured. The bending ensuring roller is set to be positioned at a position of 5mm below with respect to the guide roller.

The initial tension applied to the fiber bundle was set at 150g, and the fiber bundle was conveyed at a conveying speed of 10 m/min. The flow rate of the suction air flow in the fiber opening section (open state without fiber bundle) was 20 m/sec, and the temperature of the hot air blown out from the heating mechanism was 100 ℃. The number of vibrations of the longitudinal vibration applying means was set to 950rpm and the stroke amount of the pressing roller was set to 10 mm. The number of vibrations of the widthwise vibration applying mechanism was set to 450rpm, and the stroke amount of the bow bar was set to 5 mm. The pressing roller has a diameter of 10mm, the arched strip has a diameter of 25mm, and the surface of the arched strip is processed with pear furrows.

The fiber bundle was set and fed as described above to continuously form a slit having a sheet width of about 340mmFiber board. In the split yarn board, the fibers are uniformly dispersed without generating gaps, and the weight per unit area of the split yarn board is about 21g/m²。

In order to confirm the continuity of the spreading, 1 of 7 spreading thread sheets was taken out and the spreading width and thickness were measured at 10 positions every 1 m. As a result, the spreading width was in the range of 46 to 50mm, and the average spreading width was about 48.3 mm. There is a deviation of-4.8% to 3.5% from the average opening width. The thickness is in the range of 0.018-0.027 mm, and the average thickness is 0.023 mm. The deviation from the average thickness is-0.005 to 0.004 mm.

[ example 9]

The apparatus shown in fig. 21 is configured such that two fiber-opening sections are arranged and a longitudinal vibration applying mechanism is provided in the downstream fiber-opening section. Carbon fibers (パイロフイル TR50S-15K, manufactured by Mitsubishi レイヨン K., fiber diameter of about 7 μm, and number of bundles of 15000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 6 mm. The number of the fiber bundles was 7, and the interval between the fiber bundles was set to 48 mm. Further, a resin-adhered release sheet having a weight per unit area of 120g/m was used²A release paper (manufactured by リンテツク Co., Ltd.) having a width of 400mm was coated with a coating amount of 20g/m in a width of 350mm²A plate formed of the epoxy resin of (1). The weight per unit area of the release paper board is 120g/m²The release paper (リンテツク K.K.).

The fiber opening area, the widening area, the guide rollers, and the bend ensuring rollers were set in the same manner as in example 8. The fiber bundle was conveyed at a speed of 5 m/min, the number of vibrations of the longitudinal vibration applying means was set to 550rpm, and the number of vibrations of the width vibration applying means was set to 300 rpm. The initial tension applied to the fiber bundle, the flow rate of the suction air flow in the fiber opening section, the temperature of the hot air blown from the heating means, the diameter of the pressing roller of the longitudinal vibration applying means, the surface treatment and stroke amount, the diameter of the bow of the width direction vibration applying means, and the surface treatment and stroke amount were the same as in example 8.

The same conditions as in example 8 were used to open 7 fiber bundles, thereby forming an opened yarn sheet having a width of about 340mm and good fiber dispersibility, and the opened yarn sheet was continuously sandwiched between the resin adhesion stripper plate and the stripper plate and was conveyed.

The temperature of the heating press roll and the heating plate was set to 120 ℃, the temperature of the cooling roll and the cooling plate were set to water cooling, the pressure per unit length of the heating press roll was set to 15kgf/cm, and the pressure per unit length of the cooling roll was set to 5 kgf/cm. After being discharged from the cooling roll, only the upper stripper plate is wound up, and the fiber-reinforced plate as a product is wound up together with the stripper plate of the resin-adhered stripper plate.

When the setting and the implementation are performed as described above, a fiber-reinforced board called a prepreg resin board impregnated with an epoxy resin is continuously formed. The fiber-reinforced plate was formed in a state where the plate width was 340mm, the fibers were uniformly dispersed, and the thickness was substantially uniform.

[ example 10]

The apparatus shown in fig. 22 is configured to have two fiber-opening sections arranged, a longitudinal vibration applying mechanism provided in the downstream fiber-opening section, a mechanism for continuously supplying a thermoplastic resin film provided in place of the resin extruding mechanism, and a series of heating and pressing roller pairs and a series of cooling roller pairs. Carbon fibers (パイロフイル TR50S-15K, manufactured by Mitsubishi レイヨン K., fiber diameter of about 7 μm, and number of bundles of 15000) were used as the fiber bundles. Original width W of fiber bundle₀Is about 6 mm. The number of the fiber bundles was 7, and the interval between the fiber bundles was set to 48 mm. A polyetherimide resin film (manufactured by Mitsubishi resin corporation) having a thickness of 15 μm and a width of 350mm was used as the thermoplastic resin film. A thermosetting polyimide resin film (product name: ユ - ピレツクス S, thickness: 25 μm, product of Utsu Kagaku K.K.) having a width of 400mm was supplied as a release sheet.

The setting of the fiber opening region, the widening region, the guide rollers, and the bend ensuring rollers was the same as in example 9. The fiber bundle was conveyed at a speed of 10 m/min, the number of vibrations of the longitudinal vibration applying means was set to 950rpm, and the number of vibrations of the width vibration applying means was set to 450 rpm. The initial tension applied to the fiber bundle, the flow rate of the suction air flow in the fiber opening section, the temperature of the hot air blown from the heating means, the diameter of the pressing roller of the longitudinal vibration applying means, the surface treatment and stroke amount, the diameter of the bow of the width direction vibration applying means, and the surface treatment and stroke amount were the same as in example 9.

The same conditions as in example 9 were used to open 7 fiber bundles to form an opened yarn sheet having a width of about 340mm and good fiber dispersibility, and the opened yarn sheet and the thermoplastic resin film were continuously overlapped and sandwiched between a mold release plate and fed to a heating and pressing roll.

The temperature of the heating press roll was set to 340 ℃, the cooling roll was set to water cooling, and the pressure per unit length of the heating press roll was set to 5 kgf/cm. After being discharged from the cooling roll, the stripper plates on both sides are wound up, and the fiber-reinforced sheet as a product is wound up.

When the above setting is performed, a fiber-reinforced sheet is formed in which the split yarn sheet and the polyetherimide resin film are continuously attached. The fiber-reinforced plate was formed so that the plate width was 340mm and the fibers were uniformly dispersed.

[ comparative example ]

In the comparative example, the same apparatus configuration and the same carbon fiber bundle as in example 2 were used.

Make the fiber opening area A₁Opening width W of₁And an opening area A₂Opening width W of₂The same as in example 2, the opening region A₁Opening width W of₁25mm, opening area A₂Opening width W of₂Is 48 mm. Expanded region B₂Length L in the conveying direction of₂Set to 15mm, enlarged angleThe degree θ is set to about 37 °. The length between the guide rollers, the diameter of the guide rollers and the surface treatment, the diameter of the bend ensuring rollers and the surface treatment, and the position of the bend ensuring rollers in each fiber opening region were the same as in example 2.

The fiber bundle is set and fed as described above to form an opened fiber sheet. In the opened yarn sheet, a portion where the dispersibility of the fibers is poor and the density of the fibers is coarse is generated, and a portion where gaps are formed between the fibers is generated in a plurality of portions.

Description of the symbols

A … fiber opening area; b … expanded area; s … regional group; tm … fiber bundle; ts … split wire board; rs … stripper plate; JRs … resin-adhered stripper plate; js … resin plate; ps … fiber reinforced board; 11 … a supply body; 12 … supply wire motor; 21 … a guide roller; 22 … feed roller; 23 … supporting rollers; 24 … feed motor; 25 … supporting rollers; 26 … tension imparting roller; 27 … upper limit position detection sensor; 28 … lower limit position detecting sensor; 29 … nip rolls; 31 … guide roller; 32 … wind tunnel tubes; 33 … flow regulating valve; 34 … getter pump; 35 … guide member; 36 … bend assurance roller; 41 … pulling rolls; 42 … traction motors; 51 … supporting rollers; 52 … lifter bar; 53 … pressing roller; 54 … crank; 55 … crank motor; 61 … heating mechanism; 71 … contact roller; 72 … supporting rollers; 81 … bows; 82 … supporting rollers; 83 … crank motor; 84 … crank mechanism; 201 … supporting rollers; 202 … tension roller; 203 … spring member; 204 … guide rollers; 205 … aligning the rollers; 901 … stripper plate supply mechanism; 902 … a resin-adhered stripper plate supply mechanism; 903 … stripper plate take-up mechanism; 904 … a product take-up mechanism; 905 … heating the pressure roller; 906 … cooling the rollers; 907 … heating the plate; 908 … cooling the plate; 909 … counter-rotating rollers; 910 … resin extrusion mechanism.

Claims

1. A method for opening a fiber bundle, in which a fiber bundle comprising a plurality of fibers is conveyed in a fiber length direction, and a fluid is passed through the fiber bundle in a movable region set so that the fibers can move in a width direction, whereby the fibers are bent and moved in the width direction to open the fiber bundle, characterized in that,

n fiber separating regions A arranged in the movable region along the conveying direction of the fiber bundle_iAnd an expanded region B_iRegion group S formed in pairs_iIn a regionGroup S_jIn the above-mentioned fiber opening region A_j-1Opening width W of_j-1The opening area A_jOpening width W of_jAnd the expanded region B_jLength L of the fiber bundle in the conveying direction_jIs set to satisfy

0<(W_j-W_j-1)/2L_j≤tan30°，

Wherein j =2, …, n,

to sequentially pass through the zone groups S_iThe fiber bundle is conveyed and opened, wherein the opening area A is_iIn the above method, the fiber bundle is bent and moved in the width direction by passing a fluid through the fiber bundle, thereby opening the fiber to an opening width W_iThe expanded region B_iAnd the opening area A_iCorrespondingly arranged at the upstream side of the conveying direction and along with the fiber opening area A_iThe widthwise movement of the fiber, the expansion region B_iWherein n.gtoreq.2 and i =1, …, n, are expanded in width in a manner that the ends are enlarged.

2. The method for opening a fiber bundle according to claim 1,

in the initial said regional group S₁In the above-mentioned fiber opening region A₁The opening width W of the fiber bundle₁Relative to the original width W of the fiber bundle₀Is set to

1<(W₁/W₀)≤5。

3. The method for opening a fiber bundle according to claim 2,

the fiber opening area A₁The opening width W of the fiber bundle₁Is set to

2≤(W₁/W₀)≤4。

4. The fiber bundle opening method according to any one of claims 1 to 3,

in a region of at least a part of the opening regions, a fluid is passed through the fiber bundle in a plurality of divided regions, thereby moving the fibers in the width direction while bending.

5. The fiber bundle opening method according to any one of claims 1 to 3,

at least one contact roller that is arranged in the width direction of the fiber bundle and that comes into contact with the fiber bundle is provided in at least a part of the expanded region, and the fiber bundle is conveyed while coming into contact with the contact roller.

6. The method for opening a fiber bundle according to claim 5,

the contact roller reciprocates in a width direction of the fiber bundle.

7. The fiber bundle opening method according to any one of claims 1 to 3,

heating the fiber bundle in a region of at least a part of the expansion region and/or the fiber opening region.

8. The fiber bundle opening method according to any one of claims 1 to 3,

in at least a part of the fiber opening region, the amount of bending of the fiber bundle is varied with time.

9. The method for opening a fiber bundle according to claim 8,

in at least a part of the fiber opening region, the fiber bundle is opened while a predetermined bending amount of the fiber bundle is secured by a bending securing roller.

10. The method for opening a fiber bundle according to claim 9,

at least one of the rollers is configured to vibrate the fiber bundle in a direction orthogonal to the conveyance direction by the bending-ensuring roller.

11. The fiber bundle opening method according to any one of claims 1 to 3,

on the upstream side of the movable region, the fiber bundle is conveyed while preventing the pull-back of the fiber bundle.

12. The fiber bundle opening method according to any one of claims 1 to 3,

vibration is applied to a split thread sheet obtained by splitting the fiber bundle in the width direction.

13. The fiber bundle opening method according to any one of claims 1 to 3,

simultaneously opening the fiber bundles while conveying the fiber bundles.

14. The method of opening a fiber bundle according to claim 13,

the plurality of split thread plates formed by splitting the plurality of fiber bundles in parallel are vibrated in the width direction, and are formed in a plate state as a whole.

15. A method for manufacturing a fiber reinforced panel, characterized in that,

a fiber-reinforced board is manufactured by forming a resin layer on one or both surfaces of a split thread board obtained by the splitting method according to any one of claims 1 to 14.

16. The method of manufacturing a fiber-reinforced panel according to claim 15,

the resin layer is formed using a resin plate.

17. A method for manufacturing a fiber reinforced panel, characterized in that,

a fiber-reinforced board is manufactured by attaching the split thread sheet obtained by the splitting method according to any one of claims 1 to 14 to both faces of a resin sheet.

18. A method for manufacturing a fiber reinforced panel, characterized in that,

a fiber-reinforced board produced by impregnating a split thread board obtained by the splitting method according to any one of claims 1 to 14 with a resin material.