JP3308965B2 - Prepreg - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a prepreg used for forming a structural member such as an airframe of an aircraft.

[0002]

2. Description of the Related Art FIG. 12 is a cross-sectional view showing a part of a prepreg 1 of the related art in which interlayer particle reinforcement is applied. For example, the body of an aircraft is formed using a prepreg 1 which is a fiber-reinforced resin-based composite material. The prepreg 1 includes a fiber reinforced layer 4 in which a fiber material 2 is impregnated with a matrix resin 3, and a particle reinforced layer 6 formed on both sides in the thickness direction of the fiber reinforced layer 4 and in which fine particles 5 are mixed into the matrix resin 3. Have. Further, the prepreg 1 is covered with the release sheet 7 from the outside of each particle reinforcing layer 6 to prevent the prepreg 1 from being damaged. After releasing the release sheets 7 and laminating the prepregs 1, the matrix resin 3 is cured, and the above-described aircraft body is formed.

[0003] A prepreg 1 for molding this airframe
Has a particle reinforcing layer 6 formed in order to improve the toughness after molding and improve the impact resistance. This particle reinforcing layer 6
By forming the particles, even if hail or the like collides with the molded body and an impact force is applied, the impact force is absorbed by the deformation of the fine particles 5, and the occurrence of cracks can be prevented.

FIG. 13 is a perspective view showing a manufacturing procedure of the prepreg 1, FIG. 13 (1) shows a state in which resin sheets 12 are arranged on both sides of the fiber material 2, and FIG. 13 shows a state in which the release sheets 7 are arranged on both sides, and FIG. 13C shows a state in which the release sheets 7 are bonded to the prepreg 1. The prepreg 1 is formed by laminating a sheet material 12 of a matrix resin 3 mixed with fine particles 5 on both sides of a fiber material 2 made of carbon fiber and having a thickness of 0.12 mm, and pressing and heating from both sides in the thickness direction. The matrix resin 3 is impregnated into the fiber material 2 and partially cured to form the prepreg 1. The matrix resin 3 is, for example, a bismaleimide resin, and the thickness of the sheet material 12 is 0.04 mm. The fine particles 5
Particles made of a polyamide resin having a particle size of 10 μm,
It is mixed in the sheet material at a mixing amount of 15 g / m ² . In the prepreg 1, the total content (resin content) Rc of the matrix resin 3 is 40% by weight.

[0005]

FIG. 14 is a cross-sectional view showing an enlarged part of the prepreg 1 in detail. FIG.
5 is an enlarged cross-sectional view of one of the particle reinforcing layers 6, FIG. 15 (1) shows a cross section in a state where the release sheet 7 is partially peeled, and FIG. 3 shows a cross section in a state several minutes after the mold sheet 7 has been peeled off. In forming an aircraft body using the prepreg 1, in order to facilitate the forming operation and reduce the manufacturing cost, it is necessary to facilitate the laminating operation by laminating the prepreg 1 using a laminating apparatus. . In order to enable lamination of the prepreg 1 by the laminating apparatus, the prepreg 1 needs to have tackiness. The tackiness is obtained by the matrix resin 3. If the matrix resin 3 forms the outer surface, the tackiness sufficient for using the laminating apparatus can be obtained, but the fine particles 5 protrude outside the matrix resin 3. In such a case, the tackiness to the extent that the laminating apparatus can be used cannot be obtained.

[0006] The prepreg 1 is in a state where the curing reaction of the matrix resin 3 is suppressed in the middle as described above. In the particle reinforced layer 6 of the prepreg, the matrix resin 3 tries to penetrate into the fiber material 2 of the fiber reinforced layer 4, whereas the fine particles 5 remain outside the fiber material 2 (both in the thickness direction). Try to. When the release sheet 7 is adhered, since the matrix resin 3 is adhered to the release sheet 7, the penetration of the matrix resin 3 of the particle reinforcing layer 6 into the fiber material 2 is suppressed, and FIG. As shown in 1), when the release sheet 7 is adhered and immediately after the release sheet 7 is peeled off, a portion projecting outward from the fine particles 5 of the matrix resin 3 called resin branches or the like. 11 are present in a wide range, and the portion 11 has such tackiness that a laminating apparatus can be used.

On the other hand, when about 5 minutes have passed since the release sheet 7 was peeled off, the penetration of the matrix resin 3 of the particle reinforcing layer 6 into the fiber material 2 further progressed, and a portion 11 called a resin branch was formed. As shown in FIG. 14 and FIG. 15 (2), the fine particles 5 protrude outside the matrix resin 3 and the tackiness becomes extremely low. Therefore, when about 5 minutes or more have elapsed since the release sheet 7 was peeled off, the lamination cannot be performed using the laminating apparatus. As described above, the prepreg 1 is difficult to apply to the laminating apparatus, and is manually laminated.

To improve (improve) the tackiness of the prepreg 1, for example, it is conceivable to increase the content Rc of the matrix resin 3. However, in order to increase the content Rc of the matrix resin 3, When the thickness of the material 12 is increased, the ratio of the fine particles 5 cannot be changed in order to secure the toughness, so that the tackiness on the surface cannot be improved. Further, when laminating the prepreg 1, a method of heating the prepreg 1 to a temperature at which the viscosity of the matrix resin 3 decreases is considered, but tackiness cannot be improved because the fine particles 5 are projected outside. . Although a method of improving the viscosity by mixing a solvent with the matrix resin 3 is conceivable, this method also cannot improve the tackiness for the same reason as described above, and furthermore, the solvent component is contained in the material after molding. It remains in the form of air bubbles, which significantly lowers the quality.

An object of the present invention is to provide a high toughness after molding,
Another object of the present invention is to provide a prepreg having high tackiness.

[0010]

SUMMARY OF THE INVENTION The present invention provides a fiber reinforced layer in which a matrix material is impregnated into a fiber material, and a particle reinforced layer formed on both sides in the thickness direction of the fiber reinforced layer and in which fine particles are mixed into the matrix resin. And a coat resin layer made of a matrix resin that covers at least one of the particle reinforcing layers.

According to the present invention, a particle reinforced layer is formed on both sides in the thickness direction of the fiber reinforced layer, and at least one of the particle reinforced layers is coated to form a coat resin layer. By forming the particle reinforcing layer, generation of cracks by the fine particles after molding can be prevented, and toughness can be increased. Further, by forming a coating resin layer covering the particle reinforcing layer, on the side where the coating resin layer is formed, the fine particles in the particle reinforcing layer are prevented from protruding to the outside, and the matrix is formed so that the fine particles are not exposed. An outer surface made of resin can be formed. As a result, a decrease in tackiness due to the fine particles being exposed to the outside can be prevented, a high tackiness can be obtained, and a prepreg can be laminated using a laminating apparatus. Therefore, it is possible to manufacture a structural member having high toughness, to facilitate laminating work, to facilitate molding, and to reduce a manufacturing cost of the structural member and the like.

Further, the present invention is characterized in that the fine particle content in each particle reinforced layer is determined based on the amount of matrix resin in the fiber reinforced layer, each particle reinforced layer and the coat resin layer.

According to the present invention, fine particles having a content based on the amount of matrix resin in the fiber reinforced layer, each particle reinforced layer and the coating resin layer are mixed in each particle reinforced layer. Thus, the total amount of the fine particles contained in a molded article, for example, a structural member formed by laminating and molding a prepreg, is an amount by which sufficient toughness of the molded article is obtained,
In addition, since the matrix resin once becomes extremely low in viscosity and flows by heating during molding, the fine particles can be uniformly dispersed in the matrix resin layer including the coat resin layer. Therefore, in order to obtain a high tackiness, even when the coat resin layer is formed, the toughness of the formed structural member or the like is prevented from being reduced, and the deterioration of the quality of the formed structural member or the like is prevented. .

[0014]

FIG. 1 is a sectional view showing a part of a prepreg 20 according to an embodiment of the present invention, and FIG. 2 is a perspective view showing a roll formed by winding the prepreg 20. . FIG. 1 is a cross-sectional view taken along line II of FIG. The prepreg 20 includes a fiber reinforced layer 23 in which a fiber material 21 is impregnated with a matrix resin 22, and a fiber reinforced layer 23.
A particle reinforcing layer 25 formed on both sides in the thickness direction of the matrix resin and in which the fine particles 24 are mixed into the matrix resin 22, and a coat composed of the matrix resin 22 that covers at least one of the particle reinforcing layers 25 in the present embodiment. And a resin layer 26. A release sheet 27 is removably attached to the prepreg 20 from both sides in the thickness direction, in other words, from the outside of each coat resin layer 26.
0 is protected by each release sheet 27 so as not to be damaged. This prepreg 20 has a width W of, for example, 5
A roll is formed in a spiral shape around a winding core 28 having a belt shape of mm and having outward flanges at both ends in the axial direction.

The fibrous material 21 is constituted by, for example, drawing carbon fibers 29 having a fiber diameter of 7 μm in the same direction. Each carbon fiber 29 extends in the longitudinal direction X of the prepreg 20, which is a direction perpendicular to the paper surface of FIG. In the fiber reinforced layer 23, the fibrous material 21 is impregnated with the matrix resin 22 so that the carbon fibers 29 are dispersed in the matrix resin 22, in other words, the matrix resin 22 is filled between the carbon fibers 29. You. The thickness of the fiber reinforced layer 23 is, for example, 0.12 mm.

The fine particles 24 have, for example, a particle size of about 10 μm.
φ, for example, made of a thermoplastic resin, more specifically, a polyamide resin. In the particle reinforcing layer 25, such fine particles are dispersed and mixed in the matrix resin 22. The thickness of the particle reinforcing layer 25 is, for example, 0.1 mm.
03 mm. The coat resin layer 26 is composed of only the matrix resin 22 and does not include the carbon fibers 29 and the fine particles 24. The thickness of the coat resin layer 26 is, for example, 0.01 mm. The release sheet 27 is a sheet made of polyethylene, and is adhered to the coat resin layer 26 by the adhesive force of the matrix resin 22.

The matrix resin 22 of each of the layers 23, 25, 26 is the same resin, for example, a thermosetting resin.
More specifically, it is made of an addition-polymerized thermosetting bismaleimide resin of an imidized oligomer. Each of these layers 23, 2
5, 26 matrix resin 22 is integrally connected so that an edge continues between each layer.
2, the fiber material 21 is provided in the fiber reinforced layer 23, and the fine particles 24 are provided in the particle reinforced layer 25. Therefore, the matrix resin 22 of each of the layers 23, 25, 26 is given the same reference numeral. FIG. 1 shows boundaries between the layers 23, 25, and 26 for clarity of the layer configuration.

A prepreg (pre-impregnated) 20 is obtained by impregnating a matrix material 22 into a fibrous material 21 made of carbon fiber 29, which is a high-performance fiber, and preliminarily polymerizing the fibrous material. This is a molding material in which the curing reaction is advanced, the temperature is lowered, and the reaction is stopped halfway (B stage). The content Rc (resin content) of the matrix resin 22 of the prepreg 20 is 40% by weight as in the conventional technology. The prepreg 20 of the present embodiment is a uni-directional (UD) prepreg in which carbon fibers 29 are aligned in one direction.

FIG. 3 is a sectional view showing a part of the prepreg 20 in an enlarged manner and showing the inside in detail. FIG. 4 is an enlarged cross-sectional view showing one particle reinforcing layer 25 and the coating resin layer 26 in detail, and FIG.
FIG. 4 (2) shows a cross section in a state in which is partially peeled off.
The cross section in a state several minutes after the release sheet 7 is peeled off is shown. The prepreg 20 is in a state where the curing reaction of the matrix resin 22 is suppressed in the middle as described above.
In the prepreg 20, the matrix resin 3 of the particle reinforcing layer 25 and the coat resin layer 26 tends to penetrate into the fiber material 21 of the fiber reinforcing layer 23. On the other hand, the fine particles 24 tend to stay outside the fiber material 21 (on both sides in the thickness direction). When the release sheet 27 is stuck,
Since the matrix resin 22 is adhered to the release sheet 27, the particle reinforcing layer 25 and the coating resin layer 26
4A is suppressed, and as shown in FIG. 4A, when the release sheet 27 is adhered and immediately after the release sheet 27 is peeled, the outer surface Are formed smoothly by the matrix resin 22, and good tackiness is obtained.

In the prepreg 20, since the coating resin layer 26 is formed, about 5 minutes have passed since the release sheet 7 was peeled off, and the fibrous material 21 of the particle reinforcing layer 25 and the matrix resin 22 of the coating resin layer 26 was formed. Even if the permeation of the fine particles 24 proceeds, the presence and absence of the coating resin layer 26 prevent the fine particles 24 from projecting and being exposed to the outside. As a result, the outer surface of the prepreg 20 is formed smoothly by the matrix resin 22, and the state is maintained. Therefore, good tackiness can be obtained even after a lapse of 5 minutes or more after the release sheet 27 is peeled off.

In the prepreg 20, the particle reinforcing layer 25
Is determined based on the amount of matrix resin in the fiber reinforced layer 23, each particle reinforced layer 25, and each coat resin layer 26. More specifically,
The content is determined based on the content Rc of the matrix resin 22 in the entire prepreg in consideration of the content of the fiber material 21. The composition ratio of the prepreg 20 is, for example, 60% by weight of the fiber material 21, 12% by weight of the fine particles 24, and the resin content including the matrix resin 22 and the fine particles 24 is (Rc =) 40%.

FIG. 5 is a perspective view showing a laminating apparatus 30 for the prepreg 20, and FIG. 6 is an enlarged perspective view showing section VI of FIG. The laminating apparatus 30 is an apparatus for laminating the prepreg 20 on the outer surface of the mold 31 a plurality of times, and includes a support means 32 for supporting the mold 31 and a storage means for storing the prepreg 20 in an extendable manner. 33
And roller means 34 for extending the prepreg 20 along the outer surface of the mold 31.

The support means 32 allows the mold 31 to be detachably mounted on the two support bases 35 and to be fixed to a predetermined rotation axis L.
It is supported so as to be rotatable in one rotation direction B. A driving means 36 is provided on one support base 35, and the driving means 36 can rotationally drive the mold 31 in the rotation direction B.

The storage means 33 has a plurality of holding portions 37 for holding the roll of the prepreg 20 wound as shown in FIG. 2, and holds the prepreg 20 in each holding portion 37. You can keep. Storage means 33
Can release the held prepreg 20 from each release sheet 27 and sequentially feed it. Laminating device 30
A traveling platform 38 that can be driven to be displaced in a direction C that approaches and separates from the rotation axis L1 of the mold 31 and a direction D that is parallel to the rotation axis L1 of the mold 31, and a traveling platform 38 that is parallel to the rotation axis L1 of the mold 31. And an arm 39 provided so as to be capable of driving angular displacement in a direction E around the axis L2. At the end of the arm 39 on the side away from the mold 31,
3 is fixed.

The roller means 34 includes a roller 40 around which the prepreg 20 fed from the storage means 33 is wound, and a roller support 41 for rotatably supporting the roller 40. The roller means 34 further has a connecting portion 42, and the connecting portion 42 is connected to an end of the arm 39 on the side close to the mold 31. The connecting portion 42 is connected to the arm 39 so as to be angularly displaceable in the direction X around the axis L3 of the arm, and the roller supporting portion 41 is connected to the connecting portion 42 around the axis L4 at a position twisted with respect to the axis L3. , And an angular displacement in a direction Z about an axis L5 perpendicular to the axis L4 and at a position twisted with the axis L3.

In such a roller means 34, the roller 40 can be arranged along the outer surface of the mold 31, and the prepreg 20 wound around the roller 40 is moved along the outer surface of the mold. It can be pressed against the mold.
The prepreg 20 can be extended along the outer surface of the mold by rotating the mold 31 while pressing the prepreg 20 fed from the storage means 33 by the roller means 34. Therefore, by controlling the rotation of the mold and the displacement of the traveling platform, the prepreg 20 can be laminated according to the mold. In such a state of lamination, baking and hardening, that is, a process of causing the matrix resin 22 to undergo a curing reaction as a whole, is performed, and a predetermined structural member is formed by the prepreg 20 based on the mold. In the present embodiment, for example, structural members and the like constituting the body of an aircraft flying at supersonic speed are formed.

In laminating the prepreg 20 using the laminating apparatus 30 as described above, it is necessary to prevent the prepreg 20 from slipping with respect to the mold 31. Sex is required. Tackiness represents tackiness.

FIG. 7 is a sectional view showing a method of measuring tackiness. The tackiness is based on ASTM (American Society for T)
esting and Materials). A horizontal rolling surface 100 is formed by the prepreg 20, and a triangular stainless steel base 101 is installed on the prepreg 20, and the inclined rolling surface 102 having an inclination angle θ to the horizontal rolling surface 100 of 10 degrees is formed. Formed along the horizontal rolling surface 100,
A sphere 50 made of stainless steel (SUS304) having an outer diameter of 15 mm is placed at a height H of 4 from the horizontal rolling surface 100.
From the position 51 on the inclined rolling surface 102, which is mm, the rolling is performed on the inclined rolling surface 102 at an initial speed of 0 m / s. The tackiness is represented by a distance L from a position 52 reaching the horizontal rolling surface 100 to a stop position 53 on the horizontal plane.

FIG. 8 is a graph showing the tackiness of the prepreg. The horizontal axis indicates the holding time (min: min) after peeling the release sheet, and the vertical axis indicates the rolling distance L (c).
m). The first line 55 is the prepreg 2 of the present embodiment.
It shows a tackiness of 0. The second line 56 indicates the tackiness of the prepreg having the conventional layer structure as shown in FIG. The second line 56 indicates that the content of the matrix resin is 35
When the content is 4% by weight, the tackiness is shown.
Even if it is 0% by weight, the ratio of the fine particles contained in the matrix resin in the conventional particle-reinforced layer is the same, so that there is no difference in tackiness on the surface. Here the second
The matrix resin content of the prepreg of line 56 is 35
The percentages by weight are the ones generally used in the past and have no choice but to be on hand.

FIG. 8 shows the result of the present inventors measuring the tackiness of the prepreg 20 as shown in FIG. 7 and also measuring the tackiness of the prepreg having the conventional layer structure. . In laminating the prepreg using the laminating apparatus 30 as described above,
It is preferable that the tackiness is superior to the tackiness as an index, that is, the rolling distance L is preferably small,
The present inventor has confirmed that the laminating apparatus 30 can be used as long as the rolling distance L has tackiness of about 10 to 20 cm.

In a conventional prepreg having a layer structure, there is no tackiness that can use a laminating apparatus immediately after the release sheet is peeled off. On the other hand, the prepreg 20 according to the present embodiment
Until the elapse of minutes, tackiness that can use the laminating apparatus 30 is obtained. Moreover, the particle reinforcing layer 25
The amount (proportion) of the fine particles contained in the matrix resin of the coat resin layer 26 is the same as that of the conventional prepreg having a layer configuration, and sufficient toughness as a structural member of an aircraft can be obtained.

According to this embodiment, the particle reinforced layers 25 are formed on both sides of the fiber reinforced layer 23 in the thickness direction.
Further, the coating resin layer 26 is formed by covering each particle reinforcing layer 25. By forming the particle reinforcing layer, it is possible to prevent the occurrence of cracks by the fine particles 24 in the molded article after molding, and to increase the toughness. Further, by forming the coating resin layer 26 covering the particle reinforcing layer 25, the fine particles 24 in the particle reinforcing layer are prevented from protruding to the outside, and the fine particles 24 are not exposed so that the outer surface of the matrix resin 22 is formed. Can be formed. As a result, a decrease in tackiness due to the fine particles 24 being exposed to the outside can be prevented, a high tackiness can be obtained, and a prepreg can be laminated using a laminating apparatus. Therefore, it is possible to manufacture a structural member having high toughness, to facilitate laminating work, to facilitate molding, and to reduce a manufacturing cost of the structural member and the like.

The prepreg 20 is not only formed by laminating the prepreg 20 alone, but also provided on both sides in the thickness direction of another core material such as a foamed synthetic resin to form a structural member having a sandwich structure. Can also be used. In this case, since the matrix resin 22 of the coat resin layer 26 forms the outer surface, the matrix resin 22 can be used instead of the adhesive,
The prepreg 20 and the core material can be satisfactorily bonded to each other without using an adhesive, and a good structural member (molded product) can be manufactured. This facilitates the operation and reduces the manufacturing cost. You.

Further, since the fibrous material 21 is made of carbon fiber 29 and the matrix resin 22 is made of the above-described resin, a structural member formed by the prepreg 20, for example, is excellent in heat resistance. It can be suitably used for an aircraft flying at supersonic speed.

Each of the particle reinforcing layers 25 has a layer 23, 2
Fine particles 24 having a content based on the matrix resin amount of 5, 26, that is, based on the matrix resin amount of the entire prepreg 20 are mixed. Thus, the amount of fine particles contained in the structural member formed by laminating the prepreg is an amount that can provide sufficient toughness of the structural member. Therefore, even if the coat resin layer 26 is formed in order to obtain high tackiness, the toughness of the formed structural member or the like is prevented from being reduced, and the deterioration of the quality of the formed structural member or the like is prevented. It is.

FIG. 9 is a perspective view showing a procedure for manufacturing the prepreg 20 of the present invention. FIG.
FIG. 9 (2) shows a procedure for impregnating the matrix resin 1 with the matrix resin.
Shows the procedure for forming the coat resin layer, and FIG. 9 (3) shows the manufactured prepreg 20. The method for manufacturing the prepreg 20 includes a first step for forming the fiber reinforced layer 23 and the particle reinforced layer 25 and a second step for forming the coat resin layer 27 outside the particle reinforced layer 25. are doing.

In the first step, first, a plurality of carbon fibers 29
Are aligned to form a strip-shaped fiber material 21. Next, as shown in FIG. 9A, a sheet body 60 in which one surface of the release sheet is resin-coated is provided on both sides of the fiber material 21 with the coating resin facing the fiber material 21. The coat resin of the sheet body 60 is the matrix resin 22 mixed with the fine particles 24 and is in a state before a curing reaction. The thickness of the coat resin layer is, for example, 0.03 mm.
The fine particles 24 are mixed so that the areal density becomes, for example, 15 g / m ² . The release sheet of the sheet body 60 is made of a material (for example, polyethylene resin) that can be easily separated from the matrix resin 22 in a state where the matrix resin 22 is partially cured.

In the first step, the fibrous material 21 is sandwiched between the respective sheet members 60, and the sheet material 60 is heated to about 100 degrees from both sides in the thickness direction and pressurized at a pressure of 200 MPa, for example. The resin 22 is made to permeate the fiber material 21. At this time, although the matrix resin 22 easily permeates the fiber material 21,
The fine particles 24 hardly penetrate into the fibrous material 21 and the fibrous material 21
Remains on both sides in the thickness direction, which is outside of the film. As a result, the fiber reinforced layer 23 in which the fiber material 21 is impregnated with the matrix resin 22 is formed, and the particle reinforced layer 25 in which the matrix resin 22 is mixed with the fine particles 24 is formed. The matrix resin 22 of each layer 23, 25 undergoes a partial curing reaction by being heated and pressed as described above. Thus, the fiber reinforced layer 23 and the particle reinforced layer 25
Is formed, the release sheet contained in the sheet body 60 is peeled off, and the intermediate product 61 is obtained.

In the first step, after obtaining the intermediate product 61,
Move to the second step. In the second step, as shown in FIG. 9 (2), the sheet body 62 in which one surface of the release sheet 27 is resin-coated, the coated resin faces the intermediate product 61, and both sides of the intermediate product 61 Is provided. Sheet body 62
Is a matrix resin 22, which is in a state before a curing reaction, and the thickness of the coat resin layer is, for example, 0.01 mm. The release sheet 27 of the sheet body 62 is a release sheet 27 that covers both sides in the thickness direction of the prepreg 20, and can be easily separated from the matrix resin 22.

In the second step, the intermediate product 61 is further sandwiched between the sheet members 62 and bonded together, and is heated to, for example, about 100 degrees from both sides in the thickness direction, and at a pressure of, for example, 200 MPa. The matrix resin 22 and the matrix resin 22 of the particle reinforcing layer 25 of the intermediate product 61 are integrated. Thereby, the coating resin layers 26 are formed on both sides in the thickness direction of the particle reinforcing layer 25. The matrix resin 22 of the coat resin layer 26 also partially cures by being heated and pressed as described above. By forming the coating resin layers 26 on both sides in the thickness direction of the intermediate product 61 in this way, as shown in FIG.
The prepreg 20 is obtained in the state protected by the prepreg. Thus, the prepreg 20 can be obtained.

FIG. 10 is a front view showing a schematic configuration of a prepreg manufacturing apparatus 65, and FIG. 11 is an enlarged front view showing section XI of FIG. Manufacturing equipment 6
Reference numeral 5 denotes an apparatus for manufacturing the prepreg 1 according to the manufacturing method described with reference to FIG. 9, and includes a fiber material forming unit 66, a reinforcing layer forming unit 67, and a coat layer forming unit 68.
And The reinforcement forming means 67 is provided after the fiber material forming means 66, and the coat layer forming means 68 is provided after the reinforcing layer forming means 67.

The fibrous material forming means 66 has a fiber supply section 69 for supplying the carbon fibers 29 and an alignment section 70 for aligning the carbon fibers 29. The fiber supply unit 69 includes the carbon fiber 29
Can be fed from a plurality of rolls 71 around which a plurality of carbon fibers 29 are wound. The alignment unit 70
Each of the carbon fibers 29 supplied from the fiber supply unit 69 is wound around a plurality of rollers 72 and aligned so as to extend in the same direction and to be disposed in a predetermined positional relationship at substantially equal intervals to each other. The material 21 is formed and sent out.

The reinforcing layer forming means 67 includes a sheet supply section 73 for supplying the sheet 60, a heating / pressing section 74 for heating and pressing the fiber material 21 and the sheet 60 therebetween,
Collection unit 7 that collects a release sheet constituting sheet body 60
5 is included. The sheet body supply unit 73 feeds out and supplies the rolls from the two rolls 76 around which the sheet body 60 is wound, and is disposed on both sides in the thickness direction of the fibrous material 21. The material 21 can be sandwiched. The heating and pressing unit 74 includes a heating and pressing roller 78.
And the fibrous material 21 sandwiched between the respective sheet bodies 60
Can be heated and pressed from both sides in the thickness direction by each roller 78. After being heated by the heating and pressurizing unit, the collection unit 75 can peel off the sheet body, wind it around a roll 80, and collect it. Thus, the sheet body is recovered, and the intermediate product 61 in which the fiber reinforced layer 23 and the particle reinforced layer 25 are formed is obtained and sent out.

The coating layer forming means 68 includes a sheet supply unit 82 for supplying the sheet 62, and a heating and pressing unit 8 for heating and pressing the intermediate product 61 and the sheet 62 therebetween.
3 is included. The sheet body supply unit 82 feeds out and supplies the two rolls 85 around which the sheet body 62 is wound, respectively, and arranges the sheet on both sides in the thickness direction of the intermediate product 61. Intermediate product 6
1 can be inserted. The heating / pressing unit 83 has a heating / pressing roller 88, and the intermediate product 61 sandwiched between the sheet members 62 can be heated and pressed by the rollers 88 from both sides in the thickness direction. Thus, the prepreg 20 can be manufactured according to the method described above. The manufactured prepreg 20 is wound around a roll. Further, when the prepreg 20 is wound around a roll as shown by a virtual line in FIG. 10, one release sheet 27 may be wound in a state where it is separated and collected.

According to the manufacturing method using such a manufacturing apparatus, the step of forming the fiber reinforced layer 23 and the particle reinforced layer 25 and the step of forming the coat resin layer 26 are different steps. The above-mentioned prepreg 20 in which the coat resin layer 26 of only the matrix resin 22 containing no fine particles 24 is formed on the outer surface can be easily manufactured. Further, by making the matrix resin 22 of each layer 23, 25, 26 the same resin, the prepreg 2
The matrix resin 22 can be integrated with the entirety, and the prepreg 20 that does not cause delamination can be manufactured even with the above-described layer configuration. Therefore, the prepreg 20 manufactured in this manner has excellent mechanical properties and is suitable as a material for forming the above-described structural member of an aircraft.

The prepreg 20 is not formed by simply adding a coat resin layer to a prepreg having a conventional layer structure. That is, the prepreg 20 is not so formed that the intermediate product 61 has the same structure as the conventional prepreg 1. No, sheet body 60
By reducing the thickness of the resin layer, the thickness of the particle reinforcing layer 25 is reduced, and the total thickness of the particle reinforcing layer 25 and the coat resin layer 27 is adjusted to a thickness (for obtaining the characteristics originally required for the prepreg 20). Particle reinforcement layer 6 in the prior art
Thickness). Further prepreg 20
The content of the fine particles contained in the whole is prevented from decreasing. This makes it possible to manufacture the prepreg 20 while preventing a change in the thickness of the entire prepreg, a change in the thickness ratio of the fiber reinforced layer, and a change in the content of the fine particles. Such a prepreg 20 has improved tackiness while preventing a decrease in mechanical properties as compared with a prepreg without a coat resin layer.

The above embodiment is merely an example of the present invention, and the configuration can be changed within the scope of the present invention. For example, the coat resin layer 26 does not necessarily need to be formed on both sides, and may be formed only on one side in the thickness direction. In addition, the fiber material 21 may be made of fibers other than carbon fibers, for example, glass fibers, boron fibers, and aramid fibers, and the fibers are arranged in a crossing direction instead of being arranged in one direction. You may do so. Further, the material of the matrix resin 22 and the fine particles 24 may be changed in addition to the fiber material 21, and the particle size of the fine particles 24 is not limited to the above-described particle size.

[0048]

According to the present invention, by forming a coating resin layer covering the particle reinforcing layer, the outer surface of the matrix resin can be formed without exposing the fine particles, and high tackiness is obtained. The prepreg can be laminated using a laminating apparatus. Therefore, it is possible to manufacture a structural member having high toughness, to facilitate laminating work, to facilitate molding, and to reduce a manufacturing cost of the structural member and the like. Also, when this prepreg is provided on both sides in the thickness direction of the core material to form a structural member having a sandwich structure, when combined with other materials, the matrix resin of the coat resin layer can be used instead of the adhesive, and the adhesive is used. Without this, a good molded product can be manufactured in combination with other core material sets.

Further, according to the present invention, the total amount of fine particles contained in a structural member or the like formed by laminating and molding a prepreg is an amount capable of obtaining sufficient toughness of the structural member or the like. Therefore, even when the coat resin layer is formed, the toughness of the formed structural member or the like is prevented from lowering, and the quality of the formed structural member or the like is prevented from lowering.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a part of a prepreg 20 according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a roll of a prepreg 20.

FIG. 3 is a sectional view showing the inside of a prepreg 20 in detail.

FIG. 4 is a sectional view showing the inside of a prepreg 20 in detail.

FIG. 5 is a perspective view showing a laminating apparatus 30.

FIG. 6 is a perspective view showing a section VI of FIG. 5;

FIG. 7 is a sectional view for explaining a tackiness measuring method.

FIG. 8 is a graph showing tackiness of the prepreg 20.

FIG. 9 is a perspective view for explaining a method of manufacturing the prepreg 20.

FIG. 10 is a front view showing an apparatus 65 for manufacturing the prepreg 20.

FIG. 11 is a front view showing a section XI of FIG. 10;

FIG. 12 is a cross-sectional view showing a part of a prepreg 1 according to the related art.

FIG. 13 is a perspective view showing a layer configuration of the prepreg 1;

FIG. 14 is a sectional view showing the inside of the prepreg 1 in detail.

FIG. 15 is a sectional view showing the inside of the prepreg 1 in detail.

[Explanation of symbols]

 Reference Signs List 20 prepreg 21 fiber material 22 matrix resin 23 fiber reinforced layer 24 fine particles 25 fiber reinforced layer 26 coat resin layer 27 release sheet 30 laminating device 60 manufacturing device

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 C08J 5/24

Claims (2)

(57) [Claims] 1. A fiber reinforced layer in which a fibrous material is impregnated with a matrix resin; a particle reinforced layer formed on both sides in the thickness direction of the fiber reinforced layer, wherein fine particles are mixed into the matrix resin; A prepreg comprising: a coating resin layer made of a matrix resin which covers one of the prepregs. 2. The content of fine particles in each particle-reinforced layer is as follows:
The prepreg according to claim 1, wherein the prepreg is determined based on the matrix resin amounts of the fiber reinforced layer, each particle reinforced layer, and the coat resin layer.