JPH08134235A - Process and apparatus for continuously producing composite material - Google Patents

Abstract

PURPOSE: To obtain a process for efficiently producing a composite material at low cost. CONSTITUTION: The process comprises: the coating step in which a thermosetting resin composition scarcely containing any solvent is melted with a resin feeder 10 and the melt serving as a matrix resin is metered and evenly applied to one side of a fibrous sheet-form reinforcement A with a die coater 14; and the step in which the coated reinforcement B is covered on one or both sides with covering films C and D and he assemblage is pressed with compaction rollers 20 and 22 to evenly distribute the matrix resin and form smooth surfaces. The produced prepreg is wound around a winder 44, or cut into a given length.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a composite material in which a sheet-shaped reinforcing substrate made of fibers is impregnated with a matrix resin made of a thermosetting resin.

[0002]

2. Description of the Related Art In recent years, various fiber-reinforced composite materials have been widely used in various fields such as aerospace, land transportation, ships, construction civil engineering, industrial parts, electro-acoustic equipment, agricultural and fishery materials, and sports equipment. These fiber-reinforced composite materials are used as materials having excellent strength, heat resistance, corrosion resistance, friction, electrical characteristics, and light weight.

Among the above-mentioned composite materials, a prepreg, which is a composite material using a thermosetting resin composition containing no solvent or a small amount of solvent, has a matrix resin coated on a coated paper having good releasability from the matrix resin. It was manufactured by a two-step process of once coating, transferring and laminating it onto a sheet-like reinforcing substrate made of fibers.

Since such a manufacturing method is a two-step process, the productivity is poor, and materials such as coated paper are required, resulting in a high manufacturing cost. Furthermore, since the sheet-shaped reinforcing base material is transferred and laminated from both sides, there is also a quality defect such as inclusion of air in the reinforcing base material, which impairs the adhesiveness between the matrix resin and the reinforcing base material.

[0005]

The apparatus for producing a fiber-reinforced composite material by the applicant of the present invention is disclosed in Japanese Patent Laid-Open No. 1-19863.
No. 9, gazette is proposed.

This manufacturing apparatus will be described with reference to FIG. In the figure, the manufacturing apparatus 50 is equipped with a creel stand 52 for holding a bobbin wound with reinforcing fibers such as glass fibers to be supplied. The reinforcing fibers 53 supplied from the creel stand 52 are aligned by the roller group 54 and the tension thereof is adjusted, and the reinforcing fibers are sprayed with the atomized or atomized matrix resin from the vertical direction by the ultrasonic injection valve 56 and impregnated. Let

Next, release papers 61, 63 are provided on the downstream side of the ultrasonic injection valve 56, and the release papers 61, 63 are applied to the reinforcing fibers impregnated with the matrix resin from above and below by release paper supply rollers 60, 62.
Is further supplied and is pressed by the pair of press rollers 64 and 66 through the release papers 61 and 63 to form the resin-impregnated reinforcing fiber to a predetermined thickness.

Further, the resin impregnated reinforcing fiber 65 is attached to the heating plate 68, the press rollers 70 and 72, and the cooling plate 74.
After the heat treatment and the pressure treatment by the above, the upper release paper 61 is wound by the upper release paper take-up roller 78, and the lower release paper 63 and the resin-impregnated reinforcing fiber separated from the upper release paper 61 by the film supply roller 86. That is, the film 81 is supplied to the prepreg 65.

Then, by the press rollers 80 and 82,
The film supplied from the film supply roller 86 is brought into close contact with the prepreg, and the prepreg winding roller 84 winds the prepreg 83, and the manufacturing process is completed.

In the manufacturing apparatus configured as described above, the matrix resin is atomized by the ultrasonic injection valve and directly applied to and impregnated into the reinforcing fibers, so that bubbles are not mixed and the reinforcing fibers are not mixed. There is an advantage that a fiber-reinforced composite material having high strength can be manufactured without causing fiber disorder.

However, when the matrix resin is sprayed on the reinforcing fibers and directly applied, there is a problem that the uniform application property is poor.

Therefore, the object of the present invention is to improve productivity,
It is an object of the present invention to provide a continuous manufacturing method and apparatus of a composite material which is inexpensive in manufacturing cost.

Another object of the present invention is to provide a continuous manufacturing method and apparatus for a composite material, which prevents the entrapment of air in the reinforcing base material and has good adhesion between the matrix resin and the reinforcing base material. is there.

Another object of the present invention is to provide a continuous production method and apparatus for a composite material, which has a good uniform coating property on the reinforcing fibers of the matrix resin.

[0015]

The above object can be achieved by the method for continuously producing a composite material according to the present invention. In summary,
The present invention relates to a method for continuously producing a composite material in which a thermosetting resin is applied and impregnated on a sheet-like reinforcing base material made of fibers, and (a) is substantially composed of one or two or more components. A coating step of melting a thermosetting resin composition containing no solvent into a matrix resin to measure the matrix resin and uniformly coating the matrix resin on one surface of the sheet-like reinforcing base material from the coating portion of the coater; ) A cover film is applied to both or one side of a sheet-like reinforcing base material coated with a matrix resin, and then the matrix resin is made uniform by applying pressure, and the surface is smoothed, and then wound into a roll or a uniform shape. A continuous manufacturing method of a composite material, which comprises a step of cutting into a length.

Preferably, after the step (a), a step of impregnating the sheet-shaped reinforcing base material with the matrix resin by heating the sheet-shaped reinforcing base material made of fibers coated with the matrix resin with a non-contact type heater. Have.

Preferably, prior to the coating of the matrix resin in the step (a), there is a step of preheating the sheet-like reinforcing base material made of fiber with a contact type or non-contact type heater.

According to another aspect of the present invention, there is provided a winding unit of a sheet-like reinforcing base material made of fibers, and a matrix resin containing a composition containing a thermosetting resin substantially free of a solvent as a main component. A resin supply device that melts, a coater unit that coats the sheet-like reinforcing substrate unwound from the unwinding unit after the molten matrix resin has been subjected to processing such as weighing, and a sheet-shaped sheet that is coated with the matrix resin. A film unwinder for feeding a film that covers the cover film on both sides or one side of the reinforcing substrate, and a sheet-shaped composite that covers the cover film and then pressurizes it to make the matrix resin uniform and smooth the surface. A roll unit as a material, a roll type winding unit for winding a sheet-shaped composite material, or a cutter unit for laterally cutting into a certain length A device for continuously producing a fiber-reinforced composite material sheet characterized by having a.

After the coater unit, it is preferable to provide a non-contact type heater capable of controlling the fiber sheet-shaped reinforcing base material coated with the matrix resin at a specific temperature.

Before the coater unit, it is preferable to provide a contact type or non-contact type heater unit for heating the sheet-like reinforcing base material made of matrix fibers in advance.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The composite material manufacturing method and apparatus according to the present invention will now be described in more detail with reference to the drawings.

First, a method and apparatus for manufacturing a composite material according to the present invention will be described with reference to FIG.

FIG. 1 schematically shows an embodiment of an apparatus for producing a prepreg. This apparatus includes a die coater 14 having a hopper 12, and a resin supply device 10 for supplying a matrix resin to the die coater 14. In this resin supply device 10, a composition mainly composed of a thermosetting resin substantially free of a solvent, which is composed of one or more components, and a composition containing a curing agent and a curing accelerator. And / or a composition obtained by uniformly mixing inorganic fine particles is melted to form a matrix resin.

A raw material unwinder 7 for supplying the reinforcing base material A is provided between the lip portion of the die coater 14 and the backup roller 16 arranged so as to closely face the lip portion. Backup roller 16 and raw material unwinder 7
A heater 46 for heating the reinforcing base material A to improve the coating of the matrix resin on the reinforcing base material A is provided between the two. Raw material unwinder 7 to back-up roller 16
The matrix resin discharged from the lip portion of the die coater 14 is applied to the reinforcing base material A supplied to.

The coater used in the present invention is preferably one capable of controlling the resin to be discharged from the lip portion in a uniform distribution state. In addition to the above-mentioned gear pump-in-die type die coater, a coat hang type coater is preferable. It may be a die coater such as the ultra die coater. These die coaters can measure the matrix resin and apply it uniformly to one side of the sheet-like reinforcing base material.

In these die coaters, the lip surface of the die lip and the surface to be coated (glass cloth base material) are extremely close to each other, but they are not in contact with each other, and the coating liquid (matrix resin) is always present therebetween. It is characterized by the fact that it is flowing. The matrix resin discharged from the lip slot flows out between the lip surface and the glass cloth base material. At this time, since the glass cloth base material always moves in a fixed direction at a constant speed, the matrix resin practically passes between the lip surface and the glass cloth base material. That is, the matrix resin is
A large shear stress is applied when passing through the gap between the lip surface and the glass cloth substrate at a certain flow rate, causing a rapid change in viscosity and giving a constant film-forming force. It is applied smoothly. At this time, the flow rate of the matrix resin is determined by the pumping amount and the speed of the glass cloth base material.

An infrared ray impregnated heater 17 for indirectly heating and impregnating the matrix resin coated on the reinforcing base material A is disposed downstream of the backup roller 16.

In this embodiment, a temperature adjusting plate 13 for adjusting the softness of the matrix resin impregnated in the reinforcing base material A is disposed downstream of the infrared impregnated heater 17. still,
If necessary, the temperature control plate 13 can be omitted, or in some cases, the infrared impregnation heater 17 can be omitted and the temperature control plate 13 can be used for impregnation. In the present embodiment, downstream of the temperature control plate 13,
A film unwinder for supplying the cover films C and D to the resin-impregnated reinforcing base material B that has passed through the temperature control plate 13 from above and below, that is, the film supply roller 1.
8 and 19 are provided, respectively.

Further, downstream of the temperature control plate 13, cover films C and D are supplied from above and below to cover the resin-impregnated reinforcing base material in order to form the resin-impregnated reinforcing base material to a predetermined thickness. A pair of compaction rollers 20 and 22 for pressing are provided.

The pair of compaction rollers 20, 2
A cooling plate 2 for cooling the resin-impregnated reinforcing base material B pressed through the cover films C and D is provided downstream of the cooling plate 2.
4 are provided. The cooling plate 24 is provided with a plurality of freely rotating load rolls 26 for pressing the resin-impregnated reinforcing base material coated with the films C and D, that is, the prepreg E, to make the surface uniform and smooth when passing through the cooling plate. Is provided.

Downstream of the cooling plate 24, feed rollers 28, 3 for transferring the prepreg E in the downstream direction.
0, further downstream thereof, pull rollers 40, 42 are arranged, and downstream of the pull rollers 40, 42, a product winder 44 for winding the prepreg E is arranged. Instead of the product winder 44, a cutter for cutting the prepreg to a predetermined length may be arranged.

Next, a method of manufacturing the composite material by the manufacturing apparatus configured as described above will be described.

Matrix resin is supplied from the resin supply device 10 to the die coater 14 via the hopper 12. On the other hand, the reinforcing base material A is supplied from the raw material unwinder 7 to the backup roller 16, where the matrix resin discharged from the lip portion of the die coater 14 is applied to the reinforcing base material A. The matrix resin coated on the reinforcing base A impregnates the reinforcing base A while passing through the infrared impregnated heater 17.

Next, the resin-impregnated reinforcing base material B is adjusted in the temperature control plate 13 after the softness of the matrix resin is adjusted.
The softness of the matrix resin is adjusted by the compaction rollers 19 and 20, and both surfaces thereof are covered with the cover films C and D supplied from the film supply rollers 18 and 19.

The matrix resin is not semi-cured by the above steps. In the present specification, “semi-cured” means a state where the reaction rate of the matrix resin is 5% to 90%.

The resin-impregnated reinforcing base material B covered with the cover films C and D is passed through the cooling plate 24 and the free rotation load roll 26 to uniformize the resin and smooth the surface, and then the prepreg E. As feed roller 2
8 and 30, and pull rollers 40 and 42, and is conveyed downstream, and is wound up by the product winding machine 44.

According to the method and apparatus for producing a composite material as described above, a conventional step of directly coating a matrix resin in a thin film form on a reinforcing substrate by a die coater without using coated paper, Productivity can be improved by continuously heating the reinforcing base material coated with the matrix resin in a non-contact manner, coating both surfaces with a cover film, or performing both treatments continuously. Since no paper is required, the manufacturing cost can be reduced. Further, the adhesiveness between the matrix resin and the reinforcing base material becomes good, and the occurrence of voids can be prevented.
Furthermore, the uniform coating property of the matrix resin on the reinforcing fibers can be improved.

According to the present invention, the obtained composite material is not semi-cured, so that the manufacturing process and the manufacturing apparatus can be simplified and the manufacturing cost of the composite material can be reduced.

As the thermosetting resin used as the matrix resin, thermosetting resins such as unsaturated polyester resin, polyurethane resin and vinyl ester resin can be used in addition to the epoxy resin.

Further, as the reinforcing substrate, glass fiber, carbon fiber, aromatic polyamide fiber, aromatic polyester fiber, silicon carbide fiber, silicon nitride fiber, alumina fiber,
Fibers used for reinforcement such as stainless steel fibers are used alone or in combination, and woven and knitted fabrics, non-woven fabrics, papers and the like are used.

As the cover film, a release paper obtained by coating a paper with a release agent such as silicone, an unstretched or stretched film of polyethylene, polypropylene, polyethylene terephthalate, or the like is conveniently used, but is not limited thereto. It is not something that will be done.

Further, since release paper and thick film are expensive, it is preferable to peel them off and wind them up for repeated use. These examples will be described later.

Next, examples of the present invention will be described in more detail.

Example 1 In Example 1, the manufacturing method according to the present invention was carried out using the manufacturing apparatus shown in FIG.

Carbon fiber wound on a bobbin (T300-12Kf manufactured by Toray Industries, Inc.) is used as a reinforcing base material, the bobbin is placed on the creel stand 2, and the carbon fibers supplied from the creel stand 2 are aligned. The tension roller for controlling the tension, the yarn path guide, and the fiber opening roller group 4 led to the supply roller 6.

On the other hand, in the resin supply device 10, bisphenol A type epoxy and curing agent type 828 (oiled shell) 30 parts by weight 1001 (oiled shell) 70 parts by weight dicyandiamide 4 parts by weight dichloromethylurea 4 parts by weight The components were mixed and compounded, and a substantially solvent-free matrix resin in a molten state at 70 ° C. was supplied to a hopper 12 temperature-controlled at 70 ° C. Next, the matrix resin is supplied from the hopper 12 to the gear pump-in-die type coater 14, weighed and coated on the carbon fiber reinforced base material A arranged in a sheet shape at the lip portion of the coater at 130 g / m ² for backup. It was sent out with a roller 16. The carbon fiber reinforced base material B coated with this matrix resin was measured for the thickness in the lengthwise direction and the lateral direction with a non-contact type infrared film thickness measuring device 15 (MM55 system manufactured by Infrared Engineering Co., Ltd.).

Then, polypropylene biaxially stretched films C and D having a thickness of about 50 μm are fed from the film unwinders 18 and 19.
Is a unidirectional carbon fiber base material B impregnated with a matrix resin.
Covered from above and below and adhered, and heated to 60 ± 2 ℃ 2
Pressure 5kg with pair of pressure rollers 20, 22, 28, 30
/ Cm ² under pressure, 60 ± 2 ° C. hot plate 24 is heated, in free rotation load roll 26, after performing the smoothing of the uniform and the surface of the resin, the cooling plate 32 by cold water circulating inside surface After being cooled down by passing through the pair of pull rollers 40, 42, while controlling the tension, the winder 44 receives the sheet-shaped composite material,
A so-called prepreg was wound about 200 m.

There were no troubles during production, and the obtained prepreg had a very uniform thickness in the width direction and the length direction with a variation rate of ± 1.5% with respect to the set thickness, which was extremely good. It was Further, the uniformity of blending of carbon fibers was also good, with the blending variation rate at the set fiber specific volume being ± 2.2%.

Example 2 In Example 2, the manufacturing method according to the present invention was carried out in the manufacturing apparatus shown in FIG.

As a reinforcing base material, a glass roving cloth having a basis weight of 580 g / m ² (R manufactured by Unitika Yum Glass Co., Ltd.
C580T115P) A was supplied from the reinforcing base material unwinder 7 to the backup roller 16 for resin coating.

On the other hand, in the resin supply device 10, bisphenol A type epoxy and curing agent type 828 (oiled shell) 30 parts by weight 1001 (oiled shell) 70 parts by weight Dicyandiamide 4 parts by weight Dichloromethylurea 4 parts by weight The components were mixed and compounded, and a substantially solvent-free matrix resin in a molten state at 70 ° C. was supplied to a hopper 12 temperature-controlled at 70 ° C. The matrix resin is supplied from the hopper 12 to the gear pump-in-die type coater 14 and weighed. At the lip portion of the coater, the reinforcing base material is coated with a resin amount of 350 g / m ² , and the matrix resin is coated. The reinforcing base material B was sent out by the backup roll 16 and supplied to the non-contact type infrared heater 17 while being measured by a non-contact type infrared film thickness measuring device (MM55 system manufactured by Infrared Engineering Co., Ltd.). The infrared heater 17 controls the ambient temperature to 145 ± 3 ° C., the heater 17 controls the ambient temperature to 145 ± 3 ° C., runs in the heater 17 for 10 seconds, and coats it on the upper surface of the reinforcing base material. The processed resin was impregnated into the lower surface from the inside of the glass cloth.

Then, polypropylene biaxially stretched films C and D having a thickness of about 50 μm are fed from the film unwinders 18 and 19.
Of the reinforcing base material B impregnated with the resin from above and below to be closely adhered, and two pairs of pressure rollers 20 heated to 60 ± 2 ° C.,
Pressurized at 22, 28, 30 with a pressure of 5 kg / cm ² , 6
Hot plate 24 heated to 0 ± 2 ° C, free rotation load roll 2
After homogenizing the resin and smoothing the surface in 6, the sheet-shaped composite material, so-called prepreg E is applied to the winder 44 through the cooling plate 32 and the pair of pull rollers 40 and 42 while controlling the tension. It was wound about 100m.

There were no troubles during production, and the obtained prepreg had a variation rate of the thickness in the width direction and the length direction of ±.
The prepreg had a high uniformity of 2.0%, a good impregnation property of the resin into the reinforcing base material, and a very small number of voids of 20 / in ² , which was a high quality prepreg.

Comparative Examples 1, 2 and 3 Next, as a comparative example, Japanese Patent Laid-Open No. 1-19863 shown in FIG.
The case of manufacturing with the manufacturing apparatus proposed in Japanese Patent No. 9 will be described. In the case of the comparative example, an ultrasonic atomizer is used as a coating device instead of the coating method using a gear pump-in-die type coater, and the infrared impregnated heater 17 used in Example 2 is not used. Other than that, Example 2
The same device, resin composition, and glass cloth were used. Comparative Examples 1, 2 and 3 were carried out under the same conditions as in Example 2 except that the resin temperature conditions were changed.

[0055]

[Table 1]

Under all of the conditions, the uniformity of the resin thickness of the prepreg was poor, and the number of voids was large and the quality was unsatisfactory.

Example 3 In Example 3, the manufacturing method according to the present invention was carried out by the manufacturing apparatus shown in FIG.

As a reinforcing base material, a glass cloth (KS1600 manufactured by Kanebo Co., Ltd.) A having a basis weight of 205 g / m ² is applied from the reinforcing base material unwinder 7 to the resin, so that it passes through the heater 46 of the reinforcing base material. It was supplied to the backup roller 16.
In order to clarify the effect of the heater 46 of the reinforcing base material,
The heater temperature and the heating time by the heater were changed by changing the feeding speed of the reinforcing substrate.

On the other hand, in the resin supply device 10, of bisphenol A type epoxy and curing agent type 828 (oiled shell) 30 parts by weight 1001 (oiled shell) 70 parts by weight Dicyandiamide 4 parts by weight Dichloromethylurea 4 parts by weight The components were mixed and compounded, and a substantially solvent-free matrix resin in a molten state at 70 ° C. was supplied to a hopper 12 temperature-controlled at 70 ° C. Matrix resin is supplied from the hopper 12 to the gear pump-in-die type coater 14, weighed and coated with a resin amount of 148 g / m ² on the reinforcing base material at the lip part of the coater, and the matrix resin is applied for reinforcement. The base material B was sent out by the backup roller 16 and measured by the non-contact type infrared film thickness measuring device 15 (MM55 system manufactured by Infrared Engineering Co., Ltd.). In this example, the non-contact type infrared heater 17 was carried out without raising the temperature.

Then, polypropylene biaxially stretched films C and D having a thickness of about 50 μm are fed from the film unwinders 18 and 19.
Of the reinforcing base material B impregnated with the resin from above and below to be closely adhered, and two pairs of pressure rollers 20 heated to 60 ± 2 ° C.,
Pressurized at 22, 28, 30 with a pressure of 5 Kg / cm ² , 6
Hot plate 24 heated to 0 ± 2 ° C, free rotation load roll 2
After homogenizing the resin and smoothing the surface in 6, the sheet-shaped composite material, so-called prepreg E is applied to the winder 44 through the cooling plate 32 and the pair of pull rollers 40 and 42 while controlling the tension. It was wound about 200m.

The results of the heater temperature, heat treatment time and base fabric temperature impregnating property are shown in Table 2.

[0062]

[Table 2]

Here, an example in which expensive release paper or a thick film is peeled off, wound and repeatedly used, and other examples will be described with reference to FIGS. 4 to 7.

As shown in FIG. 4, the film supply roller 1
The cover films C and D supplied to the both surfaces of the resin-impregnated reinforcing base material B from 8 and 19 are wound around the film winding rollers 36 and 37 via the guide rollers 34 and 35, and further, the films are pulled by the pull rollers 40 and 42. The supply rollers 38 and 39 may cover less expensive cover films F and G on both surfaces of the resin-impregnated reinforcing base material B, and the product may be wound up by the product winding machine 44.

A cover film C having a structure similar to that of FIG. 4 but having one surface of a resin-impregnated reinforcing base material B coated thereon.
Only the guide roller 34 is wound around the winding roller 36,
Instead, an inexpensive cover film F may be supplied and covered from the film supply roller 38 and wound on the product winder 44.

Further, as shown in FIG. 5, the matrix resin, the reinforcing base material A and the cover film H are simultaneously supplied between the lip portion of the die coater 14 and the backup roller 16.
After forming the resin-impregnated reinforcing base material, the film supply roller 18 is coated with the cover film C on the other surface. afterwards,
The cover films C and H are wound around the film take-up rollers 36 and 37 via the guide rollers 34 and 35, and more inexpensive cover films F and G are taken from the film supply rollers 38 and 39 by the pull rollers 40 and 42. Both sides of the resin-impregnated reinforcing base material may be coated and wound on the product winder 44.

Further, in a configuration substantially similar to that shown in FIG. 5, only the cover film C on one surface supplied and covered from the film supply roller 18 is wound around the winding roller 36 by the guide roll 34, and instead of that, An inexpensive cover film F is supplied and coated from the film supply roller 38,
The product winding machine 44 may be used for winding.

Further, as shown in FIG. 6, the cover film C supplied and covered from the film supply roller 18 may be taken up by the product take-up machine 44 as it is without being peeled off, though it is different from the purpose of the above-mentioned structure. .

As shown in FIGS. 5 and 6, the creel stand 2
Supply roller 6 through the tension roller for controlling the tension, the yarn path guide, and the opening roller group 4.
Was led to. In order to coat the fibers arranged in a sheet shape (carbon fibers, glass fibers, organic fibers such as aramid fibers, metal fibers, etc.) without resin disturbance, release paper, films (polypropylene, polyethylene, polyethylene terephthalate, etc.) should be used. It is effective to supply the cover film unwinder 8 between the lip portion of the die coater 14 and the backup roller 16 along the sheet-shaped fibers.

Further, as shown in FIG. 7, the cover films C and D are supplied and coated from the film supply rollers 18 and 19, and at the same time, the resin-impregnated reinforcing base material B and the cover film C are formed, although the purpose of the structure is further different. It is also possible to manufacture the hybrid prepreg by supplying the second reinforcing base material J from the base material replenishing roller 21 in between.

It is also possible to manufacture a hybrid prepreg with the same structure as that shown in FIG. 7, omitting the supply coating of the cover film D.

[0072]

As is clear from the above description, according to the method for producing a composite material according to the present invention, (a) a thermosetting resin substantially free of solvent, which comprises one or more components. A coating step in which the composition is melted to form a matrix resin, and the matrix resin is weighed and uniformly applied to one side of a sheet-like reinforcing base material made of fibers from a coating portion of a coater, and (b) a matrix resin is coated. A step of covering the both sides or one side of the sheet-like reinforcing base material with a cover film and then applying pressure to homogenize the matrix resin and smooth the surface, and then wind it into a roll or cut it into a certain length. By having, the productivity is good and the manufacturing cost can be reduced. Further, it is possible to prevent the air contained in the reinforcing base material from being trapped, and to improve the adhesiveness between the matrix resin and the reinforcing base material. Further, it is possible to improve the uniform coating property of the matrix resin on the reinforcing fibers. Therefore, a high quality and inexpensive composite material can be manufactured.

Similar effects can be obtained by the composite material manufacturing apparatus according to the present invention.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an embodiment of a manufacturing apparatus for carrying out a method for manufacturing a composite material according to the present invention.

FIG. 2 is a configuration diagram showing a first embodiment of a composite material manufacturing apparatus according to the present invention.

FIG. 3 is a configuration diagram showing a second embodiment of the composite material manufacturing apparatus according to the present invention.

FIG. 4 is a configuration diagram showing another example of the composite material manufacturing apparatus according to the present invention.

FIG. 5 is a configuration diagram showing still another example of the composite material manufacturing apparatus according to the present invention.

FIG. 6 is a configuration diagram showing another example of the composite material manufacturing apparatus according to the present invention.

FIG. 7 is a configuration diagram showing still another example of the composite material manufacturing apparatus according to the present invention.

FIG. 8 is a configuration diagram showing an example of a conventional manufacturing apparatus for a composite material.

[Explanation of symbols]

 7 Reinforcing Base Material Unwinder 10 Resin Supply Device 13 Temperature Control Plate 14 Die Coater 16 Backup Roller 17 Infrared Impregnation Heater 18, 19 Cover Film Unwinder 20, 22 Compaction Roller 24 Cooling Plate 26 Free Rotating Load Roll 28, 30 Feed Roller 44 Product winder 46 Heater

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Takayuki Fukuda 1-3-1 Nishitsurugaoka, Oi-cho, Iruma-gun, Saitama Tonen Corporation Research Institute (72) Inventor Hiroshi Toshima Nishitsurugaoka, Oi-cho, Iruma-gun, Saitama Prefecture 1- 3-1 Inside Tonen Research Institute

Claims (6)

[Claims] 1. A method for continuously producing a composite material in which a thermosetting resin is applied and impregnated on a sheet-like reinforcing base material made of fibers, and (a) is substantially composed of one or more components. A coating step in which a thermosetting resin composition containing no solvent is melted to form a matrix resin, and the matrix resin is weighed and uniformly applied to one surface of the sheet-like reinforcing base material from the coating portion of the coater, ( b) Covering both sides or one side of a sheet-like reinforcing base material coated with a matrix resin with a cover film and then applying pressure to make the matrix resin uniform and smooth the surface, and then roll it into a roll or keep it constant. And a step of cutting the composite material into the lengths thereof. 2. After the step (a), there is a step of heating a sheet-like reinforcing base material made of fibers coated with a matrix resin with a non-contact type heater to impregnate the sheet-like reinforcing base material with the matrix resin. The manufacturing method according to claim 1, wherein: 3. The method according to claim 1, further comprising a step of preheating the sheet-like reinforcing base material with a contact type or non-contact type heater prior to the matrix resin coating in the step (a). Production method. 4. An unwinding unit of a sheet-like reinforcing base material made of fibers, a resin supply device for melting a matrix resin containing a composition containing a thermosetting resin that is substantially free of a solvent, and a melting unit. After performing processing such as weighing on the matrix resin, a coater unit for coating the sheet-shaped reinforcing base material unwound from the unwinding unit, and on both or one side of the sheet-shaped reinforcing base material coated with the matrix resin. A film unwinder for delivering a film for covering the cover film, a roll unit for covering the cover film and then applying pressure to make the matrix resin uniform and smooth the surface into a sheet-shaped composite material, and a sheet. A roll-type winding unit for winding the composite material or a cutter unit for laterally cutting the composite material into a certain length. Equipment for continuous production of fiber-reinforced composite materials. 5. The apparatus according to claim 4, wherein a non-contact type heater capable of controlling the fiber sheet-shaped reinforcing base material coated with a matrix resin at a specific temperature is provided after the coater unit. . 6. The apparatus according to claim 4, wherein a heater unit of a contact type or a non-contact type for preheating a sheet-like reinforcing base material made of a matrix fiber is arranged in front of the coater unit.