JP2001219473A - Method for manufacturing fiber-reinforced resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber-reinforced resin molding by which the fiber-reinforced resin molding obtained by impregnating a bundle of reinforcing fibers with a thermoplastic resin at a high level, can be manufactured in stable quality and with high productivity. SOLUTION: This method for manufacturing the fiber-reinforced resin molding by which the molding is manufactured by impregnating the bundle of continuous reinforcing fibers A with the thermoplastic resin while the bundle A is taken off, is characterized by that (A) the thermoplastic resin is imparted to the bundle of continuous reinforcing fibers A and (B) after that, at least one oscillator 4 heated within the range of a melt temperature T of the thermoplastic resin ±40 deg.C is directly brought into contact with the bundle of continuous reinforcing fibers A and (C) the impregnation of the bundle A with the thermoplastic resin is promoted by oscillating the oscillator 4 within the range of oscillation frequency of 1 Hz-5 kHz.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a high-quality fiber-reinforced resin molded article obtained by applying a high level of thermoplastic resin to one running or a plurality of continuous reinforcing fiber bundles running in parallel with each other at the same time. And a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a fiber-reinforced resin molded article in which a plurality of continuous reinforcing fiber bundles such as carbon fibers and glass fibers are aligned in parallel with each other and then impregnated with a resin serving as a matrix in the fiber bundles is generally used. In addition to aircraft materials and general industrial materials, they are widely used as molded articles for sports and leisure applications such as golf club shafts and fishing rods.

[0003] Such molded articles are required to have performance such as surface quality and strength. Therefore, it is expected that the reinforcing fiber bundle in the molded product is sufficiently impregnated with the resin serving as the matrix. The reason is that if the impregnation of the molded article is insufficient, not only the quality of the molded article is impaired, but also the physical properties of the molded article (for example, strength, rigidity, impact resistance, etc.) are expected to be reduced.

[0004] In order to improve the impregnating property in such a molded article, in the production process of the molded article, molding (forming) is carried out by removing air (voids) contained between single yarns in the molded article to the outside as much as possible before molding. It is necessary to devise a method for obtaining a body, that is, a method for improving the impregnation property of the molded body. In particular, when the resin serving as the matrix is a thermoplastic resin, it is very difficult to obtain a molded article having excellent impregnation properties due to its high viscosity.

Here, the impregnating property of the molded article in the present invention indicates how much the matrix resin has penetrated between the single yarns, and the cross section of the molded article in the take-off direction is observed with an optical microscope. Can be relatively evaluated. Although a method for quantifying this has not been established, it can be estimated from the void fraction. That is, when the void ratio is low, the impregnation is often high. The void ratio is calculated according to ASTM D-2734-94.

[0006] As a conventional impregnation method using a thermoplastic resin as a matrix resin, for example, Japanese Unexamined Patent Publication No. Hei 8-30034 is known.
Japanese Patent Application Laid-Open No. 9-1990 discloses a method in which a molten thermoplastic resin is applied to a reinforcing fiber bundle and then pressure is applied thereto.

However, according to the method exemplified in this publication, in order to sufficiently impregnate a reinforcing fiber bundle with a high-viscosity thermoplastic resin having a melt viscosity exceeding 50 Pa · s, for example, the fiber bundle take-up speed is 10 m. It is necessary to set a very low speed of not more than / min, which is a method with low productivity. Further, when the fiber bundle take-up speed is set to 10 m / min or more and the thermoplastic resin is not sufficiently impregnated into the reinforcing fiber bundle, and the molding is performed by a method such as filament winding, the reinforcing fibers in the molded product A region not sufficiently impregnated with the thermoplastic resin is generated in the bundle, and many voids are generated, so that the reinforcing effect of the reinforcing fiber bundle is weakened, and the mechanical characteristics of the molded article using this molded body may be reduced. is there.

[0008] Here, the melting temperature of the thermoplastic resin is a temperature at which an endothermic peak of a curve measured by a Mettler DSC is shown in the case of a thermoplastic resin showing a melting point (the rate of temperature rise during measurement is 10 ° C / min. In the case of a thermoplastic resin which does not show a melting point, the lower limit of the recommended injection molding temperature listed in the catalog of the resin is set to + 20 ° C.

On the other hand, Japanese Patent Application Laid-Open No. 10-404 discloses a technique in which an external force such as vibration is applied to a reinforcing fiber bundle before applying a resin serving as a matrix to open the reinforcing fiber bundle. However, if the reinforcing fiber bundle is opened before the application of the matrix resin, single yarn breakage of the fiber bundle is likely to occur, and the physical properties of a molded article using the molded body may be reduced. In addition, fluff due to breakage of a single yarn of the fiber bundle is liable to be scattered, and the scattered reinforcing fiber bundle may enter parts of the production apparatus, causing a problem in productivity such as malfunction of the apparatus. After applying the matrix resin, it is necessary to devise a technique of further opening the reinforcing fiber bundle in a state where the surface of the reinforcing fiber bundle is coated with the matrix resin, thereby minimizing breakage of the single yarn of the reinforcing fiber bundle.

In addition, the above publication does not disclose the type of the resin serving as a specific matrix. As the matrix resin, for example, when using a resin having a high melt viscosity such as a thermoplastic resin, for example, even after performing fiber opening before applying the matrix resin in accordance with the production method proposed in JP-A-10-404 In the step of extruding voids contained in the reinforcing fiber bundle to the outside of the fiber bundle, it is necessary to apply an extremely strong tension to the reinforcing fiber bundle. In other words, a strong tension must be applied to the reinforcing fiber bundle in at least two steps before and after the application of the matrix resin. Therefore, the damage to the reinforcing fiber bundle is increased, and the reinforcing fiber bundle is liable to fluff and break the yarn. From these points, the technique described in the above-mentioned publication has to be said to be a technique with low productivity. By simultaneously opening the reinforcing fiber bundle and impregnating the matrix resin, it is essential to reduce the tension applied to the reinforcing fiber bundle and the number of steps for applying the tension as much as possible in order to improve productivity.

Further, the above publication discloses that a vibrator is used and its heating temperature is 70 to 100 ° C. This temperature is a heating temperature for softening the sizing agent attached to the reinforcing fiber bundle and making it easier to open the reinforcing fiber bundle. Here, when the vibrator is brought into contact with the reinforcing fiber bundle in a state where the thermoplastic resin is applied to the reinforcing fiber bundle by the method described in the above publication to apply vibration to the reinforcing fiber bundle, the temperature condition described is too low. That is, the melting temperature of a general thermoplastic resin is 150 to 350 ° C., and the temperature difference between the vibrator and the thermoplastic resin is 50 ° C. or more. Therefore, the thermoplastic resin is cooled to increase the viscosity, and the impregnation is accelerated. The effect is lost.

On the other hand, JP-A-10-36531 describes a method in which a matrix resin is attached to a reinforcing fiber bundle and then the reinforcing fiber bundle is subjected to ultrasonic vibration to impregnate the resin.

However, it is obvious that the technique disclosed in the above publication has a very small amplitude of the vibrator of 0.1 to 0.5 μm and a very weak effect of opening the reinforcing fiber bundle. In the case where a thermoplastic resin is used as the matrix resin, the effect of promoting impregnation cannot be expected with this method having a weak reinforcing fiber bundle opening effect due to its high melt viscosity. As described above, no method has been found so far to open the reinforcing fiber bundle and simultaneously impregnate the molten thermoplastic resin.

[0014]

DISCLOSURE OF THE INVENTION The present invention relates to a fiber-reinforced resin which can be produced with a stable quality and a high productivity in a fiber-reinforced resin molded article in which a thermoplastic resin is impregnated into a reinforcing fiber bundle at a high level. An object of the present invention is to provide a method for manufacturing a molded article.

[0015]

Means for Solving the Problems To achieve the above object, a method for producing a fiber-reinforced resin molded article of the present invention has the following constitution.

That is, the present invention relates to a method for producing a fiber-reinforced resin molded article by impregnating a thermoplastic resin into a fiber bundle while taking a continuous reinforcing fiber bundle, and (A) adding a thermoplastic resin to the reinforcing fiber bundle. After applying, at least one vibrator heated within the range of melting temperature T ± 40 ° C. of the thermoplastic resin is brought into direct contact with (B) the reinforcing fiber bundle,
(C) A method for producing a fiber-reinforced resin molded body, characterized by promoting the impregnation of the reinforcing fiber bundle with the thermoplastic resin by vibrating the vibrator within a vibration frequency range of 1 Hz to 5 kHz. .

The fiber-reinforced resin molded article produced by the present invention refers to a molded article containing at least two types of reinforcing fibers and a thermoplastic resin serving as a matrix resin.
Examples of the types of reinforcing fibers used in the present invention include glass fibers, carbon fibers, metal fibers, aromatic polyamide fibers, polyaramid fibers, alumina fibers, silicon carbide fibers, high-strength fibers such as boron fibers, and highly elastic fibers. They can be used and two or more kinds may be mixed.

[0018] Carbon fibers are preferably used because they are excellent in imparting mechanical properties. The surface of the reinforcing fiber bundle can be subjected to a surface treatment, a coupling agent, and a sizing agent in advance.

The type of the thermoplastic resin serving as the matrix in the present invention is not particularly limited, but a thermoplastic resin having excellent impact resistance and easy molding is preferable. As such a thermoplastic resin, for example, polyethylene terephthalate, polybutylene terephthalate,
Polyester such as liquid crystal polyester, polyethylene,
Polyolefins such as polypropylene and polybutylene,
Polyoxymethylene, polyamide, polycarbonate,
Polymethylene methacrylate, polyvinyl chloride, polyphenylene sulfide, polyphenylene ether, polyimide, polyamideimide, polyetherimide, polysulfone, polyethersulfone, polyetherketone,
Examples include polyether ether ketone, phenol (novolak type), copolymers and modified products thereof, and resins blended with two or more kinds. Further, in order to further improve impact resistance, the above resin is an elastomer, or
A resin to which a rubber component is added may be used.

Further, as described above, the melting temperature T in the present invention is a temperature at which an endothermic peak of a curve measured by a Mettler DSC is exhibited in the case of a thermoplastic resin exhibiting a melting point (temperature rise during measurement). The rate is 10 ° C./min.) In the case of a thermoplastic resin that does not show a melting point, the lower limit of the recommended injection molding temperature listed in the resin catalog is + 20 ° C.

The vibrator used in the present invention is one that satisfies the following two conditions. (1) The thermoplastic resin used in the present invention has a function capable of being heated within a melting temperature range of T ± 40 ° C. (2) It has a function capable of vibrating within a range of a vibration frequency of 1 to 5 kHz, preferably within a range of an amplitude of 0.1 to 30 mm.

[0022]

Preferred embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a schematic side view of an apparatus for producing a fiber-reinforced resin molding used in the production method of the present invention.

In FIG. 1, a reinforcing fiber bundle A is so-called intercepted from a plurality of winding packages 1 of the reinforcing fiber bundle A so as not to be twisted, and a thermoplastic resin serving as a matrix (hereinafter referred to as thermoplastic resin A). ). In this case, the reinforcing fiber bundles A can be aligned from the plurality of winding packages 1 and introduced into the supply die 2 as a single bundle.

Here, before the reinforcing fiber bundle A is introduced into the supply die 2, another thermoplastic resin different from the thermoplastic resin A (hereinafter, thermoplastic resin H) can be applied. This is a cause of impairing the impregnation by applying the thermoplastic resin H having a viscosity in the range of 0.1 to 10 Pa · s to the reinforcing fiber bundle before impregnating the thermoplastic A resin, and performing impregnation. This is because air in the reinforcing fiber bundle is expelled in advance so that the thermoplastic resin can be sufficiently impregnated into the reinforcing fiber bundle. Thereby, the void ratio of the obtained molded body can be further reduced, and the production speed can be remarkably increased.

Before the reinforcing fiber bundle A is introduced into the supply die 2, the reinforcing fiber bundle A is heated to a melting temperature T ± 40 ° C. of the thermoplastic resin A by a suitable heating device. If the melting temperature is lower than T-40 ° C, the melted thermoplastic resin is cooled by the reinforcing fiber bundle A to increase the viscosity of the resin, thereby impairing the impregnation efficiency. On the other hand, when the melting temperature is T +
If the temperature is higher than 40 ° C., the applied thermoplastic resin is rapidly heated, which causes thermal decomposition of the resin and carbonization of the thermoplastic resin causes fusion of the reinforcing fiber bundle, which is not preferable. A preferable heating range of the reinforcing fiber bundle is a melting temperature T ± 20 ° C. of the thermoplastic resin, and more preferably a melting temperature T ± 10 ° C.

Next, a thermoplastic resin A is applied to the reinforcing fiber bundle A introduced into the supply die 2, and a composite B is formed. Specific examples of the method of applying the thermoplastic resin A include a method of continuously coating the periphery of the reinforcing fiber bundle A with the thermoplastic resin A using an extruder and a coating die for an electric wire coating method, and a method of flattening with a roll or the like. A method in which a molten matrix resin is adhered from one side or both sides of the reinforced fiber bundle A using an extruder and a T-die.

Here, the complex B is composed of the following. (1) Reinforcing fiber bundle A or a mixture of reinforcing fiber bundle A and thermoplastic resin H (2) Thermoplastic resin A At this time, the inlet and outlet of the reinforcing fiber bundle A of the supply die 2 are preferably By installing a nozzle having a hole processed into the shape and size described above and passing the reinforcing fiber bundle A, the attached shape and amount of the applied thermoplastic resin A can be arbitrarily controlled. The composition ratio of the complex B is
Preferably, the amount of the thermoplastic resin A is 40 to 90 parts by weight based on 10 to 60 parts by weight of the reinforcing fiber bundle A. If the reinforcing fiber bundle A is less than 10 parts by weight, the reinforcing effect of a molded article using this molded article may be significantly reduced. If the reinforcing fiber bundle A exceeds 60 parts by weight, the scaffolding reinforced by the fibers becomes too small, and the physical properties of the molded product may be significantly reduced. More preferably, the reinforcing fiber bundle A is 15 to 50.
The amount of the thermoplastic resin A is 50 to 85 parts by weight with respect to the parts by weight.

Next, the composite B is rubbed against at least one impregnating bar 3 arranged on a straight line to accelerate the impregnation of the resin A. The shape of the impregnation bar 3 is not particularly limited as long as the shape does not hinder the passage of the reinforcing fiber bundle A.

Here, the impregnating bar 3 can be heated within the range of the melting temperature T ± 40 ° C. of the thermoplastic resin A. If the melting temperature is lower than T-40 ° C., the melted thermoplastic resin A is cooled by the reinforcing fiber bundle A, the melt viscosity increases, and the impregnation efficiency deteriorates, which may not be preferable. Melting temperature T
If the temperature exceeds + 40 ° C., the applied thermoplastic resin is rapidly heated to cause thermal decomposition, and the carbonization of the resin causes the fusion of the reinforcing fiber bundle, which is not preferable. A more preferable heating range of the impregnating bar 3 is a melting temperature T ± 2 of the thermoplastic resin.
0 ° C., more preferably the melting temperature T ± 10 ° C.

Here, at least one of the impregnating bars 3
One is a vibrator 4, which is brought into contact with the composite B to apply tension, and vibrates the composite B to perform further impregnation. The tension applied at this time is preferably in the range of 1 to 50 N / piece. If the tension is less than 1 N / line, the thermoplastic resin A does not impregnate the reinforcing fiber bundle A, and voids may be generated in the molded product. When the tension exceeds 50 N / piece, damage to the reinforcing fiber bundle A increases, and fluff may be generated during passage through the process. More preferably, the tension is 3 to 40 N / line, and still more preferably 5 to 30 N / line. The method of motion of the vibrator 4 in this process is not particularly limited, but as shown in FIG. 4
Is simple and preferable.

As a vibration waveform pattern of the vibrator 4, a general reciprocating waveform pattern can be used. Examples include sine waves, rectangular waves, sawtooth waves, and the like.

The vibration frequency and amplitude of the vibrator 4 can be arbitrarily selected according to the state of contact, the applied tension, the material of the thermoplastic resin A or the reinforcing fiber bundle A. The frequency range is 1H
z to 5 kHz is preferred. When the frequency falls below 1Hz,
In some cases, the vibration frequency of the vibrator 4 becomes too low with respect to the traveling speed of the composite B, and a region where the vibration does not propagate occurs in the composite B, thereby weakening the fiber opening effect and causing unevenness in impregnation. is there. On the other hand, if the frequency exceeds 5 kHz, the resulting amplitude becomes small, and the fiber-spreading effect and the force for stirring the thermoplastic resin A and the reinforcing fiber bundle A are lost, so that the impregnation may not be easily promoted. A more preferable range of the vibration frequency of the vibrator 4 is 10 Hz to 4 kHz, and further preferably 20 Hz to 2 kHz.
kHz.

The range of the amplitude applied to the composite B is preferably 0.5 to 30 mm. If the amplitude is less than 0.1 mm, the vibration may be equivalent to no vibration, and the impregnation promoting effect may be weakened. If it exceeds 30 mm, the damage to the reinforcing fiber bundle is increased, and as a result, fluffing and yarn breakage may occur. A more preferable range of the amplitude of the vibrator 4 is 0.1 to 20 mm, and further preferably 0.5 to 10 mm.

The composite B is passed through the impregnating bar 3 and the vibrator 4 to obtain the desired molded product C in which the reinforcing fiber bundle is sufficiently impregnated with the thermoplastic resin A.

Thus, the compact C is continuously wound on the bobbin by the winding roll 5. The lower the winding speed is, the lower the running speed is, so that it is easy to impregnate the reinforcing fiber bundle with the thermoplastic resin A. However, since the traveling speed of the reinforcing fiber bundle is a rate-determining step in the productivity of the molded product C, it is necessary to consider a balance between the traveling speed and the impregnation. From that point, it is preferably 15 to 50 min / m, and preferably 20 to 5 min / m.
0 m / min is more preferable in order to achieve both impregnation and productivity. Further, at the time of winding, the formed body may be fused to a winding nip roller of the winding roll 5 or the like, so that the formed body C is cooled by air cooling or water cooling immediately before winding the formed body C onto a bobbin. Is preferably performed. In addition, the cross-sectional shape in the longitudinal direction of the molded body C obtained by the above-exemplified steps is not particularly limited.

FIG. 3 shows a cross-sectional shape of the compact C obtained by the above process. Also, preferably, the width d of the molded body C
When the aspect ratio d / t, which is the ratio of mm to the thickness tmm, is in the range of 1 to 50, it is very suitable from the viewpoint of handling such as easy winding on a bobbin. A more preferable range is the aspect ratio d.
/ T is in the range of 1 to 30.

It is desirable that the reinforcing fiber bundle is completely impregnated with the thermoplastic resin A in the molded article C obtained by the above-exemplified process. However, since the molded article C actually contains some voids, Have difficulty. That is, if the void ratio of the molded article C exceeds 60%, many voids are generated in the molded article using the molded article C, and the physical properties of the molded article may be deteriorated. The rate is preferably in the range of 0 to 60%. More preferably, 0 to 5
5%.

When winding the compact C obtained by the steps exemplified above, a plurality of compacts C may be drawn in one direction and heated and fused to form a sheet-like compact. it can. The sheet-like molded body produced by this step is superior in impregnation to a sheet-like molded body produced by a conventional method. Therefore, the void ratio of a molded article using this sheet-shaped molded article can be reduced, and the appearance and mechanical properties of the molded article can be improved.

The molding C obtained by the above exemplified process is cut at regular intervals within a range of at least 1 to 50 mm to produce a discontinuous fiber-reinforced resin molding and used, for example, injection molding, It can be made preferable in correspondence with press molding. In this case, the cutting length is 1
If it is less than mm, the fiber length as a reinforcing fiber bundle in the molded product may be short, and the fiber reinforcing effect may be reduced. Also,
If the cutting length exceeds 50 mm, the moldability and the handleability of the molded body may decrease. Preferably 2-40 mm,
Most preferably, it is 2 to 30 mm.

The fiber-reinforced resin molded product obtained by the production method of the present invention contains a flame retardant, a weather resistance improver, other antioxidants, a heat stabilizer, an ultraviolet absorber, a plasticizer, a lubricant,
Coloring agents, compatibilizers, fillers, conductive fillers, carbon black, and the like can be appropriately added. Further, a mixture of two or more of these may be added.

The fiber-reinforced resin molded product obtained by the production method of the present invention can be processed into a final product by a usual molding method. Examples of the molding method include filament winding molding, press molding, injection molding, and combinations thereof.

Examples of the molded article obtained by the above-described production method of the present invention include automobile parts such as high-strength hollow pipes, cylinder head covers, bearing retainers, intake manifolds, pedals, etc., tools such as monkeys, wrenches, etc. Examples include a housing of an electronic device.

[0044]

Examples and Comparative Examples Hereinafter, examples of the present invention will be described. (Example 1) A carbon fiber bundle (12,000 carbon fibers, carbon fiber fineness 0.6 denier) as the reinforcing fiber bundle A
Nylon 6 resin, which is a thermoplastic resin A melted at 250 ° C. from an extruder into a die by passing through a coating die for a wire coating method installed at the tip of a single screw extruder having a diameter of 40 mm. "Amilan" CM100 manufactured by Toray Industries, Inc.
1, a melting temperature of 220 ° C.), and the periphery of the reinforcing fiber bundle A was continuously covered to obtain a composite B.

Next, the composite B was passed alternately over the impregnating rolls 3 arranged in a straight line, and the composite B was shaped flat to obtain a compact C. Here, one of the impregnating rolls was vibrated as a vibrator 4 in a direction intersecting the running direction of the fiber bundle. The surface temperature of the impregnating roll 3 and the vibrator 4 is 250
° C. The vibration frequency of the vibrator at this time is 50 Hz
Met. The winding speed at this time was 30 m / min. The molded article obtained in this experiment had a void ratio of 53%. (Example 2) As the thermoplastic resin H, a terpene phenolic resin (a carbon fiber bundle heated to 300 ° C by heating and melting an adduct of a monocyclic monoterpene and phenol (12,000 carbon fibers, carbon fibers Fineness 0.6 denier)
After applying a fixed amount per unit length on the top, the carbon fiber bundle is impregnated with the terpene phenol resin to the inside, and the reinforcing fiber bundle A
And a thermoplastic resin H were obtained. At this stage, 5 parts by weight of the thermoplastic resin H relative to the composite was 5 parts by weight. Then, it is passed through a coating die for the wire coating method installed at the tip of a single-screw extruder having a diameter of 40 mm,
Nylon 6 resin which is a thermoplastic resin A melted at 250 ° C. in a die from an extruder (“Amilan” CM manufactured by Toray Industries, Inc.)
1001, a melting temperature of 220 ° C.) and the periphery of the composite was continuously covered to obtain a composite B.

Next, the composite B was passed alternately over the impregnating rolls 3 arranged in a straight line, and the composite B was shaped flat to obtain a compact C. Here, one of the impregnating rolls was vibrated as a vibrator 4 in a direction intersecting the running direction of the fiber bundle. The surface temperature of the impregnating roll 3 and the vibrator 4 is 250
° C. The vibration frequency of the vibrator at this time is 50 Hz
Met. The winding speed at this time was 30 m / min. The molded article obtained in this experiment had a void ratio of 6%. (Comparative Example 1) Carbon fiber bundle (12,000 carbon fibers, carbon fiber fineness: 0.6 denier) as reinforcing fiber bundle A
Nylon 6 resin, which is a thermoplastic resin A melted at 250 ° C. from an extruder into a die by passing through a coating die for a wire coating method installed at the tip of a single screw extruder having a diameter of 40 mm. "Amilan" CM100 manufactured by Toray Industries, Inc.
1, a melting temperature of 220 ° C.), and the periphery of the reinforcing fiber bundle A was continuously covered to obtain a composite B.

Next, the composite B was passed alternately over the impregnating rolls 3 arranged in a straight line, and the composite B was shaped flat to obtain a molded product C. Here, one of the impregnating rolls was vibrated as a vibrator 4 in a direction crossing the fiber bundle running direction. The surface temperature of the impregnating roll 3 and the vibrator 4 is 18
It was 0 ° C. The vibration frequency of the vibrator at this time is 50k
Hz. The winding speed at this time was 30 m / min. In this experiment, the thermoplastic resin A was separated from the composite B, and the molded body C could not be produced. (Comparative Example 2) As a reinforcing fiber bundle A, a carbon fiber bundle (12,000 carbon fibers, carbon fiber fineness: 0.6 denier)
Nylon 6 resin, which is a thermoplastic resin A melted at 250 ° C. from an extruder into a die by passing through a coating die for a wire coating method installed at the tip of a single screw extruder having a diameter of 40 mm. "Amilan" CM100 manufactured by Toray Industries, Inc.
1, a melting temperature of 220 ° C.), and the periphery of the reinforcing fiber bundle A was continuously covered to obtain a composite B.

Next, the composite B was passed alternately over the impregnating rolls 3 arranged in a straight line, and the composite B was flattened to obtain a compact C. The surface temperature of the impregnation roll 3 was 250 ° C. The winding speed at this time is 30
m / min. At this time, no vibration was applied to the composite B. The void ratio of the molded product obtained in this experiment was 71%. (Comparative Example 3) As the reinforcing fiber bundle A, a carbon fiber bundle (12,000 carbon fibers, carbon fiber fineness: 0.6 denier)
Nylon 6 resin, which is a thermoplastic resin A melted at 250 ° C. from an extruder into a die by passing through a coating die for a wire coating method installed at the tip of a single screw extruder having a diameter of 40 mm. "Amilan" CM100 manufactured by Toray Industries, Inc.
1, a melting temperature of 220 ° C.), and the periphery of the reinforcing fiber bundle A was continuously covered to obtain a composite B.

Next, the composite B was passed alternately over the impregnating rolls 3 arranged in a straight line, and the composite B was shaped flat to obtain a molded product C. Here, one of the impregnating rolls was vibrated as a vibrator 4 in a direction crossing the fiber bundle running direction. The surface temperature of the impregnating roll 3 and the vibrator 4 is 25
It was 0 ° C. The vibration frequency of the vibrator at this time is 6 kHz.
z. The winding speed at this time was 30 m / min. The void fraction of the molded product obtained in this experiment was 70%.
Met.

Table 1 summarizes the above.

[0051]

[Table 1]

As a result of the examination of the above Examples, Comparative Examples and Table 1, the following became clear. (1) The vibrator 4 is heated at a melting temperature T ± 40 ° C. of the thermoplastic resin A.
, It was impossible to take off the molded body C. (2) The vibration frequency of the composite B is 50 Hz by the vibrator 4
When the vibration was given, the void ratio was reduced by 18% as compared with the case where no vibration was given, and the impregnation property was improved. (3) The vibration frequency of the complex B is 6 kHz by the vibrator 4.
When the vibration was applied, the void ratio was not substantially improved even when no vibration was applied, and the impregnation was not much different. (4) When the thermoplastic resin A is applied after the reinforcing fiber bundle A is impregnated with the thermoplastic resin H, and the composite B is vibrated by the vibrator 4, as compared with the case where the thermoplastic resin H is not used. As a result, the void ratio was reduced by 47%, and the impregnation property was greatly improved.

[0053]

According to the present invention, a continuous reinforcing fiber bundle is provided with a thermoplastic resin A, and then a vibrator heated within a melting temperature T ± 40 ° C. of the resin is brought into direct contact with the vibrating frequency 1 Hz. As a manufacturing method of vibrating in the range of ~ 5 kHz to promote the impregnation of the thermoplastic resin into the reinforcing fiber bundle, the fiber bundle is greatly opened as in the related art, or the fiber bundle is damaged. It has become possible to obtain a fiber-reinforced resin molded product in which sufficient resin impregnation has been achieved with a milder tension load than in the prior art, without being stiff. In addition, fluffing and yarn breakage could be reduced, and the running speed of the fiber bundle, which was the rate-determining step in the productivity of the molded product, could be significantly increased.

[Brief description of the drawings]

FIG. 1 is a schematic side view of a manufacturing apparatus used in a manufacturing method according to the present invention.

FIG. 2 is a schematic view showing one embodiment of a motion direction of a vibrator according to the present invention.

FIG. 3 is a schematic cross-sectional view of a continuous fiber reinforced thermoplastic molded article produced according to the present invention.

[Explanation of symbols]

A: Reinforcing fiber bundle A B: Composite B C: Molded product C 1: Winding package of reinforcing fiber bundle A 2: Supply die of thermoplastic resin A 3: Impregnation bar 4: Vibrator 5: Winding roll 6: The traveling direction of the composite B 7: The direction perpendicular to the traveling direction of the composite B 8: The thermoplastic resin A or the composite of the thermoplastic resin A and the thermoplastic resin H

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F041 AA13 AB01 BA46 4F205 AA29 AD16 AG02 HA19 HA34 HA37 HB01 HB02 HC17 HM07 HT13

Claims (9)

[Claims] 1. A method for producing a fiber-reinforced resin molded article by impregnating a thermoplastic resin into a fiber bundle while taking over a continuous reinforcing fiber bundle, the method comprising: (A) applying a thermoplastic resin to the reinforcing fiber bundle; (B) At least one vibrator heated within the range of the melting temperature T ± 40 ° C. of the thermoplastic resin is brought into direct contact with the reinforcing fiber bundle, and (C) the vibration frequency is 1
A method for producing a fiber-reinforced resin molded body, characterized in that the vibrator is vibrated in the range of Hz to 5 kHz to thereby accelerate the impregnation of the reinforcing fiber bundle with the thermoplastic resin. 2. The method for producing a fiber-reinforced resin molded product according to claim 1, wherein the reinforcing fiber bundle is taken at a traveling speed in a range of 15 to 50 m / min. 3. The method for producing a fiber-reinforced resin molded product according to claim 1, wherein the reinforcing fiber bundle is rubbed against the vibrator with a take-up tension in a range of 1 to 50 N / piece. 4. The method for producing a fiber-reinforced resin molded product according to claim 1, wherein the vibrator is vibrated at an amplitude within a range of 0.5 to 30 mm. 5. The fiber reinforcement according to claim 1, wherein the reinforcing fiber bundle is heated to a temperature within a range of a melting temperature T ± 40 ° C. of the thermoplastic resin before applying the resin. A method for manufacturing a resin molded body. 6. The method according to claim 1, wherein an aspect ratio (d / t), which is a ratio of a width dmm of a cross section in a longitudinal direction of the molded body to a thickness tmm, is set in a range of 1 to 50. The method for producing a fiber-reinforced resin molded article according to any one of the above. 7. The method for producing a fiber-reinforced resin molded product according to claim 1, wherein a void ratio of the molded product is in a range of 0 to 60%. 8. The fiber-reinforced resin according to claim 1, wherein after applying the resin, a plurality of the obtained fiber-reinforced resin moldings are bundled to form a sheet-like molding. A method for producing a molded article. 9. The method for producing a fiber-reinforced resin molded article according to claim 1, wherein the fibers constituting the reinforcing fiber bundle are carbon fibers.