JP2010023359A - Method of manufacturing laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a laminate which exerts good fluidity and complicate shape-followability in molding and excellent mechanical characteristics with low variation and excellent dimensional stability when used as a fiber-reinforced plastic. <P>SOLUTION: The method comprises cutting entirely a unidirectional prepreg substrate composed of a reinforcing fiber and a matrix resin to obtain a cut prepreg substrate, winding up the cut prepreg substrate, together with a tapered support, in a roll form, supplying both the wound cut prepreg substrate and the wound tapered support continuously from a feeding reel, pressingly sticking the cut prepreg substrate by a roller to laminate and winding, on a reel, the tapered support separated from the cut prepreg substrate. Substantially the whole of the reinforcing fiber constituting the cut prepreg substrate to be delivered to the feeding reel is in a cut form with lengths L in the fiber direction of 10-100 mm. <P>COPYRIGHT: (C)2010,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 specific properties, high specific 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 (for example, Patent Document 1). In particular, ATL uses a wider prepreg than 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, this method mainly manufactures large curved members such as skin portions in aircrafts and rockets, and it is difficult to form complicated shapes such as double contour curved surfaces and uneven portions with reinforcing fibers in which continuous fibers are aligned. Therefore, by improving the pressure roller (for example, Patent Document 2), pressure bonding with a rubber shoe (for example, Patent Document 3), or increasing the movable shaft of the laminated head (for example, Patent Document 4), it is complicated. It has been devised to follow the shape. 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 5 and 6). 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 to a 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 there is a problem that particularly tensile strength and tensile fatigue strength are lowered. Furthermore, the thermoplastic resin prepreg with notches is extremely inferior in handling, and the thermoplastic prepreg becomes disjointed, making it extremely difficult to industrially form and manufacture a laminate of thermoplastic resin prepregs. was there.
US Pat. No. 6,096,164 Japanese Utility Model Publication No. 1-175817 US Pat. No. 4,601,775 US Pat. No. 5,431,749 Japanese Unexamined Patent Publication No. 63-247010 JP 9-254227 A

  The present invention has a good fluidity and a complicated shape followability at the time of molding in view of the background in which it was difficult to achieve both complex shape formation and low variation, sufficient strength, and handling in the prior art, When a fiber reinforced plastic is used, a production method for efficiently obtaining a laminate exhibiting excellent mechanical properties, low variability, and excellent dimensional stability is provided.

In order to solve the above problems, the present invention has the following configuration. That is,
(1) The notched prepreg base material obtained by cutting a unidirectional prepreg base material composed of reinforcing fibers and a matrix resin over the entire surface is wound into a roll together with a tape-shaped support and wound up. The prepreg base material and the tape-like support are continuously supplied from a supply reel, and the cut prepreg base material is pressure-bonded and laminated by a roller, and the tape-like support is separated from the cut prepreg base material. Is a method for manufacturing a laminate in which a reel is wound around a reel, and substantially all of the reinforcing fibers constituting the cut prepreg base material disposed on the supply reel have a length L in the fiber direction of 10 to 100 mm. The manufacturing method of the laminated body currently cut | disconnected by.

  (2) Substantially all the reinforcing fibers of the cut prepreg base material arranged on the supply reel are cut within an absolute value of the angle Θ between the cut and the fiber direction within a range of 2 to 25 °. The manufacturing method of the laminated body as described in (1).

  (3) The projection length Ws obtained by projecting the cuts in the vertical direction of the reinforcing fibers is within a range of 0.1 mm to 1.5 mm for substantially all the reinforcing fibers of the cut prepreg base material arranged on the supply reel. The manufacturing method of the laminated body as described in (1) or (2) cut | disconnected.

  (4) The manufacturing method of the laminated body in any one of (1)-(3) which laminate | stacks the said cut prepreg base material at least 2 layers or more in the direction from which the orientation of a reinforced fiber differs.

  (5) Substantially all the reinforcing fibers of the cut prepreg base material are cut by pressing a rotary blade roller on which at least one blade is disposed from at least one side (1) to (4) The manufacturing method of the laminated body in any one.

  (6) Substantially all the reinforcing fibers of the cut prepreg base material are cut by pressing a punching blade on which at least one blade is disposed from at least one side, (1) to (4) The manufacturing method of the laminated body of crab.

  (7) When cutting a unidirectional prepreg base material composed of reinforcing fibers and a matrix resin over the entire surface, only the reinforcing fibers of the prepreg base material are cut while maintaining the tape-like support in a continuous state. The manufacturing method of the laminated body in any one of 1)-(6).

  According to the present invention, at the time of molding, it has good fluidity and complex shape following ability to form a complex shape such as a double contour curved surface and an uneven portion, and when it is made into a fiber reinforced plastic, it has excellent mechanical properties, A laminate exhibiting low variation and excellent dimensional stability can be obtained with good handling and very efficiency.

  The present invention will be described in detail. The present invention has a good shape following property at the time of lamination and a good fluidity at the time of molding, and when made into a fiber reinforced plastic, it is a laminated material that exhibits excellent mechanical properties, its low variation, and excellent dimensional stability. As a result of earnestly examining the manufacturing method for efficiently obtaining the body using ATL, the reinforcing fiber in the prepreg base material (in the present specification, while maintaining the tape shape of the tape-shaped unidirectional prepreg base material) , Which may be simply referred to as “fiber”), was cut in advance to a specific size from the ATL supply reel, and continuously stacked and laminated, and it was found that this problem could be solved all at once. Is. Hereinafter, it will be described in detail with reference to the drawings.

  FIG. 1 is a schematic view showing an example of an apparatus for cutting reinforcing fibers of a unidirectional prepreg base material to a specific size in the present invention. FIG. 2 is a schematic view showing an example of an automatic laminating apparatus according to the present invention. FIG. 4 is a schematic plan view showing an example of a cutting pattern of the cutting prepreg base material in the present invention.

  As shown in FIG. 1, the laminate manufacturing method of the present invention cuts a unidirectional prepreg base material 3 made of reinforcing fibers and a matrix resin over the entire surface by a cutting insertion device 5, together with a tape-like support 4. As shown in FIG. 2, the cut prepreg base material 3 ′ wound up in a roll shape is continuously supplied from the supply reel 9 together with the tape-like support 4, and the cut prepreg base material 3 ′ is fed by the roller 10. A method for producing a laminate 12 in which a tape-like support 4 separated from the cut prepreg base material 3 ′ is wound around a take-up reel 11, and the cut prepreg base material 3 ′, As shown in FIG. 4, the cut fiber 13 cuts the reinforced fibers of the cut prepreg base material so that the length L in the fiber direction (hereinafter sometimes referred to as fiber length) is 10 to 100 mm. is being done Preferred. In the present invention, “substantially all the reinforcing fibers are divided by the incision” means that the area where the continuous fibers not divided by the incision of the present invention are aligned is the prepreg base material area. It is less than 5% of the proportion.

  As shown in FIG. 4, the reinforcing fibers 17 are cut by the notches 13, and the continuous reinforcing fibers are divided into short fibers. The laminated body obtained by laminating the cut prepreg base material composed of the short fibers allows the fibers to flow in any direction within the layer at the time of molding, so a complex shape such as a double contour curved surface or uneven portions It is excellent in following ability. 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. When supplying the unprepared prepreg from a supply reel, that is, when all the reinforcing fibers of the laminate are composed of continuous fibers, there is little flow in the fiber direction, and there is anisotropy in the flowable direction. For this reason, it is extremely difficult to form a complicated shape such as a quadratic curved surface or an uneven portion. In the present invention, the “short fiber” is a concept used in contrast to the case where the fiber is continuous over the entire length in the fiber direction (so-called unidirectional prepreg), and the fiber length L is 100 mm or less. Point to. Further, the “double contour curved surface” refers to a shape including at least a part of a double curved surface or more.

  Here, when the fiber length L is smaller than 10 mm, although the fluidity is improved, the reinforcing effect by the fiber is lowered, and sufficient mechanical properties may not be obtained when the fiber reinforced plastic is obtained. On the other hand, when the fiber length L is larger than 100 mm, the flow of the fiber during molding becomes worse and it becomes difficult to form a complicated shape. Considering both characteristics of moldability and physical properties, the fiber length L is more preferably in the range of 20 to 60 mm. However, depending on the shape of the cut part and the industrial process, fibers shorter than 10 mm may be mixed in a part of the cut prepreg base material, but substantially 95% or more of the total fiber amount. If the fiber is within the range of 10 to 100 mm, there is no problem in moldability and physical properties.

  In the present invention, the reinforcing fiber of the cut prepreg base material disposed on the supply reel has an absolute value of an angle Θ (hereinafter also referred to as a cut angle) formed by the cut 13 and the fiber direction 14 shown in FIG. Is preferably cut within a range of 2 to 25 °. Even if the absolute value of Θ is larger than 25 °, fluidity can be obtained, and higher mechanical properties can be obtained as compared with conventional SMC, etc., but in particular, when the absolute value of Θ is 25 ° or less. Significant improvement in mechanical properties. On the other hand, if the absolute value of Θ is smaller than 2 °, sufficient fluidity and mechanical properties can be obtained, but it is difficult to make a stable cut. That is, when the incision lies on the fiber, the fiber easily escapes from the blade when making the incision, and the proportion of uncut fibers present in the prepreg base material increases. Moreover, in order to make the fiber length L 100 mm or less, when the absolute value of Θ is smaller than 2 °, production stability is lacking, such as at least the shortest distance between notches being smaller than 0.9 mm. In addition, when the distance between the cuts is small as described above, there is a problem that handling at the time of stacking becomes difficult. In view of the relationship between the ease of controlling the cutting and the mechanical characteristics, it is more preferably in the range of 5 to 15 °. Note that Θ in the present invention means that when an arbitrary point on the cut is a point X, if the angle formed by the fiber longitudinal direction and the cut at the point X is θ (X), Θ is θ (X ) Is the average value on the notch, that is, the value given by (Equation 1). Here, as shown in FIG. 3, the end points of the incision 13 are point A and point B, respectively, the points A and B are connected, the curve along the incision is C, and the curve C at the point X is The minute line segment is ds.

  Hereinafter, an example of the preferable cutting pattern in the said cutting prepreg base material is demonstrated using FIGS.

  A plurality of controlled and aligned cuts 13 are formed on a prepreg base material in which reinforcing fibers are aligned in one direction. The fibers are divided at the notches 13 that form pairs in the fiber orientation direction, and by setting the interval 18 to 10 to 100 mm, substantially all the reinforcing fibers on the prepreg base material have a fiber length L of 10 to 100 mm. can do. As shown in FIG. 3, if the angle 15 between the cut and the reinforcing fiber is Θ, the absolute value of Θ is in the range of 2 to 25 ° over the entire surface. FIG. 5a) shows an example in which the absolute value of Θ is 90 ° and b) exceeds 25 °. However, in these examples, the high intensity obtainable by the present invention cannot be expressed.

  FIG. 6 shows a prepreg substrate having five different cutting patterns. The cut prepreg substrate 3 ′ of FIG. 6 a) has skewed continuous, straight cuts 13 b arranged at equal intervals. The cut prepreg substrate 3 ′ of FIG. 6 b) has skewed continuous and straight cuts 13 b arranged at two intervals. The cut prepreg substrate 3 ′ of FIG. 6 c) has continuous, curved (meandering) cuts 13 arranged at equal intervals. The cut prepreg base material 3 ′ in FIG. 6 d) has intermittent linear cuts 13 a arranged at equal intervals and skewed in two different directions. The cut prepreg base material 3 ′ of FIG. 6 e) has skewed intermittent straight cuts 13 a arranged at equal intervals. The incision may be a curved line as shown in FIG. 6c), but a straight line as shown in FIGS. 6a), b), d), and e) is preferable because the flowability is easily controlled. Further, the length L of the reinforcing fiber divided by the cut may not be constant as shown in FIG. 6b), but if the fiber length L is constant over the entire surface, the fluidity can be easily controlled and the strength varies. Can be further suppressed, which is preferable. Here, the prescribed linear shape means a state in which a part of a geometrical straight line is formed. However, as long as the effect of facilitating the fluidity control is not impaired, Even if there is a portion that does not form a part of the straight line, there is no problem. As a result, even if there is a portion where the fiber length L is not constant over the entire surface (in this case, the fiber length L is substantially over the entire surface). It can be said that it is constant).

  As a more preferable example [1], it is preferable that the cuts 13 are continuously formed as shown in FIGS. In the pattern of Example [1], since the cut 13b is not intermittent, the flow turbulence does not occur near the cut end, and all the fiber lengths L are constant in the region where the cut 13b is made. The flow is stable. In order to prevent the cut prepreg base material 3 'from falling apart because the cuts 13b are continuously formed, a region where the cut is not connected to the peripheral portion of the cut prepreg base material is provided. Or by gripping with a support such as a sheet-like release paper or film that is not cut, the handling property can be improved.

  Further, as another preferable example [2], as shown in FIG. 4, when Ws is a length 19 obtained by projecting the cut in the vertical direction of the reinforcing fiber, Ws is intermittent within a range of 30 μm to 100 mm. The notch 13a is provided on the entire surface of the notched prepreg base material 3 ′, and the notch 13a1 and the notch 13a2 adjacent to the notch 13a1 in the fiber orientation direction may have the same geometric shape. Here, “projection length Ws obtained by projecting the cut in the vertical direction of the reinforcing fiber” means that the vertical direction of the reinforcing fiber (fiber orthogonal direction 16) is the cut in the plane of the prepreg layer as shown in FIG. The projection plane refers to the length 19 when projected from the notch perpendicularly to the projection plane (fiber orientation direction 14). When Ws is 30 μm or less, it is difficult to control the cutting, and it is difficult to ensure that the fiber length L is 10 to 100 mm over the entire surface of the cut prepreg substrate. That is, there is a problem that if there is a fiber that has not been cut by cutting, the fluidity of the base material is remarkably lowered, and if it is cut excessively, a portion where L is less than 10 mm appears. Conversely, when Ws is greater than 10 mm, the strength is almost constant. That is, when the fiber bundle end becomes larger than a certain value, the load at which breakage starts becomes substantially equal. FIG. 4 shows an example in which both L and Ws are one type. Any of the cuts 13a (for example, 13a1) has another cut 13a (for example, 13a2) that is overlapped by translation in the fiber direction. The fiber length can be stably increased by the presence of a width in which the fibers are divided by adjacent cuts at a fiber length shorter than the fiber length L divided by the cuts 13a that form pairs in the fiber direction. The cut prepreg base material 3 ′ can be manufactured with a thickness of 100 mm or less. In the pattern of Example [2], when the obtained cut prepreg base material 3 ′ is laminated, the cut is intermittent, and thus the handleability is excellent. 6D) and 6E) also illustrate other patterns, but any pattern may be used as long as the above conditions are satisfied.

  In the preferred example [2], the length Ws projected in the vertical direction of the reinforcing fiber is preferably in the range of 0.1 mm to 1.5 mm from the viewpoint of mechanical properties. By reducing Ws, the amount of fibers cut by each cutting is reduced, and strength improvement is expected. In particular, when Ws is 1.5 mm or less, a great improvement in strength is expected. In addition, the longer the cut length, the easier it is for the base material notches to open during the laminating operation, and the handleability of the base material is greatly reduced. If the cut is 1.5 mm or less, the cut is less likely to open during the laminating operation, and a cut prepreg base material with good substrate handling properties is obtained. In the present invention, when the absolute value of the cutting angle Θ is 2 to 25 °, the projection length Ws can be reduced with respect to the cutting length. Therefore, even if it is the minimum notch | incision whose Ws is 1.5 mm or less, it becomes possible to provide industrially stably. Further, when the cutting is inserted into the prepreg base material by pressing the blade, the reinforcing fiber may meander in the direction perpendicular to the fiber at the time of cutting and escape from the blade, so that the fiber may not be cut well. In order to reduce the influence of such fiber escape, Ws is preferably 0.1 mm or more. More preferably, by setting Ws to 0.2 mm or more, it becomes possible to insert the cut into the prepreg base material without leaving more continuous fibers.

  The characteristics of the cut prepreg base material used in the present invention will be described with reference to FIGS. As a comparison of the present invention, FIG. 7 shows a laminated body 20 in which a cut prepreg base material 3 ′ whose absolute value of an angle Θ between the cut 13 and the reinforcing fiber 17 is 90 ° is laminated a), and the laminated body 20. The fiber reinforced plastic 21 formed from the above is shown in b), a plan view in which the layers derived from the cut prepreg base material 3 ′ are respectively close-up, and a cross-sectional view in which the AA cross section of the plan view is cut out. As shown in a), the cut prepreg base material 3 ′ is provided with cuts perpendicular to the fibers on the entire surface, and the cuts 13 penetrate the thickness direction of the layers. By setting the fiber length L to 100 mm or less, fluidity is ensured, and the fiber reinforced plastic 21 whose area is easily extended from the laminate 20 can be easily obtained by press molding or the like (however, the thickness is reduced). When the elongated fiber reinforced plastic 21 is obtained as in b), the short fiber layer 22 derived from the cut prepreg base material 3 ′ extends in the direction perpendicular to the fiber and has no fiber (cut opening). ) 23 is generated. This is because the reinforcing fiber generally does not expand at a molding pressure, and in the case of FIG. 7, the cut opening 23 is generated for the extended length, for example, 250 × 250 mm laminates 20 to 300 are formed. When the fiber reinforced plastic 21 of × 300 mm was obtained, the total area of the cut openings 23 was 50 × 300 mm, that is, 1/6 (about 16.7 (about 16.7) with respect to the surface area of the fiber reinforced plastic 21 of 300 × 300 mm. %) Is the calculation for the cut opening. As shown in the cross-sectional view, the region 23 is occupied by the adjacent layer 25 and the region where the resin rich portion 26 and the adjacent layer 25 have intruded. Therefore, when the laminated body 20 using the cut prepreg base material 3 ′ is stretched and formed, the undulation 27 of the layer and the resin rich portion 26 are generated at the fiber bundle end portion 24, which deteriorates the mechanical properties and the surface quality. Will affect the decline. In addition, since the rigidity is different between the part where the fiber is present and the part where the fiber is not present, the fiber reinforced plastic 21 is in-plane anisotropic, and design is difficult due to problems such as warping. Further, in terms of strength, fibers oriented to about ± 10 ° or less from the load direction transmit most of the load, but at the fiber bundle end 24, the load must be redistributed to the adjacent layer 25. Don't be. At that time, as shown in FIG. 7b), when the fiber bundle end 24 is perpendicular to the load direction, stress concentration is likely to occur, and peeling is also likely to occur. Therefore, the strength improvement cannot be expected so much.

  On the other hand, FIG. 8 shows a laminated body 20 in which the cut prepreg base material 3 ′ of the preferred example [1] of the present invention is laminated in a), and a fiber reinforced plastic 21 in which the laminated body 20 is molded in b). The top view which cut up the layer derived from the notch prepreg base material 3 ', and the sectional view which cut out the AA cross section of the top view were shown. As shown in a), the cut prepreg base material 3 ′ is provided with continuous cuts 13 b having an absolute value of the angle Θ between the fibers 17 of 25 ° or less on the entire surface, and the cuts 13 b are in the layer thickness direction. Through. By setting the fiber length L to 100 mm or less, fluidity is ensured, and the fiber-reinforced plastic 21 whose area is easily extended from the laminate 20 can be obtained by press molding or the like. When the stretched fiber reinforced plastic 21 is obtained as in b), the short fiber layer 22 derived from the cut prepreg base material 3 ′ stretches in the direction perpendicular to the fiber, and the fiber 17 itself rotates 28 to stretch. As shown in FIG. 7, the area (cut opening) 23 where no fiber is present is not substantially generated, and the area of the cut opening existing on the layer surface is compared with the surface area of the layer. It is in the range of 0.1 to 10%. Therefore, as can be seen from the sectional view, the adjacent layer 25 does not enter, and the high-strength and high-quality fiber-reinforced plastic 21 without the layer swell 27 and the resin rich portion 26 can be obtained. Since the fibers 17 are arranged all over the surface, there is no difference in rigidity in the surface, and the design can be easily applied as in the conventional continuous fiber reinforced plastic. The revolutionary effect that this fiber rotates and stretches to obtain a fiber-reinforced plastic having no layer waviness is that the absolute value of the angle Θ between the cut and the reinforcing fiber is 25 ° or less, and the cut is It can be obtained for the first time by being put continuously. Further, in terms of strength, when attention is paid to the fibers oriented to about ± 10 ° or less from the load direction as described above, the fiber bundle end portion 24 lies down with respect to the load direction as shown in FIG. I can see the situation. Since the fiber bundle end portion 24 is slanted in the layer thickness direction, the load is smoothly transmitted, and peeling from the fiber bundle end portion 24 hardly occurs. Therefore, a marked improvement in strength is expected compared to FIG. The fiber bundle end 24 is inclined in the layer thickness direction because when the fiber 17 rotates 28, there is a gentle distribution in the rotation 28 of the fiber 17 from the upper surface to the lower surface due to friction between the upper surface and the lower surface. Therefore, it is considered that the presence distribution of the fibers 17 occurs in the layer thickness direction, and the fiber bundle end portion 24 is inclined in the layer thickness direction. In such a layer of the fiber reinforced plastic 21, an oblique fiber bundle end portion is formed in the layer thickness direction and the strength is remarkably improved, and the absolute value of the angle Θ formed with the fiber 17 of the cut 13b is 25. It can be obtained for the first time when it is below °.

  In FIG. 9, the laminated body 20 in which the cut prepreg base material 3 ′ of the preferable example [2] of the present invention is laminated is cut into a), and the fiber reinforced plastic 21 formed with the laminated body 20 is cut into b). The top view which closed up the layer derived from the prepreg base material 3 'was shown. As shown in a), the cut prepreg base material 3 ′ is provided with intermittent cuts 13 a having an absolute value of the angle Θ between the fibers 17 of 25 ° or less, and the cut 13 a is a layer thickness. It penetrates the direction. A fiber reinforced plastic having a flow length ensured to be 100 mm or less over the entire surface of the cut prepreg base material 3 ′ by the cut 13a, and fluidity is ensured, and the area is easily extended from the laminate 20 by press molding or the like. 21 can be obtained. By reducing the cut length and the cut angle, the projection length Ws obtained by projecting the cut in the vertical direction of the reinforcing fiber can be made 1.5 mm or less. When the stretched fiber reinforced plastic 21 is obtained as in b), the short fiber layer 22 derived from the cut prepreg base material 3 'does not stretch in the fiber direction when stretched in the fiber vertical direction. Is generated, but the adjacent short fiber group flows in the direction perpendicular to the fiber, thereby filling the cut opening 23 and reducing the area of the cut opening 23. . This tendency becomes particularly remarkable when the projected length Ws obtained by projecting the cut in the vertical direction of the reinforcing fiber is 1.5 mm or less, and the cut opening 23 is not substantially generated and exists on the layer surface. The area of the cut opening can be in the range of 0.1 to 10% compared to the surface area of the layer. Accordingly, the adjacent layer 25 does not penetrate in the thickness direction, and the high-strength and high-quality fiber-reinforced plastic 21 without the layer swell 27 and the resin-rich portion 26 can be obtained. Since the fibers 17 are arranged all over the surface, there is no difference in rigidity in the surface, and the design can be easily applied as in the conventional continuous fiber reinforced plastic. The epoch-making effect of filling the notch opening with the flow in the direction perpendicular to the fiber to obtain a fiber-reinforced plastic without layer waviness is that the absolute value of the notch angle Θ is 25 ° or less and the notch is made of the reinforcing fiber. It can be obtained for the first time when the projection length Ws projected in the vertical direction is 1.5 mm or less. More preferably, when Ws is 1 mm or less, higher strength and higher quality can be achieved.

In the manufacturing method of the laminated body of this invention, it is preferable to laminate | stack the said cut prepreg base material at least 2 layers or more in the direction where 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 in which the reinforcing fiber is cut by the incision causes anisotropy in the flow between the fiber direction and the fiber orthogonal direction when the fiber flows during molding, so that the fiber can flow effectively. For this, 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, “the orientation of the reinforcing fibers is different” in the present invention means that the absolute value of the angle formed by the directions of the reinforcing fibers is 10 to 170 °.

  It is preferable that the manufacturing method of the laminated body of this invention is performed using the cutting prepreg base material obtained by cut | disconnecting a prepreg base material by one of the methods shown below.

  First, as the method [1], by pressing a rotary blade roller having at least one blade arranged at a predetermined position from at least one side, substantially all the reinforcing fibers of the prepreg base material are length L in the fiber direction. Is preferably cut so as to be 10 to 100 mm. As the rotary blade roller, for example, one in which one or a plurality of cutting blades 29 are arranged on a cylindrical roller 30 as shown in FIGS. 10 and 11 is preferably used. Here, the rotary blade roller 31 may cut out the blade (sharp convex portion) directly from a cylindrical metal roller, or may be a curved plate mounted on the roller. I do not care. A rotary blade roller obtained by directly cutting a blade from a cylindrical metal roller is preferable because it is expensive but has excellent durability. On the other hand, the rotating blade roller mounted on the roller by curving the flat plate on which the blade is arranged is inferior in terms of durability compared to the one obtained by directly cutting the blade from a metal roller, but is inexpensive and excellent in cost. It is preferable because the cutting pattern can be easily changed.

  In the present invention, a rubber or metal nip roller is pressed from the opposite side with respect to the rotary blade roller, and a notch is inserted into the prepreg substrate by passing the prepreg substrate between both rollers. Virtually all reinforcing fibers are cut. Since the rotary blade roller is a mechanism that cuts while rotating, it can be cut continuously and the cutting process can be carried out efficiently. 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, as the method [2], by pressing a punching blade having at least one blade disposed at a predetermined position from at least one side, substantially all the reinforcing fibers of the prepreg base material have a length L in the fiber direction. Is preferably cut so as to be 10 to 100 mm. As the punching blade, for example, a blade in which a plurality of cutting blades 29 are arranged on a flat base 39 as shown in FIG. 13 is preferably used. Here, the punching blade may be one obtained by directly cutting a blade from a metal plate, or may be one in which the blade is directly embedded in a flat base such as metal or veneer. What cut | disconnected the blade directly from the metal plate is preferable at the point which is excellent in durability. On the other hand, those in which the blade is directly embedded in the flat base are preferable because the cutting pattern can be easily changed and the protrusion amount of the blade can be easily adjusted.

  In the present invention, by punching the prepreg base material with a punching blade by air pressure or hydraulic pressure, a notch is inserted into the prepreg base material, and substantially all the reinforcing fibers are cut. In order to prevent the prepreg base material from being caught by the punching blade when punching, intermittent feeding that temporarily lowers the supply speed of the prepreg base material or stops at the punching site and proceeds to the next punching site. However, when the punching blade is used, it is possible to cut with a small number of blades, and it is possible to save the space of the device for inserting the cut. . The size of the flat base on which the blade is arranged is not particularly limited, but if the size of the prepreg base material in the conveying direction 40 is too wide, it can be cut with the above-mentioned few blades, and a punching blade that saves space in the device Therefore, the width in the prepreg base material conveyance direction 40 is preferably about 30 mm to 150 mm. Moreover, about the magnitude | size of the direction 41 orthogonal to a prepreg base material conveyance direction, if it is smaller than the width | variety of a prepreg base material, in order to cut | disconnect substantially all the fibers, it is a punching blade itself with respect to a conveyance direction. Since it is necessary to provide a movable mechanism in the orthogonal direction, it is preferably about (prepreg base material width + 100 mm).

  Moreover, in the method of inserting a cut into the two prepreg base materials described above, the material of the cutting edge of the cutting blade used is not particularly limited, but in consideration of durability and the like, super hard steel, diamond and ceramics are preferable. . Furthermore, there is no particular limitation on the speed at which the prepreg base material is transported, that is, the speed at which the cut is inserted into the prepreg base material, but when the speed is too high, the cutting blade may be caught on the prepreg base material or when the cut is inserted. There is concern that the viscosity of the resin of the prepreg base material decreases due to the generated frictional heat, and the resin adheres to the cutting blade and the sharpness decreases. Moreover, since efficiency will fall and the characteristic of this invention will be lost when a speed is too slow, it is preferable that the speed which conveys a prepreg base material is 5-18 m / min.

  When cutting the prepreg base material in the present invention, the reinforcing fiber and the tape-like support may be cut together, but the tape-like support is substantially continuous by adjusting the insertion depth of the cut. It is more preferable to cut only the reinforcing fibers of the prepreg base material while maintaining the above. The cut prepreg base material is more likely to be deformed as the number of cuts increases and the longer the cut, the lower the rigidity of the cut prepreg base material. Thereby, handling becomes difficult, for example, the shape of the cut prepreg base material collapses in the lamination step. In order to avoid such a problem, as shown in FIG. 15, the side opposite to the side where the cutting blade 29 is pressed in the prepreg base material 3 is gripped by the tape-like support 4, and the tape-like support 4 is removed. It is preferable to carry out so-called half-cutting, in which only the prepreg base material 3 is cut while being kept substantially continuous. Thereby, even if the amount of cutting is large, the tape-like support 4 suppresses deformation of the cutting prepreg base material 3 ′, so that the handling property of the base material is greatly improved and the prepreg base before being cut. Similar to the material, it has a form-retaining property that can withstand a 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. At this time, as the amount that the tip 48 of the cutting insertion portion enters the prepreg base material 3, even if the amount that the tip 48 of the cutting insertion portion enters is just the depth at which the fibers of the prepreg base material 3 are cut. However, in this case, if the cutting blade 29 is worn due to many cuttings, there is a possibility that uncut portions frequently occur. Therefore, it is preferable that the tip 48 of the cutting insertion portion penetrates the prepreg base material 3 and only a part of the tape-like support 4 enters (in this case, there is a portion where the tape-like support is not continuous). However, since it is not penetrated in the thickness direction, it can be said that the tape-like support is “maintained substantially continuously”). Furthermore, as the thickness of the tape-shaped support body 4, if the thickness is large, the material cost increases, which is not economical. However, if the thickness is too thin, it is difficult to keep the tip 48 of the cutting insertion portion inside the tape-like support 4 when the cutting blade 29 is pressed against the prepreg base material 3. As a result, when the tip 48 of the cut insertion part completely penetrates the tape-like support 4, the handleability of the cut prepreg base material 3 ′ is deteriorated, and the tip 48 of the cut insertion part becomes the tape-like support 4. If not reached, the fiber cannot be cut, and the continuous fiber remains in 3 ′ in the cut prepreg base material, and the fluidity during molding is lowered. Therefore, the thickness of the tape-like support is preferably 30 to 300 μm, more preferably 50 to 200 μm. Here, the “tape-like support” in the present invention includes papers such as kraft paper, polymer films such as polyethylene / polypropylene, metal foils such as aluminum, etc., and further provides releasability from the resin. Therefore, a silicone-based or “Teflon (registered trademark)” release agent, metal vapor deposition, or the like may be applied to the surface.

  Examples of reinforcing fibers constituting the prepreg base material in the present invention include organic fibers such as aramid fibers, polyethylene fibers, polyparaphenylene benzoxador (PBO) fibers, glass fibers, carbon fibers, silicon carbide fibers, alumina fibers, Examples thereof include inorganic fibers such as Tyranno fiber, basalt fiber, and ceramic fiber, metal fibers such as stainless fiber and steel fiber, and reinforcing fibers using boron fiber, natural fiber, modified natural fiber, and the like as fibers. Among them, carbon fiber is particularly lightweight among these reinforced fibers, and has particularly excellent properties in specific strength and specific modulus, and is also excellent in heat resistance and chemical resistance. Is suitable for a member such as an automobile panel. Among these, PAN-based carbon fibers that can easily obtain high-strength carbon fibers are preferable.

  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. In the case of using a thermoplastic resin, it is preferable to carry out pressure lamination while heating in order to ensure tackiness. In this case, the heating temperature is preferably set to a temperature at which the thermoplastic resin used can maintain a semi-cured state in a series of lamination steps.

  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 during 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.

  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. The laminated body of the prepreg base material was arrange | positioned in this metal mold | die center part, and it was made to harden | cure on the conditions of 150 degreeC * 30 minute (s) under the pressurization of 6 MPa with the heating type press molding machine. This obtained the molded object of the fiber reinforced plastic.

  In terms of fluidity, when the base material is stretched and molded, fiber reinforced plastic is filled in the mold cavity, and the base material placed on the outermost layer also extends to the vicinity of the mold edge. Is fluidity ○, but fiber reinforced plastic is filled in the mold cavity, but when the base material arranged on the outermost layer is not stretched, fluidity △, fiber reinforced plastic is in the mold cavity. When there was an unfilled part, it evaluated as fluidity | liquidity x.

  For sleds, if the molded body is placed on a flat test bench and the molded body is in contact with the entire surface of the test bench, the sled ○, and the molded body can be tested by placing the molded body on a flat test bench. When the molded body is not in contact with the entire surface and the molded body is in contact with the entire surface of the test table with the finger when the molded body is pressed against the entire surface of the test table, warping is required. When the molded body was pressed against the table, if there was a portion where the molded body was not in contact with the test table, it was evaluated as a sled x.

<Mechanical property evaluation>
From the flat part of the fiber reinforced plastic obtained by the above procedure, a tensile strength 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 prescribed 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. Further, a standard deviation was calculated from the measured value, and the standard deviation was divided by an average value, thereby calculating a variation coefficient (CV value (%)) as an index of variation.

(Example 1) [Cutting mode: continuous cutting]
The apparatus shown in FIG. 1 was used as an apparatus for cutting a unidirectional prepreg base material into a specific dimension. This apparatus has a rotary blade roller 31 shown in FIG. The cylindrical roller 30 has a diameter of 70 mm and a width of 350 mm. The cutting blade has a spiral shape, the circumferential distance between the cutting blades is 30 mm so that the reinforcing fiber is cut to 30 mm in the fiber direction, and the angle between the cut and the fiber direction is 10 mm. Arranged so that continuous cuts that are ° can be inserted. Further, when cutting the prepreg base material, the cutting blade 29 was arranged so that the end portion 5 mm of the base material was not cut and the base material was not separated by the insertion of the cut. The prepreg conveyance speed at the time of cutting insertion was set to 13 m / min.

An automatic laminating apparatus having the structure shown in FIG. 2 was used. The prepreg supply reel 9 of this apparatus is provided with the 300 mm wide cut prepreg equipment, and the laminated configuration is [−45 / 0 / + _45/90 ] 16 layers were laminated _{so as to be 2S, and} a laminate was obtained.

  In addition, since the cut length of the cut prepreg base material is long, in the winding operation after the insertion of the cut at the time of the cut insertion, the transfer to the supply reel at the time of automatic lamination, and the lamination process, There were some difficulties such as a shift.

  Using the laminated body constituted by the obtained cut prepreg base material, molding was performed by the above-described method to obtain a fiber reinforced plastic having uneven portions and rib portions.

  The obtained 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 modulus of the flat plate section cut out from the obtained laminate is 46 GPa, which is expressed as the theoretical value. Also, the tensile strength is as high as 580 MPa, and the CV value is 5%, which is very small variation. It became. From these results, it was found that mechanical properties and quality that can be applied to structural materials and outer plate members were obtained. Further, when the obtained fiber reinforced plastic was cut out and attention was paid to the layer having a cut-out surface of 0 °, there was no layer undulation or fiber-free portion as shown in FIG. 7b), and there was almost no resin-rich portion. . Moreover, the fiber bundle end was also inclined in the thickness direction (about 5 ° or less from the fiber direction), and it was considered that the stress transmission efficiency was high.

(Example 2) [Cutting mode: intermittent]
A fiber reinforced plastic having uneven portions and rib portions was obtained in the same manner as in Example 1 except that the cutting blade 29 as shown in FIG. .

  The cutting blade 29 installed on the cylindrical roller 30 was produced by cutting a number of blades from a metal plate having a size of 350 mm × 350 mm and a thickness of 5 mm. FIG. 12 shows a layout of the cutting blade 29. A plurality of blades having a length of 1.5 mm are arranged at an interval of 1.5 mm in the central portion 340 × 340 of the metal plate 32 to form a row 33 of blades. An angle α (36) between the row of blades and the reference direction 34 of the metal plate is 10 °. Further, the rows 33 of adjacent blades are arranged at a spacing 37 of 15 mm in the reference direction 34 of the metal plate, and the rows of adjacent blades are shifted from each other by a half phase in a direction 35 perpendicular to the reference direction. The metal plate on which the plurality of cutting blades are arranged is wound around the cylindrical roller 30 so that the reference direction 34 of the metal plate and the feeding direction of the prepreg base material (fiber longitudinal direction of the prepreg base material) coincide with each other. Is an intermittent rotary blade roller 31. The cutting pattern of the cut prepreg base material obtained from the rotary blade roller 31 is a pattern in which the arrangement of the blades in FIG. 12 is transferred, and the fiber length L, the cut and the fiber direction of the cut prepreg base material Were measured, and the projection length Ws obtained by projecting the cut in the vertical direction of the reinforcing fiber was L = 30 mm, Θ = 10 °, and Ws = 0.51 mm.

  In addition, the cut prepreg base material obtained by this method has a shorter cut length than that of Example 1, and the base material is not deformed throughout the entire process, and a laminate can be easily obtained. .

  The obtained fiber reinforced plastic exhibited the same surface smoothness as that of Example 1, and the fibers were in the shape of the concavo-convex part, and no wrinkles were formed, and the fiber was filled up to the tip of the rib part. About the tensile strength of the flat plate part cut out from the obtained laminated body, a value higher than 640 MPa and Example 1 expressed.

(Examples 3 to 5) [Comparison of fiber length (Table 1)]
A fiber reinforced plastic having uneven portions and rib portions was obtained in the same manner as in Example 1 except that the fiber length L was changed by changing the notch interval. L was 10 mm in Example 3, 60 mm in Example 4, and 100 mm in Example 5, respectively.

  The obtained fiber reinforced plastic exhibited good surface smoothness except for Example 5, 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 ends of the rib portions. In Example 5, there was a portion where the fiber did not sufficiently flow to the end at the surface portion where the undulation of the fiber and the friction between the mold and the die were received. In addition, none of the fiber reinforced plastic has warpage, and there is almost no part where the reinforcing fiber is not present and the reinforcing fiber of the adjacent layer is peeking out in the cut portion of the outermost layer, and the appearance quality is good. The smoothness was maintained. The tensile modulus was 46 to 47 GPa, the tensile strength was as high as 510 to 650 MPa, and the CV value of the tensile strength was also as small as 3 to 6%.

(Examples 6 to 11) [Comparison of cutting angles (Table 2)]
A fiber reinforced plastic having concavo-convex portions and rib portions was obtained in the same manner as in Example 1 except that the angle between the cut and the fiber direction was changed. In Example 6, the cutting angle Θ is 1 °, Example 7 is 2 °, Example 8 is 5 °, Example 9 is 15 °, Example 10 is 25 °, and Example 11 is continuous in the direction of 45 °. Cuts were made.

The obtained fiber reinforced plastic exhibited good surface smoothness in Examples 7 to 10, the fibers were in 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 modulus was 45 to 47 GPa, the tensile strength was as high as 470 to 670 MPa, and the CV value of the tensile strength was as small as 3 to 5%. Particularly, in Examples 7 and 8 having a small cutting angle, a tensile strength of 600 MPa or more was expressed. About Example 6, since the cut angle is small, the interval between the cuts is as small as about 0.5 mm, it is difficult to stably cut the base material, and the CV value of the tensile strength is also 12%. Although it was high, the tensile modulus was 45 GPa and the tensile strength was 640 MPa. In Example 11, although the tensile strength was a little low at 340 MPa, the tensile elastic modulus was 44 GPa, which was almost the same value as in the other examples, there was no fiber undulation, and the fiber flowed evenly to its end. (Examples 12 to 16) [Comparison of projection length Ws (Table 3)]
The fiber which has an uneven | corrugated | grooved part and a rib part similarly to Example 2 except having changed the cutting length and the space | interval of a cutting by changing the length and space | interval of a blade in the cutting pattern of Example 2. A reinforced plastic was obtained. In Example 12, the projection length Ws and the notch interval were both 0.02 mm, Example 13 was 0.17 mm, Example 14 was 1 mm, Example 15 was 2 mm, and Example 16 was 10 mm. The actual cut lengths are 0.12 mm in Example 12, 1 mm in Example 13, 5.8 mm in Example 14, 11.5 mm in Example 15, and 58 mm in Example 16.

  The obtained fiber reinforced plastics all exhibited good surface smoothness except for Example 12, the fibers were in the shape of the concavo-convex portions, no wrinkles were formed, and the fibers were filled up to the tips of the rib portions. It was. Also, the tensile strength was very high at 560 to 680 MPa. In particular, the smaller the projection length Ws (cutting length), the higher the strength, but it was confirmed that this tendency appears remarkably when Ws is 1.5 mm or less. In Example 12, although the fibers are in the shape of the concavo-convex portion, some of the fibers on the outermost surface are not cut by the fiber escape, the fibers undulate, and the ends of the ribs are filled with fibers. There was a part that was not. Further, although the CV value was slightly high as 10% and the variation was large, the tensile strength showed the highest value of 700 MPa.

(Example 17) [Using a punching blade for insertion]
As the incision insertion device 5, a punching blade by air pressure shown in FIG. 13 was used, and the concave and convex portions and the rib portions were formed in the same manner as in Example 2 except that the cutting was inserted by pressing the blade at an interval of 60 times / min. A fiber reinforced plastic was obtained.

  FIG. 13 is a layout view of the cutting blade 29 in the punching blade. A plurality of blades having a blade length of 1.5 mm are arranged at intervals of 1.5 mm on a rod-shaped base having a width of 100 mm in the prepreg base material transport direction 40 and a width in a direction 41 orthogonal to the prepreg base material transport direction of 400 mm. Thus, a row 33 of blades is formed. The row 33 composed of the blades is inclined by 10 ° with respect to the prepreg base material conveyance direction 40, that is, the fiber direction of the prepreg base material. Further, the rows 33 composed of adjacent blades are arranged at an interval of 15 mm in the prepreg base material transport direction, and the rows 33 composed of adjacent blades are half of each other with respect to a direction 41 orthogonal to the prepreg base material transport direction. Out of phase. In this way, a number of cutting blades 29 arranged intermittently on the base were used as the punch 38 to insert a cut into the prepreg base material. The cut pattern of the obtained cut prepreg base material was a pattern in which the arrangement of the blades in FIG. 13 was transferred over the entire surface of the prepreg base material, and the same cut prepreg base material as in Example 2 was obtained. The fiber length L of the cut prepreg base material, the angle Θ between the cut and the fiber direction, and the projected length Ws obtained by projecting the cut in the vertical direction of the reinforcing fiber were measured. L = 30 mm and Θ = 10 °, Ws = 0.51 mm.

  Further, the obtained 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 was 630 MPa, which was almost the same value as in Example 2.

(Example 18) [Half cut]
The fiber of the prepreg base material without cutting into the tape-like support by changing the pressure that presses the rotary blade roller against the prepreg base material to reduce the insertion depth of the cut during the insertion. A fiber reinforced plastic having a concavo-convex portion and a rib portion was obtained in the same manner as in Example 1 except that only the portion was cut.

  Although the cut prepreg base material obtained by this method has a long cut length, the tape-like support is not cut and only the fibers of the prepreg base material are cut. The deformation of the embedded prepreg base material was suppressed, and a laminate was easily obtained.

  The obtained 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 was 570 MPa, which was almost the same value as in Example 1.

(Comparative Example 1) [Comparison with continuous fiber prepreg base material]
A fiber reinforced plastic having concavo-convex portions and rib portions was obtained in the same manner as in Example 1 except that the prepreg base material was not cut.

  The resulting fiber reinforced plastic has irregularities formed, but because the reinforced fibers and matrix resin were drawn into the irregularities, the ends of the fiber reinforced plastic were missing, and the fibers bridged at the edges of the irregularities. The part was resin-rich. Furthermore, wrinkles were generated in the flat portion, and almost no fibers were filled in the rib portion, so that it seemed impossible to apply as a product.

(Comparative Example 2) [Comparison with SMC]
Example 1 except that the unidirectional prepreg base material was cut into a fiber length of 25 mm and a width of 5 mm to obtain a chopped raw material prepreg, and the chopped raw material prepreg was pressed with a nip roll while being randomly oriented and bonded to each other. Similarly, a fiber reinforced plastic having an uneven portion and a rib portion was obtained.

  The obtained fiber reinforced plastic had fibers along the shape of the concavo-convex part, no wrinkles, and the fiber was filled up to the tip of the rib part, but because the flow state was not uniform, the difference in linear expansion coefficient Sled. Further, the tensile strength was 180 MPa, which was significantly lower than that of each Example, and the CV value was 12%, which showed a large variation.

(Comparative Examples 3 and 4) [Comparison of fiber length]
In the cutting pattern of Example 1, a fiber reinforced plastic having uneven portions and rib portions was obtained in the same manner as in Example 1 except that the fiber length L was changed by changing the cutting interval. The fiber length L was 7.5 mm in Comparative Example 3 and 120 mm in Comparative Example 4.

  In Comparative Example 3, the obtained fiber reinforced plastic exhibited good surface smoothness, the fibers were aligned 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. However, the tensile strength was 430 MPa, which was a low value compared to Example 1 and Examples 3 to 5. Regarding Comparative Example 4, in the obtained fiber reinforced plastic, the fibers did not flow completely over the entire cavity of the mold, and a resin rich portion was observed at the end. The fibers swelled and warped.

  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 apparatus which cut | disconnects the unidirectional prepreg base material in this invention to a specific dimension. It is the schematic which shows an example of the automatic lamination apparatus in this invention. It is an enlarged plan view which shows an example of the cutting pattern of the cutting prepreg base material used for the prepreg laminated base material of this invention. It is a schematic plan view which shows an example of the cutting pattern of the cutting prepreg base material used for the prepreg laminated base material of this invention. It is a schematic plan view which shows an example of the cutting pattern of the cutting prepreg base material used for the prepreg laminated base material of this invention. It is a schematic plan view which shows an example of the cutting pattern of the cutting prepreg base material used for the prepreg laminated base material of this invention. It is a top view and a sectional view showing an example of a layered product for comparison and fiber reinforced plastic. It is the top view and sectional view which show an example of the lamination substrate of the present invention, and fiber reinforced plastics. It is a top view which shows an example of the laminated base material of this invention, and a fiber reinforced plastic. 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 rotary blade roller in this invention. It is a schematic plan view which shows an example of arrangement | positioning of the cutting blade for cutting insertion in this invention. It is the schematic which shows an example of the punching blade 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 sectional drawing which shows an example of the manufacturing method of the cutting prepreg base material in this invention.

Explanation of symbols

1: A device for cutting a unidirectional prepreg base material into a specific dimension 2: A prepreg base material supply reel 3: A prepreg base material 3 ′: A cut prepreg base material 4: A tape-like support 5: A cutting insert device 6: A prepreg base Material support roller 7: Pre-preg base material take-up reel 8: Automatic laminator 9: Pre-preg base material supply reel 10: Press roller 11: Tape-like support take-up reel 12: Laminate 13 (13a, 13b): Notch 14 : Fiber orientation direction 15: Cutting angle Θ
16: Fiber orthogonal direction 17: Reinforcing fiber 18: Fiber length L (interval between cuts)
19: Projection length Ws obtained by projecting the cut in the vertical direction of the reinforcing fiber
20: Laminated body 21 of cut prepreg base material: Fiber reinforced plastic 22: Short fiber layer 23: Cut opening (region where no reinforcing fiber exists)
24: Fiber bundle end portion 25: Adjacent layer 26: Resin rich portion 27: Layer waviness 28: Reinforcement fiber rotation 29: Cutting blade 30: Cylindrical roller 31: Rotary blade roller 32: Metal plate 33 on which the cutting blade is arranged : Row 34 composed of blades: reference direction 35 of the metal plate 35: direction perpendicular to the reference direction of the metal plate 36: angle α between the row of blades and the reference direction of the metal plate
37: Spacing in the reference direction of the reference plate of the row of blades 38: Uncut blade 39: Base 40: Transport direction of the prepreg base material 41: Direction orthogonal to the transport direction of the prepreg base material 42: Fiber reinforced plastic molding die 43: Uneven portion 44: Rib molding groove 45: Upper die 46: Lower die 47: Cutting insertion portion 48: Tip of cutting insertion portion 49: Release film 50: Foundation of cutting blade

Claims (7)

The notched prepreg base material obtained by winding a wound prepreg base material obtained by cutting a unidirectional prepreg base material composed of reinforcing fibers and a matrix resin over the entire surface together with a tape-like support, and winding it up. And the tape-like support are continuously supplied from a supply reel, the cut prepreg base material is pressure-bonded and laminated by a roller, and the tape-like support separated from the cut prepreg base material is provided on the reel. A method of manufacturing a laminate to be wound, wherein substantially all the reinforcing fibers constituting the cut prepreg base material arranged on the supply reel are cut so that the length L in the fiber direction is 10 to 100 mm. The manufacturing method of the laminated body. The substantially all reinforcing fibers of the cut prepreg base material disposed on the supply reel are cut within an absolute value of an angle Θ between the cut and the fiber direction within a range of 2 to 25 °. The manufacturing method of the laminated body of 1. Substantially all the reinforcing fibers of the cut prepreg base material arranged on the supply reel are cut within a projection length Ws obtained by projecting the cut in the vertical direction of the reinforcing fibers within a range of 0.1 mm to 1.5 mm. The manufacturing method of the laminated body of Claim 1 or Claim 2. The manufacturing method of the laminated body in any one of Claims 1-3 which laminate | stacks the said cut prepreg base material at least 2 layers or more in the direction from which the orientation of a reinforced fiber differs. The substantially all reinforcing fibers of the cut prepreg base material are cut by pressing a rotary blade roller on which at least one blade is disposed from at least one side. A manufacturing method of a layered product. The laminate according to any one of claims 1 to 4, wherein substantially all the reinforcing fibers of the cut prepreg base material are cut by pressing a punching blade having at least one blade disposed from at least one side. Body manufacturing method. When cutting a unidirectional prepreg base material composed of reinforcing fibers and a matrix resin over the entire surface, only the reinforcing fibers of the prepreg base material are cut while maintaining the tape-like support substantially continuous. The manufacturing method of the laminated body in any one of claim | item 1 -6.

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