JP2009019313A - Method for producing reinforcing fiber-woven fabric intermediate material impregnated with resin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a reinforcing fiber-woven fabric intermediate material, capable of obtaining the reinforcing fiber-woven fabric intermediate material represented by a prepreg-impregnated with a high quality resin by adopting the hot-melt process having a high production efficiency and without developing stitch deflections in the weft yarns of the reinforcing fiber-woven fabric in producing the prepreg obtained by impregnating a matrix resin with the reinforcing fiber-woven fabric. <P>SOLUTION: This method for producing the reinforcing fiber-woven fabric intermediate material is provided by weaving the reinforcing fiber-woven fabric (3) by using warp yarns (1) and weft yarns (2) consisting substantially of continuous carbon fibers, and succeedingly, impregnating the hot melt resin continuously with the reinforcing fiber-woven fabric. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an efficient method for producing an intermediate material of a reinforced fiber fabric impregnated with a resin, which is an intermediate of a fiber reinforced composite material impregnated with a resin. The present invention relates to a method for producing a reinforcing fiber fabric intermediate material impregnated with a resin, which eliminates bending, has excellent shape stability and has required mechanical properties.

  For example, aircraft, special vehicles, industrial equipment, or sporting goods such as skis, golf shafts, fishing rods, and tennis rackets that require excellent mechanical properties are prepregs that are intermediate materials made of resin impregnated with reinforcing fibers. A fiber reinforced resin molded body (hereinafter, referred to as a molded body) produced by heating and curing after laminating the molded body in a molded body shape is widely used. The prepreg used at that time is mainly a UD prepreg in which a reinforcing fiber bundle aligned in one direction is impregnated with a resin and a cross prepreg in which a woven or non-woven fabric woven with reinforcing fibers is impregnated with a resin. Can be separated.

  The UD prepreg has reinforced fibers arranged in one direction, so the mass per unit area of the reinforced fibers can be reduced compared to the cross prepreg, and it is suitable for a molded product that is desired to be lighter. Since the strength in the direction perpendicular to the direction is weak, the UD prepreg is laminated while changing the angle in the fiber direction to complement this, and the strength in the direction perpendicular to the fiber axis direction is improved. The process of laminating the UD prepreg was complicated and the production efficiency of the molded body was low. One cross prepreg has reinforcing fibers arranged in a biaxial direction, so that it is easy to handle, can be cut and laminated easily, and can easily produce a molded body. There is an advantage that it can be controlled.

  Many proposals have been made on a method for producing a cross prepreg. For example, according to Japanese Patent Laid-Open No. 58-31716 (Patent Document 1), a woven sheet is bonded to a resin film coated on a substrate with a constant film thickness, and the resin is uniformly distributed in the woven sheet. In the impregnation, after the fabric sheet comes into contact with the resin film, the fabric sheet is continuously drawn while applying tension along the curved surface of the base material having at least a part of a curved surface such as a column or cylinder. By adopting such a configuration, the thickness is uniform and there are few defects in appearance such as fluff, fluff, gaps, fish eyes, etc., especially in thin to thick prepregs, each filament of the woven sheet is sufficient for the resin Thus, a prepreg sheet impregnated in the above can be obtained.

  Further, for example, according to Japanese Patent Application Laid-Open No. 60-165211, (Patent Document 2), sheets having at least one of resin-supporting sheets are overlapped on both sides of a reinforcing fiber fabric, and the overlapped body is heated with a heating roll. In manufacturing a prepreg in which the resin is transferred and impregnated into the reinforcing fiber by pressure, a resin pool control plate is provided in front of the nip point of the heating roll at a position close to or in contact with at least the lower surface of the laminated body. The presence of the resin pool control plate suppresses the appearance of the resin pool, suppresses the occurrence of fluff due to cutting of the reinforcing fiber single yarn by the resin pool, and prevents uneven resin impregnation due to the accumulation of the fluff. I can do it.

  Further, for example, according to Japanese Patent Application Laid-Open No. 2002-327076 (Patent Document 3), a reinforced fiber fabric is impregnated with a matrix resin so as to form at least a continuous resin layer, and then the resin is impregnated. At least one surface of the reinforcing fiber fabric is attached to the reinforcing fiber fabric of a protective film having an uneven surface. In that state, it is allowed to stand at 30 to 60 ° C. and atmospheric pressure for 12 hours or more. The obtained prepreg is composed of a resin-impregnated portion in which a continuous resin is present and at least one surface thereof is substantially impregnated with an impregnated resin and a fiber portion substantially free of resin.

According to the prepreg manufacturing method proposed by Patent Documents 1 to 3 above, all of the reinforced fiber fabrics obtained by weaving are used as the reinforcing fiber sheets, but all are woven in advance and taken down from the loom. , The resin surface of the resin-carrying sheet carrying the matrix resin is superimposed on at least one of the front and back surfaces, and then heat-pressed with a pressure heating roll, and the matrix resin is transferred and impregnated inside the reinforced fiber fabric. A so-called hot-melt impregnation adhesion method is disclosed. For example, according to Japanese Patent Application Laid-Open No. 2003-136550 (Patent Document 4), a reinforcing fiber fabric woven on a loom is woven without being taken down from the loom. After continuously spreading the particulate matrix resin on the surface of the reinforced fiber fabric, pressurize and heat to melt the molten resin. We propose a method for producing a prepreg wound from impregnated therein into a roll.
JP 58-31716 A JP-A-60-165211 JP 2002-327076 A JP 2003-136550 A

  By the way, as described in Patent Documents 1 to 3 described above, many of prepregs, which are intermediate materials for fiber reinforced resin moldings based on conventional reinforced fiber fabrics, employ a so-called hot melt method. ing. Here, the hot melt method is generally a mold release sheet (release paper or synthetic resin film) whose surface is release-treated with a silicon resin or the like, and a matrix resin such as an epoxy resin is uniformly coated and supported. In this method, the resin surface is superposed on one of the front and back surfaces of the reinforcing fiber fabric or both of the front and back surfaces, heated and pressurized by a heating roll or the like, and the resin is impregnated inside the fiber fabric to obtain a prepreg. In general, two release sheets are used, and at least one of the release sheets carries a matrix resin, which are combined on both sides of the fiber sheet. After impregnating the resin, sufficiently cool it with a cooling plate, etc., then remove the release sheet on one side, wind up the overlapped body of one release sheet and the resin-impregnated fiber fabric, and roll it up Get the prepreg.

  According to this hot melt system, the matrix resin can be uniformly applied to the surface of the reinforcing fiber fabric, and the inside of the reinforcing fiber fabric can be uniformly impregnated. Further, since the matrix resin does not contain a solvent, the solvent does not remain in the prepreg sheet, and as a result, the solvent does not vaporize during heating in the molding process and no voids are generated. Furthermore, a large-scale drying facility is unnecessary. On the other hand, in the method in which the particulate matrix resin disclosed in Patent Document 4 is dispersed on the surface of the reinforcing fiber fabric and heated and pressurized to impregnate the molten resin into the fabric, the matrix resin is evenly applied to the fabric surface. It is extremely difficult to spread.

  By the way, when the above-mentioned advantage by adopting the hot melt method is performed independently in the separate process from the weaving of the reinforcing fiber fabric, for example, as in Patent Documents 1 to 3 described above, A big trouble has occurred in the prepreg process due to the quality. In particular, when the resin impregnation method is a hot-melt method, there are many cases where the wefts of the reinforcing fiber fabric meander and bend when the reinforcing fiber fabric and the matrix resin are overlapped. In this way, when a molded body is made using a prepreg in which wefts meander and bends, the resulting fiber is meandering, resulting in a molded body laminated in a state where the fiber axis is shifted, and the original mechanical properties of carbon fiber Cannot be obtained.

  The present invention has been made to solve the above-mentioned problems, and a specific object thereof is to obtain a reinforcing fiber woven fabric intermediate material represented by a prepreg impregnated with a high-quality resin, and a hot-melt method with high production efficiency. It is an object of the present invention to provide a method for producing a reinforcing fiber fabric intermediate material impregnated with a resin in which the weft of the reinforcing fiber fabric does not bend in the production of a prepreg in which the reinforcing fiber fabric is impregnated with a matrix resin.

  When the hot melt method is adopted as the resin impregnation method as described above, the present inventors have various mechanisms for causing the wefts of the reinforcing fiber fabric to meander and cause bending when the reinforcing fiber fabric and the matrix resin are overlapped. We examined from the viewpoint. As a result, if there is uneven tension between the warp yarns when weaving the reinforcing fiber fabric, uneven warp tension of the reinforcing fiber fabric, that is, there is a difference in length between the unwinding from the paper basket and the weaving. appear. It was discovered that after the length difference between the warp yarns was lowered from the loom, the tension was relaxed and became apparent on the reinforced fiber fabric, which led to the weft yarn being bent particularly when the resin was impregnated by the hot melt method. Therefore, it is effective to strictly adjust the tension to keep the warp tension constant on the loom in order to suppress the occurrence of the bend.

  However, particularly when weaving this type of reinforcing fiber fabric, the warp yarns are individually unwound from a large number of bobbins hung on the bobbin creel, aligned, and supplied directly onto the loom. Furthermore, since large tension fluctuations frequently occur in warp yarns, for example, during beating and warp opening movements, on the weaving machine, the individual warp tensions over multiple yarns are made uniform throughout. It is extremely difficult to adjust. Therefore, the inventors have further studied, and by adopting the characteristic configuration of the present invention, even if a normal tension difference occurs between the warp yarns, the reinforcing fiber by the hot melt method is used. I knew that there was no special bend in the weft when the fabric was impregnated with resin.

  That is, the most basic configuration of the present invention is that a substantially continuous carbon fiber is used for warp and weft to weave a carbon fiber woven fabric, and subsequent to the weaving, a resin is continuously applied to the carbon fiber woven fabric by a hot melt method. There is a method for producing a reinforcing fiber fabric intermediate material impregnated with a resin comprising impregnation.

According to a preferred embodiment, the basis weight of the carbon fiber woven fabric is 150 to 600 g / m ² . Further, a preferred aspect of the hot melt method is that a resin surface of a hot melt film carrying a resin on one side is continuously attached to the surface or both front and back surfaces of the carbon fiber fabric to be woven, and the resin surface is woven. In the case where the application printing is performed only on the surface of the carbon fiber fabric, the release paper is continuously applied to the back surface of the carbon fiber fabric, and between the hot melt films and between the hot melt film and the release paper. The carbon fiber woven fabric that is sandwiched and moved is heated and pressurized with a heating roll to transfer and impregnate a hot melt film into the carbon fiber woven fabric, and the carbon fiber woven fabric that has been impregnated with resin is used as a winding roll. Including continuous winding. Furthermore, it is preferable to emboss the surface of the heating roll.

Effects of the invention

  The warps made of carbon fibers individually fed from a large number of bobbins of the bobbin creel are aligned through a cocoon according to a conventional method, and after wefts made of carbon fiber are inserted into the openings of the warp, the warp is made into a woven fabric. . At this time, each warp undergoes tension fluctuations during winding of the paper tube and large tension fluctuations due to warp opening and beating, so it is extremely difficult to accurately manage all the tensions of the individual warp yarns supplied. However, even if slight, there is a difference in tension variation between the warps. After the woven fabric is unloaded from the loom, the yarn length difference between the warp yarns increases as the fabric relaxes and becomes longer. Conventionally, when a fabric lowered from a loom is impregnated with a resin by a hot melt method, the difference in length between warp yarns based on the relaxation or fluctuation of the above tension becomes obvious in the warp yarn, and the weft yarn is bent. generate.

  However, in the present invention, the reinforcing fiber woven woven on the loom is continued without being taken down from the loom, and the hot melt process, that is, the reinforcing fiber woven fabric, the hot melt film carrying the resin on both the front and back sides is supported. Attaching the resin surface and continuously moving to the heating roll, heating and pressurizing with a heating roll in a state where the reinforcing fiber fabric is sandwiched between the hot melt film or between the hot melt film and the release paper, The fabric is impregnated with molten resin. At this time, a plurality of heating rolls can be provided, and it is more preferable to impregnate stepwise with a heating roll having a temperature of about 50 ° C. to about 90 ° C. At the time of impregnation with this resin, the fabric does not relax even when it reaches the heating and pressing part, and at the same time, the front and back surfaces are sandwiched and transferred between the resin of the hot melt film and the release film, The tension at the time of weaving is not dispersed in the yarn length direction, and no difference in yarn length occurs. As a result, the weft yarn is not bent even during resin impregnation.

Here, when the surface of the heating roll is embossed, the molten resin spreads evenly over the entire surface of the fabric along the embossed surface, and the convex surface makes the hot melt film stronger than the concave surface. The molten resin penetrates between a large number of carbon fibers constituting the carbon fiber fabric by pressing to ensure adhesion between the carbon fibers. Meanwhile, the a basis weight of 150 g / m ² less than the carbon fiber woven fabric, thin reinforcing woven fabric intermediate material resin impregnated even handle is flame Kashiku as a preform, the resin is woven inside exceeds 600 g / m ² It becomes difficult to impregnate evenly.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 shows a schematic configuration of a production apparatus used for effectively carrying out a method for producing a reinforcing fiber fabric intermediate material impregnated with a resin of the present invention.
As shown in the figure, in the manufacturing method according to the present invention, after weaving a reinforcing fiber fabric on a loom, the matrix fabric is then impregnated directly using a hot melt method into the finished weaving fabric. It is characterized by.

According to this embodiment, carbon fibers are used as reinforcing fibers for the warp 1 and the weft 2 of the reinforcing fiber fabric. This carbon fiber is suitably used because the mechanical properties of a molded product obtained after subsequent molding are good. As the carbon fiber, any of polyacrylonitrile (PAN) -based carbon fiber and pitch-based carbon fiber can be used. Further, the warp 1 and the weft 2 are used in a state where a large number of carbon fibers are aligned. The basis weight of the carbon fiber fabric 3 is preferably 150 to 600 g / m ^{2, and} is appropriately selected depending on the application.

However, the reinforcing fibers used in the reinforcing fiber fabric are reinforcing fibers composed of long fibers, and various carbon fibers can be used depending on the purpose of use of the molded body formed from the reinforcing fiber intermediate material. . Examples thereof include organic reinforcing fibers such as graphite fibers and aramid fibers, silicon carbide fibers, alumina fibers, boron fibers, tungsten carbide fibers, and glass fibers. These can be used alone or in combination. As the carbon fiber and graphite fiber, fibers having various kinds of properties can be used depending on the application, but those having a tensile strength of 400 kgf / mm ² or more and a tensile modulus of 15 MPa or more are particularly mechanical properties. Therefore, it is preferably used.

  Further, the material of the hot melt film is not particularly limited, and can be appropriately changed according to the kind of the matrix resin in consideration of the adhesiveness with the matrix resin. For example, a polyethylene film that has been conventionally used as a release film can be used. The release film in the present invention includes paper having a release treatment on the surface.

  The matrix resin is not particularly limited. The resin used in the present invention is preferably a thermosetting resin. For example, an epoxy resin, a polyester resin, a vinyl ester resin, a phenol resin, a maleimide resin, a polyimide resin, a combination of cyanate ester and bismaleimide resin (Mitsubishi Gas Chemical ( BT resin and the like can be used, and an epoxy resin can be used.

  Examples of the epoxy resin include bisphenol A type epoxy resin, bisphenol F type epoxy resin, biphenyl type epoxy resin, naphthalene type epoxy resin, dicyclopentadiene type epoxy resin, fluorene type epoxy resin, or a combination thereof. Resins etc. are preferably used.

  Furthermore, a trifunctional or higher polyfunctional epoxy resin can also be used. Examples of the polyfunctional epoxy resin include phenol novolac type epoxy resin, cresol type epoxy resin, glycidylamine type epoxy resin such as tetraglycidyldiaminodiphenylmethane, triglycidylaminophenol, tetraglycidylamine, and tetrakis (glycidyloxyphenyl) ethane. Glycidyl ether type epoxy resins such as tris (glycidyloxymethane) or combinations thereof are preferably used.

  It is preferable to add a curing agent to the matrix resin of the present invention. Examples of the curing agent include aromatic amines such as diphenylmethane and diaminodiphenylsulfone, aliphatic amines, imidazole derivatives, dicyandiamide, tetramethylguanidine, thiourea addition amine, and carboxylic acid anhydrides such as methylhexahydrophthalic anhydride. Carboxylic acid hydrazide, carboxylic acid amide, polyphenol compound, novolac resin, polymercaptan, Lewis acid complex such as boron trifluoride ethylamine complex, and the like.

  Moreover, those obtained by encapsulating these curing agents can also be suitably used in order to increase the storage stability of the prepreg. These curing agents can be combined with an appropriate curing accelerator in order to increase the curing activity. Preferred examples include a combination of dicyandiamide with a urea derivative such as 3- (3,4-dichlorophenyl) -1,1, dimethylurea (DCMU) or an imidazole derivative as a curing accelerator, carboxylic acid anhydride or novolak resin. Examples include combining triamines as curing accelerators.

  These epoxy resins and curing agents, or those obtained by pre-reacting some of them, can also be blended in the matrix resin composition. This method may be effective for adjusting viscosity and improving storage stability.

  Further, in addition to the matrix resin described above, a thermoplastic resin may be blended for the purpose of controlling the resin viscosity and controlling the prepreg handling property. In that case, the resin is selected in consideration of compatibility with the epoxy resin and not adversely affecting the physical properties of the composite material. Preferable examples include polyvinyl formal, polyvinyl butyral, polyethylene oxide, polymethyl methacrylate, polyamide, polyester, polyethersulfone, polysulfone, polyetherimide, and polyimido. Two or more kinds of these resins may be mixed.

  Further, rubber particles, soluble rubber, core-shell structure rubber, and the like can be contained as additives. These are at least partially dissolved in the base resin, or exist in the form of particles without being dissolved, but in the present invention, in order to obtain a prepreg of good quality, when present in the form of particles, substantially It is preferable to pulverize or dissolve the particles in advance so that particles having a diameter of about 50 μm or more are not included.

  In the method for manufacturing the carbon fiber fabric intermediate material according to the present embodiment, as shown in FIG. 1, a bobbin creel 11 is used by using a shuttleless loom such as a conventional lepier loom, grip loom, water jet loom, air jet loom or the like. A large number of warp yarns 1 made of, for example, about 500 carbon fiber bundles released from the large number of bobbins 12 are passed through a plurality of guide rolls and nip rolls without going through a warping process as in normal weaving. After the wefts 2 made of carbon fiber bundles are driven into the openings formed between a number of warps 1 by vertical movement of the heels 13 based on the woven structure, the wefts 2 made of carbon fiber bundles are driven by the heels 14. A beating is made into a woven fabric. Usually, the rotational speed of the loom is 200 rpm, and the feed speed of the warp 1 is 0.4 m / min. The carbon fiber woven fabric 3 after weaving is sent to a drawing roll 15 disposed forward after the weaving without being lowered from the loom. A first guide roll 16 is disposed below the draw roll 15, and the carbon fiber fabric 3 moves forward through the first guide roll 16.

  On the other hand, a release film 4 wound in a roll shape with a release agent such as silicone applied on one side behind the first guide roll 16 overlaps the carbon fiber fabric 3 with the release agent application surface. The carbon fiber woven fabric 3 and the release film 4 are overlapped with each other and fed forward. A second guide roll 17 for joining and guiding the hot melt resin to the carbon fiber fabric is disposed in front of the first guide roll 16. The carbon fiber fabric 3 and the release film 4 are introduced on the lower surface side of the second guide roll 17 in an overlapped state.

  As shown in an enlarged view in FIG. 2, two hot melt resin layers 5, which are wound up in a roll shape and serve as a matrix resin impregnated in the carbon fiber woven fabric 3, are disposed on the diagonally front above the second guide roll 17. A roll body 9 of a hot melt film 8 is provided in which both the front and back surfaces are sandwiched by a single release film 6, 7. The thickness of the resin layer at this time is preferably 80 to 300 μm when impregnating one side of the fabric, and preferably 40 to 150 μm for both sides. The hot melt film 8 drawn out from the roll body 9 is introduced between the carbon fiber fabric 3 and the second guide roll 17 after being wound around the second circumference of the second guide roll 17. Prior to this introduction, the release film 6 disposed on the surface of the hot melt film 8 opposite to the second guide roll 16 is guided through the release guide roll 18 and peeled off from the hot melt resin layer 5. Then, the film is wound around the release film winding paper tube 10. Therefore, when the hot melt film 8 is introduced into the second guide roll 17, the hot melt resin layer 5 is directly attached to the upper surface of the carbon fiber fabric 3. In the present embodiment, one release film 6 is made of polyethylene, and the other release film 7 is made of release paper that has been subjected to a release treatment.

  In front of the second guide roll 17, a pair of upper and lower heating and pressing rolls 19 and 20 are arranged. The carbon fiber fabric 3, the release film 4, the hot melt resin layer 5 and the release film 7 are integrated and introduced between the heating and pressing rolls 19 and 20 and heated and pressurized. At this time, it is preferable that the heating and pressurizing rolls 19 and 20 are provided in multiple stages, and the temperature is gradually increased, the preheating temperature is preferably 50 to 60 ° C., and the final main heating temperature is 80 to 110 ° C. It is preferable to set it as ° C. Moreover, the applied pressure at this time shall be 0.1-0.3 Mpa. By this heating and pressurization, the hot melt resin layer 5 is melted and fluidized, and the carbon fiber fabric 3 can be effectively impregnated. The carbon fiber intermediate material 3 ′ impregnated with the hot melt resin is guided by the third guide roll 21 and taken up by a winder (not shown).

  In the above embodiment, a hot melt resin layer carried on one side of a single hot melt film is attached to one side of a carbon fiber fabric, and this is heat-pressed to form a hot melt resin as a matrix resin on the carbon fiber fabric. Impregnated. However, the present invention is not limited to the above-described embodiment, and a hot melt film having a hot melt resin layer formed on one side is sandwiched from both the front and back sides of the reinforcing fiber fabric with the resin surface inside, and the resin is applied to the reinforcing fiber fabric. Can also be impregnated.

  Since the carbon fiber fabric intermediate material obtained by the above-described embodiment is continuously impregnated with the hot melt resin by the hot melt method without continuously dropping the carbon fiber fabric to be woven from the loom, Even when impregnated, the warp yarn maintains the tension distribution immediately after weaving, so that the texture form does not change, and in particular, the occurrence of weft yarn bending is effectively suppressed. Further, according to the present embodiment, the peripheral surface of the heating and pressing roll 18 is embossed. Of course, it may be formed on a smooth surface without embossing. Thus, by this embossing, the convex portion and the concave portion of the embossed surface press the carbon fiber fabric 3 with a difference in strength through the hot melt resin layer 5 at the time of heating and pressing. The hot melt resin in the melted state is uniformly impregnated throughout the carbon fiber woven fabric 3 and penetrates between the constituent fibers of the carbon fiber woven fabric 3 to firmly bond the fibers together. It is better and better.

[Examples 1 to 5 and Comparative Examples 1 to 3]
Below, this invention is demonstrated with a comparative example based on a more specific Example.

In Examples 1 to 5 and Comparative Examples 1 to 3, the same Mitsubishi Rayon Co., Ltd. pyrofil (carbon fiber) is used as the reinforcing fiber for the warp and weft of the reinforcing fiber fabric. It consists of a fiber bundle in which carbon fibers made of 3000 filaments are aligned. In Examples 1 to 5 and Comparative Examples 1 to 3, 500 warps are used, and the basis weight of the carbon fiber fabric is 200 g / m ² . A rapier type loom is used as the loom used. The loom speed is 200 rpm and the warp feed rate is 0.4 m / min.

  As shown in FIG. 1, the weaving of the carbon fiber fabric is performed by directly turning each warp consisting of 500 carbon fiber bundles released from the bobbins on the bobbin creel through a plurality of guide rolls and nip rolls. After weaving and aligning, weaving a weft of carbon fiber bundles into the openings formed between the warps, and then punching to form a woven fabric. In Examples 1 to 5 and Comparative Examples 1 and 2, the carbon fiber woven fabric after weaving is fed to a drawing roll disposed forward after weaving without lowering from the loom. The carbon fiber fabric sent to the drawing roll moves further forward through the first guide roll.

  Here, in Examples 1 and 2 and Comparative Examples 1 and 3, a hot melt resin layer, which is a matrix resin, is disposed on one side of a carbon fiber fabric and is impregnated with transfer. Therefore, when the carbon fiber fabric passes through the first guide roll, the release agent application surface of the release film having a release agent such as silicone applied on one side is overlapped with and merged with the carbon fiber fabric.

  Moreover, in Examples 3 to 5 and Comparative Example 2, the hot melt resin layer, which is a matrix resin, is disposed on both the front and back surfaces of the carbon fiber fabric and is impregnated with transfer. Therefore, the resin surface of the sheet in which the hot melt resin layer is supported on the release agent application surface of the release film in which the release agent such as silicone is applied on one side to the carbon fiber fabric introduced into the first guide roll. The sheets are joined together so as to overlap the carbon fiber fabric.

  The merged carbon fiber fabric and release film or sheet are introduced to the lower surface side of the second guide roll disposed in front of the first guide roll. At the same time, a hot melt film shown in FIG. 2 in which a hot melt resin layer serving as a matrix resin is sandwiched between two front and back surfaces with two release films is wound around a half circumference of the second guide roll, and then the carbon fiber It introduce | transduces between a textile fabric and a 2nd guide roll. In Examples 1 to 5 and Comparative Examples 1 to 3, the material of one of the release films peeled from the hot melt film is polyethylene, and the other of the hot melt resin layers is sandwiched between the carbon fiber fabric. Release paper that has been subjected to a release treatment is used as the material of the release film. The transition thicknesses of the hot melt resin layers of Examples 1 to 5 and Comparative Examples 1 to 3 are as shown in Table 1.

  The carbon fiber fabric in which the hot melt resin layer is superposed on one side or both sides and then integrated is then introduced together with the release film between the two pairs of upper and lower heat and pressure rolls arranged in front of the second guide roll. And heated and pressurized. At this time, the temperatures of the first set of heat and pressure rolls and the second set of heat and pressure rolls are as shown in Table 1. Further, the applied pressure at this time is as shown in Table 1. By this heating and pressing, the hot melt resin layer is melted and fluidized, and impregnated inside the carbon fiber fabric. The carbon fiber intermediate material impregnated with the hot melt resin is guided by the third guide roll and wound by the winder.

  Here, although Examples 1-5 and Comparative Examples 1 and 2 have obtained the carbon fiber intermediate material through the above-mentioned continuous process, as described above, in Comparative Example 3, the carbon fiber fabric is lowered from the loom after weaving. Once wound up, the carbon fiber fabric is impregnated with a hot melt resin through the above-described steps.

  In Table 1, in the weft determination of the weft, “◯” indicates that there is almost no bend, “Δ” indicates that a slight bend occurs, and “×” indicates a case where a bend occurs. .

  As can be seen from Table 1, when the pressing force of the heating and pressing roll is increased by 0.4 Mpa or more and the resin thickness at the time of resin transfer is 110 μm or more, the weft yarn becomes prominent, and at the same time, the carbon fiber fabric is hot. Resin flow occurs when the melt resin is impregnated. Even if the pressure of the heating and pressing roll is smaller than 0.4, the carbon fiber woven fabric can be obtained without weaving the matrix resin based on the hot melt method into the carbon fiber woven fabric following the weaving of the carbon fiber woven fabric. Even if a resin impregnation treatment is performed after the loom is once lowered from the loom after weaving, a carbon fiber intermediate material having excellent mechanical properties cannot be obtained.

It is explanatory drawing which shows the manufacturing process of this invention roughly. It is an enlarged view of the A section shown by the arrow in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Warp 2 Weft 3 Carbon fiber fabric 3 'Carbon fiber fabric intermediate material 4 Release film 5 Hot melt resin layer 6, 7 Release film 8 Hot melt film 9 Roll body 10 Release film winding paper tube 11 Bobbin creel 12 Bobbin 13 Hell
14 筬 15 Drawer roll 16 First guide roll 17 Second guide roll 18 Peeling guide rolls 19 and 20 Heating and pressing roll 21 Third guide roll

Claims (6)

  Resin comprising weaving a reinforcing fiber fabric using warps and wefts composed of substantially continuous reinforcing fibers, and subsequently impregnating the reinforcing fiber fabric with a resin by a hot melt method following the weaving Of a reinforcing fiber woven fabric intermediate material impregnated with.   The method for producing an intermediate material for reinforcing fiber fabric according to claim 1, wherein the warp and weft of the reinforcing fiber fabric are carbon fiber fabrics made of carbon fibers. The method for producing a reinforcing fiber fabric intermediate material according to claim ² , wherein the basis weight of the carbon fiber fabric is 150 to 600 g / m2. The hot melt method is:
Continuously attaching the resin surface of the hot melt film carrying the resin on one side of the release film to the surface of the carbon fiber fabric to be woven;
Continuously attaching a release film to the back surface of the carbon fiber fabric to be woven;
The carbon fiber fabric that is sandwiched and moved between the hot melt film and the release film is heated and pressurized with a heating roll, and the carbon fiber fabric is transferred and impregnated with a resin supported on the hot melt film. When,
Winding the carbon fiber woven fabric impregnated with resin continuously on a winding roll;
A method for producing a reinforcing fiber fabric intermediate material impregnated with the resin according to claim 2 or 3. The hot melt method is:
Continuously attaching the resin surface of the hot melt film carrying the resin on one side of the release film to the front and back surfaces of the carbon fiber fabric to be woven;
Heating and pressurizing the carbon fiber woven fabric sandwiched between the hot melt films with a heating roll, and transferring and impregnating the carbon fiber woven fabric with a resin carried on the hot melt film;
Winding the carbon fiber woven fabric impregnated with resin continuously on a winding roll;
A method for producing a reinforcing fiber fabric intermediate material impregnated with the resin according to claim 2 or 3.   The method for producing a reinforcing fiber fabric intermediate material impregnated with a resin according to claim 4 or 5, comprising embossing the surface of the heating roll.

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