JP2008238809A - Method of manufacturing laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a laminate which has good fluidity and good following-up property to complicated shape in molding, also exhibiting superior dynamic characteristic being little in dispersion and superior dimensional stability when it is made into a reinforced plastic. <P>SOLUTION: The method of manufacturing the laminate is for continuously supplying a one-directional prepreg base material wound in rolled state together with a tape-like supporter from a supply reel, pressure-bonding the prepreg base material by a roller to laminate it, and winding the remaining tape-like supporter onto the reel. The prepreg base material is cut so that it is divided into independent regions having areas ranging from 0.3 to 15,000 mm<SP>2</SP>over the whole area, by mutually adjacent cut parts to the direction of fibers and lines parallel to reinforcing fibers, and then it is pressure-bonded. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention efficiently obtains a laminate that has good fluidity and molding followability during molding, and exhibits excellent mechanical properties, low variability, and excellent dimensional stability when used as a fiber-reinforced plastic. It relates to a manufacturing method. More specifically, in a structure having a complicated shape such as a double contour curved surface or an uneven portion, to efficiently obtain a laminate that can easily form a complicated shape while minimizing the deterioration of mechanical properties. It relates to the manufacturing method.

  Fiber reinforced plastic consisting of reinforced fiber and matrix resin is attracting attention in industrial applications because it has high strength, non-elastic modulus, excellent mechanical properties, weather resistance, chemical resistance, etc. The demand is increasing year by year.

  As a molding method of fiber reinforced plastic having high functional properties, a semi-cured intermediate base material impregnated with matrix resin is laminated on continuous reinforcing fiber called prepreg, and heated and pressurized in a high temperature and high pressure kettle. Autoclave molding in which a matrix resin is cured and a fiber reinforced plastic is molded is most commonly performed. In many autoclave moldings, such as aircraft and automobiles, where large parts are manufactured, an auto tape layup machine (hereinafter referred to as ATL) or an auto fiber placement machine that automatically laminates multiple layers of prepregs in the lamination process. An automatic laminating apparatus (hereinafter referred to as AFP) is used. In particular, ATL uses a wide prepreg as compared to AFP, so that the time required for lamination is short, and it is excellent in mass productivity. A fiber reinforced plastic obtained by laminating using ATL and obtained by autoclave molding has excellent mechanical properties because the reinforced fiber is a continuous fiber. Further, since the base material can be controlled in a desired arrangement by ATL, it is possible to easily design the required mechanical characteristics, and there is little variation in the mechanical characteristics. However, on the other hand, it is difficult to form a complicated shape such as a double contour curved surface or a concavo-convex part because the reinforcing fiber is a continuous fiber. Therefore, it has been devised to follow a complicated shape by improving the pressure roller (for example, Patent Document 1) or by pressure bonding with a rubber shoe (for example, Patent Document 2). However, since the prepreg itself has poor stretchability, it is difficult to follow a complicated shape such as a double-contour curved surface or a concavo-convex portion, and it is difficult to stack, mainly to members close to a primary curved surface or a planar shape. It's real.

  As a molding method suitable for a complicated shape such as a double contour curved surface or an uneven portion, there is press molding using SMC (sheet molding compound). In this molding method, the SMC sheet which is made into a semi-cured state by impregnating a chopped strand, which is usually cut to about 25 mm, with a thermosetting matrix resin, is heated and pressed using a press. In many cases, the SMC is cut to be smaller than the shape of the molded body before pressurization and placed on the mold, and is stretched (flowed) into the shape of the molded body by pressurization. Therefore, the flow can follow complicated shapes such as a double contour curved surface and an uneven portion. However, SMC has a problem that distribution unevenness and alignment unevenness of the chopped strands are inevitably generated in the sheet forming process, so that the mechanical characteristics are lowered and the variation is increased. Furthermore, warpage, sink marks, and the like are likely to occur particularly in a thin member, which is often unsuitable as a structural material.

On the other hand, in order to fill the drawbacks of the materials as described above, a base material that can be flowed and reduced in variation in mechanical properties by cutting into a prepreg composed of continuous fibers and a thermoplastic resin is disclosed. (For example, Patent Documents 3 and 4). However, compared with SMC, the mechanical properties are greatly improved and the variation is small, but it cannot be said that the strength is sufficient for application as a structural material. Compared with the continuous fiber base material, since it has a configuration including a defect called a notch, the notch which is a stress concentration point becomes a starting point of fracture, and in particular, there is a problem that tensile strength and tensile fatigue strength are lowered. Furthermore, the thermoplastic resin prepreg with a notch is extremely inferior in handling property, and the thermoplastic prepreg is broken apart, and it is extremely difficult to industrially form and manufacture a laminate of the thermoplastic resin prepreg. There was a point.
Japanese Utility Model Publication No. 1-175817 US Pat. No. 4,601,775 Japanese Unexamined Patent Publication No. 63-247010 Japanese Patent Laid-Open No. 9-254227

  In view of the background of such prior art, the present invention has excellent fluidity and complex shape following properties at the time of molding, and excellent mechanical properties, low variation, and excellent dimensional stability when used as a fiber reinforced plastic. Provided is a production method for efficiently obtaining a laminate exhibiting properties.

The present invention employs the following means in order to solve such problems. (1) A unidirectional prepreg base material wound in a roll with a tape-shaped support is continuously supplied from a supply reel together with the tape-shaped support, and the prepreg base is pressure-bonded and laminated by a roller. A method for producing a laminate in which the remaining tape-shaped support is wound on a take-up reel, and has an area of 0.3 to 0.3 over the entire surface by a cut portion adjacent to the fiber direction and a line parallel to the fiber. as it will be divided into separate areas in the range of 15000 ^2, after cutting the prepreg base material, method for producing a laminate, characterized by crimping.

  (2) The manufacturing method of the laminated body as described in (1) which cuts a prepreg base material so that the length to the fiber direction of the said independent area | region may be 10-100 mm.

  (3) The manufacturing method of the laminated body as described in (1) or (2) which cuts a prepreg base material so that all the shapes of the said independent area | region are substantially the same, and the distribution becomes equal.

  (4) The manufacturing method of the laminated body in any one of (1)-(3) which cut | disconnects a prepreg base material so that the width | variety to the fiber orthogonal direction of the said independent area | region may be 30 micrometers-100 mm.

  (5) A prepreg base material so that the cutting direction forms an angle of 0 to 20 ° with the fiber orthogonal direction, and the independent regions adjacent to each other in the fiber orthogonal direction are shifted by 3 to 50 mm in the fiber direction. The manufacturing method of the laminated body in any one of (1)-(4) which cut | disconnects.

  (6) The manufacturing method of the laminated body in any one of (1)-(4) which cut | disconnects a prepreg base material so that the direction of the said cutting may make an angle of more than 20 degrees and 85 degrees or less with a fiber orthogonal direction.

  (7) The prepreg so that the cutting direction forms an angle of more than 20 ° and not more than 85 ° with the fiber orthogonal direction, and the line connecting the centers of gravity of the independent regions adjacent to each other in the fiber orthogonal direction is orthogonal to the fiber. The manufacturing method of the laminated body as described in (6) which cut | disconnects a base material.

  (8) Cutting the prepreg base material so that the cutting direction forms an angle of more than 20 ° and not more than 85 ° with the fiber orthogonal direction and continuously in the width direction of the prepreg base material (1) to (3 ) A method for producing a laminate according to any one of the above.

  (9) The method for producing a laminate according to any one of (1) to (8), wherein at least two layers of the prepreg base material are laminated in directions in which the orientations of fibers are different.

  (10) The manufacturing method of the laminated body in any one of (1)-(9) which cuts a prepreg base material by pressing the rotary blade roller which has arranged a plurality of blades from at least one side.

  (11) The manufacturing method of the laminated body in any one of (1)-(9) which cuts a prepreg base material by pressing the punching blade which has arrange | positioned the several blade from at least one side.

  (12) In the cutting of the prepreg base material, the tape-like support is in a continuous state so that it can be wound without being cut, and only the prepreg base material is selectively cut. The laminate according to any one of (1) to (11) Body manufacturing method.

  According to the present invention, a laminate that has good fluidity and complex shape followability at the time of molding, and exhibits excellent mechanical properties, its low variation, and excellent dimensional stability when made into a fiber reinforced plastic. Can be obtained efficiently.

  The present invention has the above-mentioned problem, good shape following property at the time of lamination using ATL, and good fluidity at the time of molding, and when made into a fiber reinforced plastic, it has excellent mechanical properties, its low variation, and excellent As a result of earnestly examining a manufacturing method for efficiently obtaining a laminate exhibiting dimensional stability, the prepreg is maintained while maintaining the tape shape of the tape-shaped unidirectional prepreg base material at a position upstream from the crimping portion of the ATL device. Reinforcing the reinforcing fibers in the base material (sometimes referred to simply as “fibers” in this specification) to a specific dimension, and continuously laminating them to solve these problems at once. Has been investigated.

  Hereinafter, it will be described in detail with reference to the drawings.

  FIG. 1 is a schematic view showing an example of an automatic laminating apparatus according to the present invention.

  FIG. 2 is a plan view showing an example of an independent region constituted by a cut portion and a line parallel to the reinforcing fiber in the present invention.

  FIG. 6 is a plan view showing an example of an independent region constituted by a cut portion and a line parallel to the reinforcing fiber in the present invention. In this example, as will be described later, the end portion of the prepreg base material corresponds to a line parallel to the reinforcing fiber.

As shown in FIG. 1, the laminate manufacturing method of the present invention includes a unidirectional prepreg base material 3 wound in a roll shape together with a tape-like support 6, and a continuous supply reel 2 together with the tape-like support 6. 2 is a method of manufacturing a laminate 8 in which the prepreg base material 3 is pressure-bonded and laminated by a roller 5 and the remaining tape-like support 6 is wound around a take-up reel 7, as shown in FIG. as the area over the entire surface by a cutting portion adjacent a line parallel to the reinforcing fibers relative to the direction it is divided into separate areas in the range of 20mm ² ~15000mm ^2, after cutting the prepreg base material, crimped Is. Here, as shown in FIG. 2, the cut portion adjacent to the fiber direction refers to the cut portions 9 and 9 ′, the line parallel to the reinforcing fibers refers to the line segments 10 and 10 ′, and the independent region is The closed region 11 surrounded by the cutting portions 9 and 9 ′ and the line segments 10 and 10 ′ is indicated. In addition, in the manufacturing method of this laminated body, as shown in FIG. 6, cut | disconnecting parts 9 and 9 'are covering the full width of a prepreg base material, and the line | wires 10 and 10' parallel to a reinforced fiber are the edge parts of a prepreg base material. It can also be.

Thus, prior to crimping by roller 5, the area over the entire surface by a 'line parallel 10, 10 and the reinforcing fibers' cuts 9,9 or less prepreg width is 0.3mm ² ~15000mm ² By cutting the prepreg base material so as to form the independent region 11 in the range, the prepreg base material is composed of short fibers while maintaining the sheet shape. When the area of the independent region is less than 0.3 mm ² , it means that the cut portions are too adjacent to each other, or the length in the fiber direction in the independent region is too short, and obtained. The fiber reinforced plastic cannot exhibit the excellent mechanical properties, its low variability, and excellent dimensional stability, which are the problems of the present invention. On the other hand, if the area of the independent region exceeds 15000 mm ² , it means that the cut portions are too far apart, or the fiber weight per independent region becomes too heavy, and good flow which is a problem of the present invention at the time of molding. Properties and molding followability cannot be expressed.

  In the present invention, the short fiber is a concept used in comparison with a fiber that is continuous over the entire length in the fiber direction (so-called unidirectional prepreg), and refers to a fiber having a length of 100 mm or less. A laminated body composed of short fibers is excellent in followability of complicated shapes such as a double contour curved surface and a concavo-convex portion because the fibers can flow in any direction in the layer at the time of molding. When laminating without cutting, that is, when all of the reinforcing fibers of the laminate are continuous fibers, it hardly flows in the fiber direction and has anisotropy in the flowable direction. It is extremely difficult to form a complicated shape such as. Furthermore, in the method of the present invention, by making the manufacturing process of the laminate as described above, it can be handled while maintaining the tape shape of the prepreg base material made of short fibers, which enables continuous manufacturing, which is very It becomes possible to produce a laminate with high production efficiency. In the present invention, the double contour curved surface refers to a shape including at least part of a double curved surface or more.

  Here, the independent area | region comprised by the cutting part adjacent with respect to the fiber direction in this invention and a line parallel to a reinforced fiber is demonstrated below using FIG. 2 and FIG. First, in FIG. 2, the cutting portions 9 and 9 ′ are obtained by cutting at least a plurality of fibers, and are represented by finite-length line segments. There is no restriction | limiting in particular as a form of a cut part, such as a straight line, a curve, or a random line. Next, the line parallel to the reinforcing fiber means the straight line 10, 10 ′ in the fiber direction starting from the end of the cut part 9 or the cut part 9 ′ adjacent to the part where the cut part is translated in the fiber direction. Represents. The straight line is an apparent line. However, since the region surrounded by the straight line and the cut portion flows as one unit at the time of molding, it is important to consider a line parallel to the reinforcing fiber. By arranging the independent region 11 formed by the straight line and the cut portion without any gap in the prepreg base material, all the reinforcing fibers are constituted by short fibers, but in the actual prepreg base material, some reinforcing fibers In some cases, swells, twists, and the like are involved, resulting in longer reinforcing fibers than desired. Therefore, in order to prevent such a problem, the independent regions may be arranged in a slightly overlapped state as shown in FIG. The range in which the independent regions overlap is preferably up to about 10% of the width of the independent regions in consideration of a decrease in physical properties when a fiber reinforced plastic is used. Next, in FIG. 6, the cut portions 9 and 9 ′ extend over the entire width of the prepreg base material and are represented by a finite-length line segment. There is no restriction | limiting in particular as a form of a cut part, such as a straight line, a curve, or a random line. Next, the line parallel to the reinforcing fiber means the straight line 10, 10 ′ in the fiber direction starting from the end of the cut part 9 or the cut part 9 ′ adjacent to the part where the cut part is translated in the fiber direction. In FIG. 6, it coincides with the end of the prepreg base material.

  Examples of the tape-like support 6 in the present invention include papers such as kraft paper and release paper, polymer films such as polyethylene and polypropylene, metal foils such as aluminum, and the like, and release properties from the matrix resin. In order to obtain it, a silicone-based or “Teflon (registered trademark)”-based release agent, metal vapor deposition, or the like may be applied to the surface. Even if the prepreg base material 3 in close contact with the tape-like support 6 is cut so as to form an independent region constituted by a cutting part having a width less than the prepreg width and a line parallel to the reinforcing fiber, As in the case of the above, it has a form-retaining property that can withstand the above-described continuous lamination method (can be handled while maintaining the sheet shape), and there is no problem that fibers fall off and fall apart during lamination. In the prepreg base material that does not have the tape-like support 6, it is difficult to perform continuous and stable lamination because the shape retention is poor as described above. The tape-like support 6 may be cut along with the prepreg base material 3 in the cutting step before pressure bonding with a roller, or may be selectively cut without cutting, only the prepreg base material.

  In particular, in this cutting process, when the prepreg base material is selectively cut so that the tape-like support can be wound up, lamination using an automatic laminating apparatus (ATL, AFP, etc.) is extremely efficient. Therefore, it can be said to be a preferable embodiment in the present invention. Specifically, the state where the tape-like support is continuous so as to be wound is that only the prepreg base material is selectively cut and the tape-like support is not cut, or the tape-like support is not cut. It refers to a state in which only a part is cut, and it is preferable that the tape-shaped support does not have a cut portion that penetrates. The effect of efficiently obtaining the laminate of the present invention is exhibited to the maximum by setting the continuous state so that it can be wound without having a cut portion through which the tape-like support penetrates.

  In the manufacturing method of the laminated body of this invention, it is preferable to cut | disconnect a prepreg base material so that the length to the fiber direction of the said independent area | region may be 10-100 mm. When the length in the fiber direction is smaller than 10 mm, the reinforcing effect by the fiber is lowered, and sufficient mechanical properties may not be obtained when a fiber reinforced plastic is obtained. It is sometimes difficult to form complex shapes due to poor fiber flow. Considering both characteristics of moldability and physical properties, a more preferable length in the fiber direction is 10 to 50 mm. However, depending on the shape of the cut portion and the industrial process, fibers shorter than 10 mm may be mixed in a part of the prepreg base material, but the fibers are substantially 95% or more of the total fiber amount. Is within the range of 10 to 100 mm, there is no problem in formability and physical properties.

  In the manufacturing method of the laminated body of this invention, it is preferable to cut | disconnect a prepreg base material so that the width | variety to the fiber orthogonal direction of the said independent area | region may be 30 micrometers-100 mm. The width in the direction perpendicular to the fiber, that is, the width of the cut portion, corresponds to the number of fibers cut by one cut portion. At the time of molding, the fiber flows with the independent region as a unit. Therefore, when the width of the cut part is larger than 100 mm, the fluidity of the fiber at the time of molding may be deteriorated because the number of fibers per independent region becomes too large. The variation in the size may also increase. Further, in the cut portion, stress concentration occurs when a load is applied to the fiber reinforced plastic, and there is a high possibility that it becomes a starting point of fracture. Therefore, the smaller width of the cut portion is advantageous in terms of strength. On the other hand, if the width is smaller than 30 μm, it may be difficult to control the cutting, and the length of the independent region in the fiber direction is ensured to a desired length. Can be difficult. Furthermore, when the width of the cut portion is smaller than 30 μm, the number of fibers per independent region becomes too small, so that the obtained fiber-reinforced plastic has excellent mechanical properties, its low variation, In addition to the difficulty of exhibiting dimensional stability, the fibers are likely to swell due to the flow during molding, and the mechanical properties of the fiber-reinforced plastic may be reduced. A more preferable width of the cutting part is preferably 2 to 100 mm from the viewpoint of improving productivity by cutting with a simple apparatus, while it is 30 μm to 2 mm from the viewpoint of obtaining particularly excellent mechanical properties. It is preferable.

  In the manufacturing method of the laminated body of this invention, it is preferable to cut | disconnect a prepreg base material so that all the shapes of the said independent area | region are substantially the same, and the distribution becomes uniform. Since the shapes of the independent regions are all substantially the same and the distribution is uniform, the flow of fibers during molding is further uniform, so that the flow of fibers is more uniform, and a fiber reinforced plastic is obtained. It is preferable because warpage in the case can be suppressed.

  Here, in the present invention, that the distribution of the independent areas is uniform means that the independent areas are periodically arranged. Especially, it is preferable that the line which tied the gravity center of arbitrary independent area | regions and the independent area | region adjacent to this independent area | region in a fiber orthogonal direction becomes a substantially straight line. Referring to FIG. 13, FIG. 13A and FIG. 13B do not satisfy the above condition, and in FIG. 13C, the line connecting the centers of gravity is substantially a straight line and satisfies the above condition.

  Examples of the cutting method in the present invention that satisfies the above conditions include the following.

  As a first example, so that the cutting direction forms an angle of 0 to 20 ° with the fiber orthogonal direction, and the independent region adjacent to the fiber orthogonal direction is shifted by 3 to 50 mm in the fiber direction, It is preferable to cut the prepreg substrate. By reducing the angle formed by the cutting direction and the direction perpendicular to the fiber, the length of one cutting portion can be shortened when the same number of fibers are cut by one cutting portion. However, in particular, when the cutting direction is the fiber orthogonal direction (the angle formed with the fiber orthogonal direction is equivalent to 0 °), if the independent regions are arranged in the fiber orthogonal direction, the cut portion is continuous in the fiber orthogonal direction. It is preferable to dispose the independent region in the fiber direction. When the length shifted in the fiber direction is shorter than 3 mm, the cut portions are connected to each other, and the handleability of the prepreg base material may be lowered. In addition, when the length of the independent region in the fiber direction is 100 mm and only one minimum value is shifted in the fiber direction, the upper limit value is 50 mm. There is no particular upper limit for the number shifted in the fiber direction. However, as the number increases, it becomes difficult to control the flow of fibers during molding, and it becomes difficult to mold a molded body as designed. is there. An example of the arrangement of the cutting satisfying the above is shown in FIG.

  As a second example, the prepreg base material is preferably cut so that the cutting direction forms an angle of 20 to 85 ° with the fiber orthogonal direction. More preferably, the cutting direction forms an angle of 20 to 85 ° with the fiber orthogonal direction, and the line connecting the centers of gravity of the independent regions adjacent to each other in the fiber orthogonal direction is substantially orthogonal to the fiber direction. It is preferable to cut the prepreg base material. As an example of the form of the prepreg base material that satisfies the above conditions, the form shown in FIG. 5 may be mentioned. When the angle between the cutting direction and the fiber orthogonal method is less than 20 °, the ends of the cutting parts arranged in the fiber orthogonal direction are too close to each other, and the cutting parts are connected to each other. It may decrease. On the other hand, when the angle exceeds 85 °, the fibers easily escape from the blade during cutting, so that it is difficult to stably cut the fibers, and the shape retention of the prepreg base material may be lowered. Furthermore, when the line connecting the centroids of the independent regions adjacent to each other in the fiber orthogonal direction is substantially orthogonal to the fiber direction, the distance between the cut portions is the largest, so that the prepreg base material is excellent in handleability. From this point of view, it is preferable to cut the prepreg base material under the above conditions.

  Moreover, the following can be illustrated as a cutting method in this invention from another viewpoint.

  It is preferable to cut the prepreg base material so that the cutting direction forms an angle of 20 to 85 ° with the fiber orthogonal direction and continuously in the width direction of the prepreg base material. As an example of the form of the prepreg base material that satisfies the above conditions, the form shown in FIG. 6 may be mentioned. When the angle formed by the cutting direction and the fiber orthogonal method is less than 20 °, it is not preferable because excessive pressure is applied to the cut portion at the time of pressure bonding, and the layer cannot be laminated well. On the other hand, when the angle exceeds 85 °, the length of the cut portion becomes long and it becomes difficult to stably cut, and the form retaining property of the prepreg base material also decreases, which is not preferable. From this point of view, it is preferable to cut the prepreg base material under the above conditions.

In the manufacturing method of the laminated body of this invention, it is preferable to laminate | stack the said prepreg base material at least 2 layers or more in the direction from which the orientation of a reinforced fiber differs. By laminating the reinforcing fibers in different directions, the dimensional stability in the case of a fiber reinforced plastic is excellent. Furthermore, the prepreg base material cut so as to form the independent region causes anisotropy in the flow between the fiber direction and the direction perpendicular to the fiber when the fiber flows during molding, so that the fiber flows effectively. For this purpose, it is important to laminate the reinforcing fibers in different directions. Among them, it is an isotropic laminate such as [0/90] _nS , [0 / ± 60] _nS , and [+ _45/0 / −45 / 90] _nS and a symmetrical laminate, so that the flow during molding is uniform. In view of the properties and warpage reduction in the case of a fiber reinforced plastic, it is preferable.

  Here, in the present invention, that the orientation of the reinforcing fibers is different means that the absolute value of the angle formed by the directions of the reinforcing fibers is 10 to 170 °.

  As a manufacturing method of the laminated body of this invention, it is preferable to cut | disconnect a prepreg base material with one of the manufacturing methods shown below.

  First, in the first manufacturing method, by pressing a rotary blade roller in which a plurality of blades are arranged at predetermined positions from at least one side, an independent region composed of lines parallel to the cut portion and the reinforcing fiber is formed. It is preferable to cut the prepreg substrate. An example of the rotary blade roller is shown in FIGS. 7, 9, 10, and 11. A rotary blade roller is one in which one or more blades are arranged on a cylindrical roller as shown in FIGS. 7B, 10 and 11B. A rubber or metal nip roller is pressed against the rotating blade roller from the opposite side, and a prepreg base material is passed between both rollers, whereby a cut portion is formed in the prepreg base material, and the independent region is It is formed. Since the rotary blade roller is a mechanism for cutting while rotating, there is no time loss due to the cutting process, and a laminate can be manufactured at a speed equivalent to that of a general tape layup machine. When cutting the prepreg base material, the prepreg base material and the tape-like support may be cut together, or only the prepreg base material may be cut by adjusting the cutting depth of the blade.

  Although there is no restriction | limiting in particular about the material of the blade edge | tip of a cutting blade, Carbide steel, diamond, and ceramics are preferable when durability etc. are considered. Although there is no restriction | limiting in particular as a magnitude | size of a cylindrical roller, When a diameter is about 50-300 mm, replacement | exchange of a blade etc. are comparatively easy, and it is preferable.

  Next, in the second manufacturing method, by pressing a punching blade in which a plurality of blades are arranged at predetermined positions from at least one side, an independent region constituted by a line parallel to the cutting portion and the reinforcing fiber is formed. It is preferable to cut the prepreg substrate. The punching blade will be described with reference to FIG. 8. A plurality of blades are arranged on a rod-shaped base. By punching the prepreg base material with air pressure or hydraulic pressure, the cutting edge is formed in the prepreg base material, and the independent region is formed. In order to prevent the prepreg base material from being caught by the punching blade when punching, the supply speed of the prepreg base material is temporarily reduced when punching, or it is temporarily stopped at the punching site and punched and advanced to the next punching site. It is necessary to devise on the conveyance such as applying a typical conveyance, but when using the punching blade, it can be cut with a small number of blades, and further, by changing the distance of the intermittent conveyance, It becomes possible to easily change the length of the independent region in the fiber direction.

  The prepreg base material in the present invention preferably has a base material width of about 10 to 1000 mm. If it is smaller than 10 mm, the supply amount of the prepreg base material is reduced and the productivity is poor, and if it is larger than 1000 mm, the apparatus becomes too large, and the degree of freedom of lamination is limited. In view of the balance between productivity and handleability, the width of the prepreg base material is more preferably about 25 mm to 500 mm.

  The matrix resin used for the prepreg substrate in the present invention may be a thermosetting resin such as an epoxy resin, a polyester resin, a vinyl ester resin, a phenol resin, or a thermoplastic resin such as polyamide, polypropylene, or polyethylene. Or a mixed resin thereof. However, since it is necessary to pressure-bond the prepreg base material at the time of lamination, a semi-cured thermosetting resin excellent in tackiness is more suitable. Among these, as such a thermosetting resin, an epoxy resin is preferable in consideration of tackiness in a process of pasting and mechanical characteristics when a fiber reinforced plastic is used.

  Carbon fibers are preferred as the reinforcing fibers used in the present invention. Carbon fiber has a low specific gravity, and has particularly excellent properties in specific strength and specific modulus, and is also excellent in heat resistance and chemical resistance. Suitable for members. Among these, PAN-based carbon fibers that can easily obtain high-strength carbon fibers are preferable.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not particularly limited thereto.

<Production of tape-shaped prepreg base material>
An epoxy resin composition was obtained by the following procedure.

  (A) Epoxy resin (“Epicoat (registered trademark)” 828: 30 parts by weight, Epicoat 1001: 35 parts by weight, Epicoat 154: 35 parts by weight) manufactured by Japan Epoxy Resin Co., Ltd., and thermoplastic resin polyvinyl formal (Chisso ( "Vinylec (registered trademark)" K) 5 parts by weight is stirred for 1 to 3 hours while heating at 150 to 190 ° C to uniformly dissolve polyvinyl formal.

  (B) After lowering the resin temperature to 55 to 65 ° C., 3.5 parts by weight of a curing agent dicyandiamide (DICY7 manufactured by Japan Epoxy Resin Co., Ltd.) and a curing accelerator 3- (3,4-dichlorophenyl) -1, 4 parts by weight of 1-dimethylurea (DCU99 manufactured by Hodogaya Chemical Co., Ltd.) was added, kneaded at the temperature for 30 to 40 minutes, and then taken out from the kneader to obtain an epoxy resin composition.

  The obtained epoxy resin composition was apply | coated on the release paper using the reverse roll coater, and the resin film was produced.

Next, two resin films are stacked on both sides of the carbon fiber on carbon fiber (tensile strength 4,900 MPa, tensile elastic modulus 235 GPa) aligned in one direction in a tape shape, heated and pressurized to impregnate the resin composition. Thus, a tape-shaped prepreg base material having a width of 305 mm, a carbon fiber basis weight of 150 g / m ² , and a resin weight fraction of 33% was produced.

<Fiber-reinforced plastic mold>
Molding evaluation was performed using a mold as shown in FIG. The center portion of the mold is provided with five uneven portions, and a rib forming groove is provided around the upper die.

<Mechanical property evaluation>
From the plate portion of the obtained fiber reinforced plastic, a test piece was obtained by cutting into a length of 250 ± 1 mm and a width of 25 ± 0.2 mm. According to the test method specified in JIS K-7073 (1998), the tensile strength was measured at a crosshead speed of 2.0 mm / min with a distance between the gauge points of 150 mm. In this example, an Instron (registered trademark) universal testing machine 4208 type was used as a testing machine. The number of test pieces measured was n = 5, and the average value was the tensile strength.

Example 1
An automatic tape lay-up machine having a structure shown in FIG. 1 having a rotary blade roller shown in FIG. The cylindrical roller 13 has a diameter of 70 mm and a length of 350 mm. In the shape shown in FIG. 7 (A), a cemented carbide blade 12 having a blade length of 15 mm and a thickness of 1 mm is spaced 15 mm in the length direction of the roller, and a circle. They were arranged at intervals of 27.4 mm in the circumferential direction. Further, carbide blades were similarly arranged at intervals of 15 mm in the length direction of the roller and 13.7 mm in the circumferential direction. Both blades protrude from the cylindrical roller 13 by 4.2 mm, and the interval between the blade edges in the circumferential direction is 30 mm. The area of the formed independent areas by a line parallel to the reinforcing fibers and the cutting portion becomes 450 mm ^2.

A 305 mm wide tape-shaped prepreg base material is hung on the prepreg base material supply reel 2, and the laminated structure is formed on a preform mold having the same shape as the lower mold 16 via a pressure roller while cutting the prepreg base material with a rotary blade. [−45 / 0 / + 45/90] 16 layers were laminated _{so as to be 2S} to obtain a laminate. The time required for lamination was 150 seconds.

  The obtained laminate was placed in a mold heated to 150 ° C. and then cured under conditions of 150 ° C. × 30 minutes to obtain a fiber reinforced plastic having uneven portions and rib portions. The fiber reinforced plastic exhibited good surface smoothness, the fibers were in line with the shape of the concavo-convex portions, no wrinkles were formed, and the fibers were filled up to the tips of the rib portions. The tensile strength of the flat plate portion cut out from the obtained laminate was 420 MPa.

(Example 2)
As the cutting insertion device 4, a laminate was obtained in the same manner as in Example 1 except that a punching blade with air pressure shown in FIG. 8 was used. There are two types: a punching blade in which a cemented carbide blade with a blade length of 15 mm and a thickness of 1 mm is arranged on a rod-shaped base at intervals of 15 mm, and a similar punching blade shifted by 15 mm in the length direction of the base. Using. The prepreg base material was cut so that the punching blades were alternately and evenly punched, and the cutting interval was 30 mm. The area of the independent region constituted by the line parallel to the cut portion and the reinforcing fiber is 450 mm ² . When punching, in order to prevent the prepreg base material from being caught by the punching blade, the prepreg base material was intermittently conveyed and cut when stopped. The time required for lamination was 300 seconds.

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, it exhibited good surface smoothness, the fibers were in the shape of the concavo-convex part, no wrinkles were formed, and the fiber was filled up to the tip of the rib part. . The tensile strength of the flat plate portion cut out from the obtained laminate was 420 MPa.

(Example 3)
A laminated body was obtained in the same manner as in Example 2 except that the carbide blade had a blade length of 21.2 mm and was arranged so as to form an angle of 45 ° with respect to the length direction of the base. The area of the independent region constituted by the line parallel to the cut portion and the reinforcing fiber is 450 mm ² . The time required for lamination was 300 seconds.

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, it exhibited good surface smoothness, the fibers were in the shape of the concavo-convex part, no wrinkles were formed, and the fiber was filled up to the tip of the rib part. . The tensile strength of the flat plate portion cut out from the obtained laminate was 340 MPa.

Example 4
A laminated body was obtained in the same manner as in Example 1 except that the shape of the carbide blade was V-shaped as shown in FIG. 9, the blade length was 20 mm, and the angle formed by the V-shaped was 98 °. The time required for lamination was 150 seconds. The area of the independent region constituted by the line parallel to the cut portion and the reinforcing fiber is 450 mm ² .

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, it exhibited good surface smoothness, the fibers were in the shape of the concavo-convex part, no wrinkles were formed, and the fiber was filled up to the tip of the rib part. . The tensile strength of the flat plate part cut out from the obtained laminate was 320 MPa.

(Example 5)
A laminated body was obtained in the same manner as in Example 1 except that a cylindrical metal shown in FIG. 10 was used as the cutting insertion device 4 and a rotary blade roller provided with a plurality of blades on the circumference was used. The blade on the rotary blade roller is provided such that the blade length is 1 mm, the angle between the blade and the circumferential direction is 10 °, and the circumferential interval is 30 mm. The area of the independent region constituted by the line parallel to the cut portion and the reinforcing fiber is 5.1 mm ² . The time required for lamination was 150 seconds.

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, it exhibited good surface smoothness, the fibers were in the shape of the concavo-convex part, no wrinkles were formed, and the fiber was filled up to the tip of the rib part. . The tensile strength of the flat plate portion cut out from the obtained laminate was 670 MPa.

(Example 6)
The shape of the cemented carbide blade is the spiral shape shown in FIG. 11 (A), and the rotating blade roller shown in FIG. 11 (B) is arranged so as to form an angle of 45 ° with respect to the fiber orthogonal direction. Similarly, a laminate was obtained. The area of the independent region constituted by the line parallel to the cut portion and the reinforcing fiber is 9150 mm ² . The time required for lamination was 150 seconds.

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, it exhibited good surface smoothness, the fibers were in the shape of the concavo-convex part, no wrinkles were formed, and the fiber was filled up to the tip of the rib part. . The tensile strength of the flat plate portion cut out from the obtained laminate was 310 MPa.

(Comparative Example 1)
A laminate was obtained in the same manner as in Example 1 except that the cutting insertion device 4 was not used. The time required for lamination was 150 seconds.

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, although the concavo-convex part was formed, the reinforcing fiber and the matrix resin were drawn into the concavo-convex part, so that the end of the fiber reinforced plastic was missing, and the edge of the concavo-convex part Since the fiber was bridged, the portion was rich in resin, wrinkles were generated in the flat portion, and the fiber was hardly filled in the rib portion. The tensile strength of the flat plate portion cut out from the obtained laminate was 800 MPa.

(Comparative Example 2)
Example 2 except that the carbide blade length was 100 mm, the two types of punching blades were shifted by 100 mm in the length direction of the base, and the prepreg base material was cut so that the cutting interval was 200 mm. A laminate was obtained. The area of the independent region constituted by the line parallel to the cut portion and the reinforcing fiber is 20000 mm ² . The time required for lamination was 300 seconds.

  As a result of molding the fiber reinforced plastic in the same manner as in Example 1, although the concavo-convex part was formed, the reinforcing fiber and the matrix resin were drawn into the concavo-convex part, so that the end part was missing, and the fiber was bridged at the edge of the concavo-convex part. Therefore, the portion was rich in resin, wrinkles were generated in the flat portion, and fibers were hardly filled in the rib portion. The tensile strength of the flat plate portion cut out from the obtained laminate was 240 MPa.

  As a use of the fiber reinforced plastic molded using the laminate obtained by the production method of the present invention, strength, rigidity, light weight is required, sports equipment such as bicycle equipment, golf shaft and head, There are automotive parts such as doors and seat frames, and mechanical parts such as robot arms. In particular, the present invention can be preferably applied to automobile parts such as a seat panel and a seat frame that require a molding followability of a complicated shape in addition to strength and light weight.

It is the schematic which shows an example of the automatic lamination apparatus in this invention. It is a top view which shows an example of the independent area | region comprised by the cut part in this invention, and the line | wire parallel to a reinforced fiber. It is a top view which shows an example of the overlap of the independent area | region comprised by the cut part in this invention and the line parallel to a reinforced fiber. It is a top view which shows an example in which the independent area | region comprised by the cut part in this invention and the line parallel to a reinforced fiber shifted | deviated only 1 in the fiber direction. It is a top view which shows an example in which the independent area | region comprised by the cut part in this invention and the line parallel to a reinforced fiber does not shift | deviate in a fiber direction. It is a top view which shows an example in which the independent area | region comprised by the cut part in this invention and the line parallel to a reinforced fiber does not shift | deviate in a fiber direction. It is the schematic which shows an example of the cutting blade shape (A) and rotary blade roller (B) in this invention. It is the schematic which shows an example of the punching blade in this invention. It is the schematic which shows an example of the cutting blade shape in this invention. It is the schematic which shows an example of the rotary blade roller in this invention. It is the schematic which shows an example of the cutting blade shape (A) and rotary blade roller (B) in this invention. It is the top view (A) and CC sectional drawing (B) of the metal mold | die which concern on one embodiment of this invention. It is explanatory drawing which shows the distribution state of the independent area | region in this invention.

Explanation of symbols

1: Automatic laminating device 2: Pre-preg base material supply reel 3: Pre-preg base material 4: Cutting insertion device 5: Pressure roller 6: Tape-like support 7: Tape-like support take-up reel 8: Laminate 9, 9 ′: Cutting section 10, 10 ': Line 11 parallel to reinforcing fiber 11: Independent region 12 constituted by cutting section and line parallel to reinforcing fiber 12: Cutting blade 13: Cylindrical roller 14: Bar-shaped base 15: Upper mold 16: Lower mold 17: Uneven portion 18: Rib forming groove 19: Center of gravity of independent region 20: Line connecting the centers of gravity of independent regions adjacent to each other in the fiber orthogonal direction

Claims (12)

A unidirectional prepreg base material wound in a roll with a tape-shaped support is continuously supplied from a supply reel together with the tape-shaped support, and the prepreg base material is pressure-bonded and laminated by a roller, and the remaining tape-shaped base A method for producing a laminate in which a support is wound on a take-up reel, wherein the area is in a range of 0.3 to 15000 mm ² over the entire surface by a cut portion adjacent to the fiber direction and a line parallel to the fiber. A method for producing a laminate, comprising: cutting a prepreg base material so as to be divided into independent regions and then crimping. The manufacturing method of the laminated body of Claim 1 which cuts a prepreg base material so that the length to the fiber direction of the said independent area | region may be 10-100 mm. The manufacturing method of the laminated body of Claim 1 or 2 which cuts a prepreg base material so that all the shapes of the said independent area | region are substantially the same, and the distribution becomes equal. The manufacturing method of the laminated body in any one of Claims 1-3 which cut | disconnects a prepreg base material so that the width | variety to the fiber orthogonal direction of the said independent area | region may be 30 micrometers-100 mm. The prepreg base material is cut so that the cutting direction forms an angle of 0 to 20 ° with the fiber orthogonal direction, and the independent regions adjacent to each other in the fiber orthogonal direction are shifted by 3 to 50 mm in the fiber direction. The manufacturing method of the laminated body in any one of Claims 1-4. The manufacturing method of the laminated body in any one of Claims 1-4 which cut | disconnect a prepreg base material so that the direction of the said cutting may make an angle of more than 20 degrees and 85 degrees or less with a fiber orthogonal direction. The prepreg base material is arranged so that the cutting direction forms an angle of more than 20 ° and not more than 85 ° with the fiber orthogonal direction, and the line connecting the centers of gravity of the independent regions adjacent to each other in the fiber orthogonal direction is orthogonal to the fiber. The manufacturing method of the laminated body of Claim 6 cut | disconnected. The prepreg substrate is cut in such a manner that the cutting direction forms an angle of more than 20 ° and not more than 85 ° with the direction perpendicular to the fiber and continuously in the width direction of the prepreg substrate. The manufacturing method of the laminated body. The manufacturing method of the laminated body in any one of Claims 1-8 which laminates | stacks the said prepreg base material at least 2 layers or more in the direction from which the orientation of a fiber differs. The manufacturing method of the laminated body in any one of Claims 1-9 which cut | disconnects a prepreg base material by pressing the rotary blade roller which has arrange | positioned the several blade from at least one side. The manufacturing method of the laminated body in any one of Claims 1-9 which cut | disconnect a prepreg base material by pressing the punching blade which has arrange | positioned several blades from at least one side. The method for producing a laminate according to any one of claims 1 to 11, wherein in cutting the prepreg base material, the tape-like support is in a continuous state so as to be wound without being cut, and only the prepreg base material is selectively cut.

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