Method of producing resin-impregnated fiber bundle roll body

Patent metadata

Field	Value
Publication number	US-11046025-B2
Application number	US-201816485960-A
Country	US
Kind code	B2
Filing date	Feb 5, 2018
Priority date	Feb 22, 2017
Publication date	Jun 29, 2021
Grant date	Jun 29, 2021

Abstract

A method of producing a resin-impregnated fiber bundle roll body includes unwinding a fiber bundle from a bobbin; winding the fiber bundle on a winding core rotating around a fixed axis through a movable winding head to prepare a product; and leading the fiber bundle taken off in the unwinding to the winding between the unwinding and winding, wherein the leading or winding includes a resin impregnating the fiber bundle, and the winding includes a fiber content calculation of a fiber content in a layer of the fiber bundle on the winding core of an intermediate product to control one according to the fiber content: a resin adhesion amount in the resin adhesion operation; a winding tension of the fiber bundle applied to the intermediate product; a removal amount of a surplus resin layer on an outer surface of the intermediate product; and a resin viscosity in the intermediate product.

First claim

The invention claimed is:

1. A method of producing a resin-impregnated fiber bundle roll body, comprising:
an unwinding step that takes off a fiber bundle from a bobbin;
a winding step that rolls up the fiber bundle on a winding core rotating around a fixed axis through a movable winding head to prepare a product; and
a leading step that leads the fiber bundle taken off in the unwinding step to the winding step between the unwinding step and the winding step, wherein
the leading step or the winding step includes a resin adhesion operation to impregnate the fiber bundle with a resin,
the winding step includes a fiber content calculation operation to calculate a fiber content V f [%] in a layer of the resin-impregnated fiber bundle being rolled up on the winding core of an intermediate product to control any one of (i) to (iv) according to the fiber content V f [%]:
(i) a resin adhesion amount in the resin adhesion operation;
(ii) a winding tension of the fiber bundle applied to the intermediate product;
(iii) a removal amount of a surplus resin layer generated on an outer surface of the intermediate product; and
(iv) a resin viscosity in the intermediate product,
the winding step further includes a resin-impregnated fiber bundle layer thickness calculation operation to calculate a thickness t FRP of the layer of the resin-impregnated fiber bundle and then the fiber content calculation operation is performed by using the thickness t FRP ,
the winding step further includes an outer diameter measurement operation to measure an outer diameter of the winding core or the intermediate product, and
the thickness t FRP of the layer of the resin-impregnated fiber bundle, formed between a first time t 1 and a second time t 2 later than first time t 1 , is calculated by using: a first outer diameter d 1 of the winding core or the intermediate product at the first time t 1 , and a second outer diameter d 2 of the winding core or the intermediate product at the second time t 2 , the first and second outer diameters d 1 and d 2 being measured by the outer diameter measurement operation.

2. The method according to claim 1 , wherein
the winding step further includes a surplus resin layer thickness measurement operation to measure a thickness tr of the surplus resin layer generated on the outer surface of the intermediate product, and
the thickness t FRP of the layer of the resin-impregnated fiber bundle formed between the first time t 1 and the second time t 2 is calculated by using: the first outer diameter d 1 ; the second outer diameter d 2 ; and the thickness tr of the surplus resin layer measured by the surplus resin layer thickness measurement operation at the second time t 2 .

3. The method according to claim 2 , wherein the surplus resin layer thick-ness measurement operation is performed by a photoelectric means or an ultrasonic wave means.

4. The method according to claim 1 , wherein the outer diameter measurement operation is performed by a photoelectric means.

5. The method according to claim 2 , wherein the outer diameter measurement operation is performed by a photoelectric means.

6. The method according to claim 3 , wherein the outer diameter measurement operation is performed by a photoelectric means.

Assignees

• Toray Industries

Inventors

• Takahashi Jumpei
• Kawashima Shigeru
• Nagamatsu Daisuke
• Watanabe Tadashi

Classifications

• B29C70/54 Primary

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• B29C70/32 Primary

  on a rotating mould, former or core · CPC title

• G01B11/105

  using photoelectric detection means · CPC title

• G01B11/0691

  of objects while moving (G01B11/0616 takes precedence) · CPC title

• B29C53/665

  Coordinating the movements of the winding feed member and the mandrel · CPC title