Production apparatus for producing a fiber-reinforced resin and a production method for producing a fiber-reinforced resin

Patent metadata

Field	Value
Publication number	US-12583193-B2
Application number	US-202218552264-A
Country	US
Kind code	B2
Filing date	Mar 17, 2022
Priority date	Mar 26, 2021
Publication date	Mar 24, 2026
Grant date	Mar 24, 2026

Abstract

The present application provides an apparatus that is for producing a fiber-reinforced resin having reinforcement fibers aligned in one direction and that is capable of, with a relatively simple configuration, connecting a preceding reinforcement fiber and a subsequent reinforcement fiber when switching between the reinforcement fibers. An apparatus according to the present invention is for producing a fiber-reinforced resin having reinforcement fibers aligned in one direction, and comprises: an impregnation part which impregnates a reinforcement fiber with a resin; and a switching device which performs switching of reinforcement fibers on the upstream side of the impregnation part, from a preceding reinforcement fiber to a new reinforcement fiber. During the switching operation, the switching device forms a fabric using the preceding reinforcement fiber and the new reinforcement fiber as warp and other fibers as weft so as to connect the new reinforcement fiber with the preceding reinforcement fiber.

First claim

The invention claimed is:

1 . A production apparatus for producing a fiber-reinforced resin in which a reinforcing fiber is arranged to be oriented in a single direction, the production apparatus comprising:
an impregnation section that impregnates the reinforcing fiber with a resin; a switching apparatus that switches the reinforcing fiber from a preceding reinforcing fiber to a new reinforcing fiber at an upstream side of the impregnation section, wherein when switching the reinforcing fiber, the switching apparatus connects the new reinforcing fiber and the preceding reinforcing fiber to each other by forming a textile in which the preceding reinforcing fiber and the new reinforcing fiber are used as warp threads and another fiber is used as a weft thread; a gripping section that grips the new reinforcing fiber and guides the new reinforcing fiber to the switching apparatus; and a cutting portion that cuts the preceding reinforcing fiber after the textile is formed, wherein only the preceding reinforcing fiber passes the switching device before the switching of the reinforcing fiber, and only the new reinforcing fiber passes the switching device after the switching of the reinforcing fiber.

2 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , wherein
the switching apparatus includes:
a first heald that holds one of the new reinforcing fiber and the preceding reinforcing fiber and moves up and down,
a second heald that holds an other of the new reinforcing fiber and the preceding reinforcing fiber and moves up and down, and
a weft insertion mechanism that passes a reinforcing fiber laterally between reinforcing fibers held by the first heald and the second heald.

3 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , further comprising:
a plurality of holding sections that, at respective different positions, hold a plurality of the reinforcing fibers; and a uniting section that receives the plurality of reinforcing fibers from the plurality of holding sections, unites the plurality of reinforcing fibers, and delivers the plurality of reinforcing fibers to the impregnation section, wherein a plurality of the switching apparatuses are disposed on the plurality of holding sections, respectively.

4 . The production apparatus for producing the fiber-reinforced resin according to claim 3 , wherein:
each of the plurality of holding sections holds the plurality of reinforcing fibers, and the uniting section disposes a plurality of reinforcing fibers alternately to unite the plurality of reinforcing fibers into a sheet shape, the reinforcing fibers being received from the plurality of holding sections, and arrangement of the plurality of reinforcing fibers received from the plurality of holding sections is changed before and after switching of the reinforcing fiber by the switching apparatus.

5 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , wherein
the switching apparatus forms the textile by using, as the weft thread, a reinforcing fiber that is made of a same material as the new reinforcing fiber and the preceding reinforcing fiber.

6 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , wherein
the switching apparatus forms the textile by using, as the weft thread, a reinforcing fiber that is made of a material different from that of the new reinforcing fiber and the preceding reinforcing fiber.

7 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , further comprising:
a removal section that removes, from the fiber-reinforced resin, a portion where the reinforcing fiber forms the textile, the fiber-reinforced resin being obtained by impregnation with a resin at the impregnation section.

8 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , wherein
the reinforcing fiber is a carbon fiber.

9 . The production apparatus for producing the fiber-reinforced resin according to claim 1 , wherein
the resin is a thermoplastic resin.

10 . A production method for producing a fiber-reinforced resin in which a reinforcing fiber is arranged to be oriented in a single direction, the production method comprising:
producing the fiber-reinforced resin while switching the reinforcing fiber, by using a production apparatus for producing the fiber-reinforced resin according to claim 1 .

Assignees

• Mitsui Chemicals Inc

Inventors

• Yano Masahiro
• Miyata Atsushi

Classifications

• B29K2507/04

  Carbon · CPC title

• B29K2105/0881

  unidirectional · CPC title

• B29C2793/0027

  Cutting off · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title

• B29C70/20

  oriented in a single direction, e.g. roofing or other parallel fibres {(B29C70/083, B29C70/226 take precedence)} · CPC title