JPH03270908A - Manufacture of multi-layer prepreg - Google Patents

Abstract

PURPOSE:To eliminate the labor for sticking a film and manufacture a multi- layer prepreg easily by forming a prepreg composed of reinforced fiber and matrix resin and simultaneously bonding and laminating a thermoplastic film on said prepreg. CONSTITUTION:First and second release sheets 6 and 11 composed of matrix resin layers and reinforced fiber 2 inserted between the layers are clamped by press rolls 13a and 13b and pressurized therein to embed the reinforced fiber 2 into the matrix resin layers, and the area between each of the reinforced fibers 2 is impregnated with the matrix resin. After that, semi-curing of matrix resin impregnating the areas between the reinforced fibers 2 and bonding of a film 4 are carried out by using a hot plate 20, and then said material is clamped again between the press rolls 15a and 15b and pressurized again therein. A prepreg 3 composed of reinforced fiber 2 and matrix resin is formed by said process, and a multi-layer prepreg 1 composed of prepregs 3 on which the thermoplastic resin film 4 is laminated is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION 1. The present invention provides a method for forming a cured prepreg body by heating and curing a prepreg layer obtained by laminating prepregs made of reinforcing fibers and a matrix resin. The present invention relates to a method for manufacturing a multilayer prepreg that can easily obtain properties.

For example, it is known that golf shafts, tennis rackets, etc. can be manufactured by forming a prepreg cured body using prepreg with carbon fiber as a reinforcing fiber and thermosetting resin such as epoxy resin as a matrix resin. It is being

To briefly explain the case of manufacturing a golf shaft as an example, a prepreg having the same length as the rod is wrapped around a rod that becomes the mold of the golf shaft and laminated.
A pressure tape is wound around the laminated prepreg layer, and the prepreg layer is heated and cured while the pressure tape prevents deformation of the prepreg layer, thereby obtaining a golf shaft-shaped prepreg cured body. Next, after removing the mold rod and the holding tape, the surface of the cured prepreg is smoothed by polishing to remove wrinkles on the surface of the cured prepreg caused by the holding tape during heat curing. By painting the surface accordingly, a golf shaft made of a cured prepreg body is obtained.

As mentioned above, when manufacturing a golf shaft or the like made of a cured prepreg body using prepreg, wrinkles are formed on the surface of the cured prepreg body due to the pressure tape during heat curing, so in order to remove these wrinkles. The surface of the cured prepreg body is polished and smoothed.

However, since the prepreg that forms the cured prepreg uses a thermosetting resin such as epoxy resin as a matrix resin, the cured prepreg obtained is extremely hard. There is a problem in that it is not easy to remove such particles by methods such as methods, and requires a great deal of effort.

In addition, when carbon fiber is used as a reinforcing fiber, the cured prepreg material exhibits a black color, and in the case of golf shafts, etc., the surface tends to lack decorative properties, so there is a problem that painting is often required. .

The above has described the case of manufacturing golf shafts etc. made of prepreg cured bodies, but when reinforcing structures such as pillars of buildings and bridge girders using prepreg, it is also possible to In order to form a prepreg cured product by wrapping a pressure tape around it and heating and curing it while preventing the deformation of the prepreg layer, the surface of the obtained prepreg cured product will have wrinkles due to the pressure tape, so the prepreg cured product A similar problem arises in areas where it is required to improve the appearance of the image.

Furthermore, since fiber-reinforced plastics such as prepreg cured bodies are generally more brittle and lack toughness than metals, measures to compensate for these drawbacks are also desired.

The present inventors used prepregs made of reinforcing fibers and matrix resin to manufacture golf shafts, tennis rackets, etc., and also to strengthen structures such as pillars of buildings and bridge girders. We have conducted extensive research to make it possible to easily remove wrinkles on the surface, ensure surface decoration without necessarily painting, and compensate for the lack of toughness.

As a result, it was found that the outermost layer of the prepreg layers laminated to form a cured prepreg body may be a multilayer prepreg in which a thermoplastic resin film is laminated on the prepreg.

In light of the above, an object of the present invention is to provide a method for manufacturing a multilayer prepreg that can easily produce a multilayer prepreg in which a thermoplastic resin film is laminated on a prepreg.

The above-mentioned purpose to achieve this is accomplished by the method for manufacturing a multilayer prepreg according to the present invention. In summary, the present invention provides a matrix resin layer provided on a first release paper via a thermoplastic resin film, and a matrix resin of the same resin as the matrix resin layer provided on a second release paper. between the first layer and the first layer.
, by applying heat and pressure from at least one side of the first and second release papers while continuously supplying the reinforcing fibers in synchronization with the running of the second release paper, the reinforcing fibers and the This method of manufacturing a multilayer prepreg is characterized in that a multilayer prepreg is obtained by laminating a film of the thermoplastic resin on a prepreg made of a matrix resin.

Todorowara Examples of the present invention will be described in detail below.

First, a multilayer prepreg manufactured by the method of the present invention will be explained.

As shown in FIG. 1, a multilayer prepreg 1 is made by laminating a film 4 of thermoplastic resin such as polyurethane elastomer on a prepreg 3 made of reinforcing fibers such as carbon fiber and matrix resin such as epoxy resin. There is.

In principle, any thermoplastic resin film 4 can be used as long as it is transparent, such as polyurethane, polyester, nylon, polycarbonate, PB, etc.
Films of thermoplastic resins such as T, polyacetal, ABS, PPS, and PP can be used, but preferably,
For example, when an epoxy resin is used as the matrix resin of the prepreg 2, it is preferable to use a thermoplastic resin film having good compatibility with the matrix resin, such as a polyurethane resin film. If such a compatible thermoplastic resin film 4 is used, the film 4 can be well adhered to the prepreg 3 and the film 4 can be obtained without peeling or the like, and is stable on the surface of the prepreg cured product. It can be provided as follows.

The thickness of the thermoplastic resin film 4 is preferably 5 to 1
It is assumed to be about 00 μm. The thickness of the film 4 is 5 μm
If it is less than that, it will be too thin and it will be difficult to absorb and remove wrinkles generated on the film 4 by the pressing tape during heating and curing of the prepreg 3 layer by heating and pressing the film 4. On the other hand, if the thickness of the film 4 exceeds 100 μm, it is too thick, and the decrease in surface strength and increase in weight of the cured prepreg product cannot be ignored.

By being transparent, the thermoplastic resin film 4 described above can impart decorative properties to the surface of the resulting cured prepreg. When using
A prepreg cured product can be obtained by patterning the surface of the prepreg located at the outermost layer of the prepreg 3 with a pattern of thin metallic lines such as gold lines or silver edges, and then covering it with a thermoplastic resin film 4 from above. Since the thin metal-colored lines can be seen through the surface of the prepreg, the decorativeness of the surface of the cured prepreg can be further improved. In addition, according to the thermoplastic resin film 4, it is also possible to give the prepreg cured body surface decoration by painting as in the conventional manner.

As the reinforcing fiber for the prepreg 3, any reinforcing fiber can be used in principle, but carbon fiber, aramid fiber, silicon carbide fiber, alumina fiber, glass fiber, etc. can be suitably used. As the matrix resin for the prepreg 3, any thermosetting resin can be used in principle, but epoxy resins, unsaturated polyester resins, diallyl phthalate resins, phenol resins, etc. can be suitably used.

When manufacturing a golf shaft, for example, the multilayer prepreg 1 described above is produced by wrapping the prepreg 3 around a rod-shaped body 1o that becomes a mold of the golf shaft and laminating it to form a prepreg layer 3A, as shown in FIG. When doing so, it is used as the outermost layer of the prepreg layer 3A.

A thermoplastic resin film 4 is placed on such prepreg 3.
If the multilayer prepreg 1 provided with this is the outermost layer of the laminated prepreg layers 3A, wrinkles caused by the pressure tape during heat curing will be formed on this film 4. Since this film 4 is made of thermoplastic resin and softens with heat, wrinkles can be easily absorbed into the film 4 by heating the film 4 from the surface of the obtained prepreg cured product and pressing it to smooth out the wrinkles. It is possible to obtain a cured prepreg product with no wrinkles on the surface.

In addition, when using prepreg 3 made of carbon fiber as a reinforcing fiber, the cured prepreg material exhibits a black color, and in the case of golf shafts, tennis rackets, etc., the surface is likely to lack decorative properties, so painting is required. However, if the surface of the prepreg cured product is covered with a transparent film layer, the surface of the cured prepreg product will have excellent decorative properties. Since the thermoplastic resin film 4 is transparent, its placement on the surface of the cured prepreg material easily satisfies this requirement and allows the surface to be easily decorated. Further, according to the thermoplastic resin film 4, it is also possible to give the cured prepreg body surface decoration by painting as in the conventional manner.

Furthermore, since a relatively flexible surface layer called the thermoplastic resin film 4 is provided on the surface of the cured prepreg body, for example, golf shafts and tennis rackets made of the cured prepreg body can easily absorb impact. Even if the prepreg cured body lacks toughness compared to metal, it can make up for the disadvantages of the cured prepreg body, such as absorbing moisture and preventing the scattering of broken pieces when broken.

Therefore, problems that conventionally occur when manufacturing golf shafts, tennis rackets, etc. by forming a prepreg cured body using only prepreg without a thermoplastic resin film can be easily solved. Similarly, problems associated with reinforcing structures such as building columns and bridge girders using the prepreg cured body are also solved.

Now, the multilayer prepreg 1 described above can be obtained by pasting a thermoplastic resin film 4 on one surface of the prepreg 3 using an adhesive, but in order to simplify manufacturing by eliminating the trouble of pasting, In the present invention, the multilayer prepreg 1 is manufactured in the following manner.

FIG. 3 is an explanatory diagram showing an embodiment of the manufacturing method of the present invention.

In FIG. 3, 7 is a first unwinder (unwinding part) around which a first release paper 6 on which a thermoplastic resin film 4 is laminated is wound, and 9 is a second unwinder on which no film is laminated.
This is a second unwinder around which a release paper 11 is wound. The first release paper 6 that is drawn out from the first unwinder 7 and runs is coated with a matrix resin at a coating roll 8, and a matrix resin layer is formed on the film 4. Similarly, the second release paper 11 that runs when pulled out from the second unwinder 9 is coated with a matrix resin layer of the same resin as the matrix resin layer formed on the film 4 on the first release paper 11. It is formed by application on the roll 12. These first and second release papers 6° 11 are fed and inserted between the pair of press rolls 13a and 13b while facing each other with their respective matrix resin layers on the inside.

The reinforcing fibers 2 are supplied between the matrix resin layers of the first and second release papers 6.1.1.

The reinforcing fiber 2 is passed through the third unwinder 1 that wraps the reinforcing fiber 2.
After being pulled out from the press roll 13a and subjected to a fiber opening process by a fiber opening means (not shown).

13b between the first and second release papers 6.
11 is continuously supplied between these matrix resin layers. In this way, the reinforcing fibers 2 are sandwiched between the matrix resin layers of the first and second release papers 6.11.

The first and second release papers 6.11 with reinforcing fibers 2 sandwiched between the matrix resin layers are rolled onto the press roll 1.
By sandwiching and pressurizing between 3a and 13b, the reinforcing fibers 2 are buried in the matrix resin layer and the matrix resin is impregnated between the reinforcing fibers 2, and then heated with the hot plate 20, The matrix resin impregnated between the reinforcing fibers 2 is semi-cured and the film 4 is bonded, and then the reinforcing fibers 2 and A prepreg 3 made of a matrix resin is formed to obtain a multilayer prepreg 1 in which a thermoplastic resin film 4 is laminated on the prepreg 3.

Thereafter, the first release paper 6 of the first and second release paper 6.11 on the film 4 of the multilayer prepreg 1 is peeled off by the winder 16, and if necessary, the cover film is supplied from the unwinder 17. 18 on the film 4 and then winding it up on the winder 19.

In the above, a pair of press rolls 13a are described.

By using a 13b% hot plate 20 and a pair of press rolls 15a and 15b, the matrix resin was impregnated between the reinforcing fibers 2, the matrix resin was semi-cured, and the film 4 was bonded. If it is possible to achieve the above-mentioned effects such as matrix resin impregnation by applying heat and pressure from at least one of the first and second release papers 6.11 with reinforcing fibers 2 sandwiched between the resin layers. For example, any pressure and heating means may be used, and the present invention does not care about the form of the pressure and heating means.

As explained above, in the manufacturing method of the present invention, the matrix resin layer is provided on the first release paper via a thermoplastic resin film, and the matrix resin layer is provided on the second release paper via a thermoplastic resin film. While continuously supplying reinforcing fibers between the leaked matrix resin layer and a matrix resin layer made of the same resin in synchronization with the running of the first and second release papers, the first and second release papers are added. By applying heat and pressure from at least one side of the paper pattern, a prepreg made of reinforcing fibers and matrix resin is formed, and at the same time, a thermoplastic resin film is bonded and laminated on top of the prepreg. A multilayer prepreg in which a thermoplastic resin film is laminated on a prepreg can be easily produced without requiring the effort of attaching a film with an adhesive or the like.

FIG. 2 is a perspective view showing how the multilayer prepreg of FIG. 1 is used.

FIG. 3 is an explanatory diagram showing an embodiment of the manufacturing method of the present invention.

6, 9 8, 12 3 al 5b 0 :Multilayer prepreg double reinforced fiber niblibreg :Thermoplastic resin film :Release paper : Application roll 13b, 15a, nibbles roll :Hot plate 46

[Brief explanation of drawings]

FIG. 1 is a perspective view showing one embodiment of a multilayer prepreg manufactured by the manufacturing method of the present invention.

Claims (1)

[Claims] 1) Between the matrix resin layer provided on the first release paper via a thermoplastic resin film and the matrix resin layer made of the same resin as the matrix resin layer provided on the second release paper. , by applying heat and pressure from at least one side of the first and second release papers while continuously supplying reinforcing fibers in synchronization with the running of the first and second release papers; A method for producing a multilayer prepreg, which comprises obtaining a multilayer prepreg by laminating a film of the thermoplastic resin on a prepreg made of reinforcing fibers and the matrix resin.