IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

US011491685B2

(12) United States Patent (10) Patent NO.: US 11s491s685 B2

Oehi et al. (4s) Date of Patent: Nov. 8,2022

(54) PRODU&'TION MKTIIOD I(OR PRKPRI((;, (52) U.S. Cl.

PRKPR10(3 TAPI':, AND I/113KR RKINFOR(:KD CPC .......... 8298 ll//6 (2013.01), 829K 206t/00
COMPOSITK MATKRLAI« AND PRI(PRKG (2013.01): 829/( 2307/04 (2013.01)
PRODU('TION DEVICE (58) leield of ()lassification Search
None
(71) Applicant Toray Industricv, Inc.„'tiokyo (IP) Siu applicauon file liar complete search lustory.

Inventors: Takashi Ochi, Ehime (JP): Yoshikazu (56) Refcrcnccs ('itcd

(72)
Kunu, Elumc (JP). So Nivhino, Otsu U S PA'l l:N'I D(X'UMEN Ig
(JP), Junichi Aoki. Ehune (JP),
Kiyoshi Minoura. Otsu (Ip); Tamotsu 3.378,884 A e 01968 Me/acr 029C 70:521
Suzuki, Otsu (.)P) 156ii51
S.SZ),6SZ 4 e 6'1996 029( '8:34
156i180
(73) Assignee. Turay Industriea, Int«Tokyo (JP)
(Colitiiiucil)
" Notice Subject to any disclaimer. the term of tlus
( )
patent is extended or adjusted under 35 FOREI(iN PATENT DOCUMENTS
U S C. 154(b) by 0 days. CN 201 45120 11 a 2i2011
./P 491311453 4 3,'1974
(21) Appl. No 17/266,413 (Colitiiiueil)

(22) PCT Filed Aug. 20, 2019 O'I'I IER PU131 I( Ai IONS

Machine 1raoslatios of tapaacse patent 64-5674 I, 1)atc Unknown v

(86) PCT Noc PCT/JP2019/032496
(Contimied)
ss 371 (c)(1),

(2) Date. Feb. 5, 2021 Priinarv Eiaminer Jefi'ry H Aftergut

(74) 4(i«meit .48«n(, «r Eirin Ratilerprestia
(87) PCT Pub. Noc WO2020/040154
PCT Pub. Date: Feb. 27, 2020 (57) ABSTRACT
A method is dcscnbixi for producing u prcftrcg formed by
(65) Prior Publication Data applyin a matrix resin to a reinforcing fiber sheet, wherein
the method can efi'ect continuous rumfing without clogging
US 2021/0291405 Al S«7t. 23, 2021 due to generated fuzz even at a high running speed and effect
etficient impregnation of the reinforcing fiber sheet ivith a
(30) Foreign Application Priority Data matrix resin. A method of producing a prcprcg includes
allowing a rcuiforcing fiber sheet to pass substantmlly
Aua 22, 2018 (JP) .IP20i8-155066 vertically downward tiuough the inside of a coating section
Aug. 22, 2018 (JP) ... IP2018-155077 stonng a matrix resin to obtain a matrix resin-impregnated
reinforcing fiber sheet in which the matrix resin is applied to
(51) Int. CL the reinforcing fiber sheet and at least heating the matrix
8298 11/l6 (2006 01) resin-impregnated reinforcing fiber sheet„wherein the coat-
82 9K di3/(1(/ (2006 01) ing section includes a liquid pool and a narrowed section
82 9K 30?/04 (2006 01) (Colitiiiueil)

zii
 US 11,491,68i B2
Page 2

which are in comniunication w:ith each other, v herein the .IP 0 2(2372 (n,i(99 5
liquid pool has a portion whose cross-sectional area JP 32(2278 B2 2 2002
JP 2011132389 A 7(2011
decreases continuously alon a mnning direction of the .IP 201201fi657 I,i2012
rcinibrcuig liber sheet. JP 2013022868 A 2(2013
.IP 201(022799 A 2 201(
10 Claims, 22 Drawing Sheets JP 2016203397 12(201G
.IP 201 1(4330 9,i2017
WO 0128951 A2 4 2001
WO W'0-0 k 2895 I A2 v 4(2001
WO 2005002819 A2 I(200(
i56) References Cited WO voopmvv(i Al 11(2009
WO 20101(0022 AI 12 2010
U.S. PATENT DOCUMENTS WO 2012002417 AI I(2012
WO 20130(fi(21 AI I,i2013
(,911,932 A "'
1999 Dyksterhouse B29B I( 122 WO 20(5060299 Al 4 201(
264 136 WO 2015076981 Al 5(2015
9.233,336 B2 I 2016 Ishibashi et al. WO 20170681(9 AI 4(2017
9.410,004 B2 8 "2016 Asano e( al WO v 0 Pj0 t 705 i Al 1(2019
11.192,280 B2 ivi I0(1 Ochi B29B I( 12(
B2"'1.224,993
I "20 i2 Ochi 13iijB 11'1(i O'I'I II(R PUIII I(
'014
0175694 A I 6 2014 Mwuta et al
AT IONS
2016(0303 77 Al 10 "2016 Miyauchi ei al
2020i013132( Al 4(2020 Ymnaibs ct al Machine Ti ansia tie n of Chinese Patent 201745 120, Date Unknown."
Machine Translation of Japanese Patent 1-178412, Date Unknovvn"
Kawabe, K, f New Spieading Technology foi Carbon Ftbei Tow
FOREIGN PATENT DOCUMENTS and It( Application to Composite Matci ialsk Sen i (iakkaisbi, vol
64. No 8. 2008, pp 262-267
JP A I 1989
.Ii'10IG612
JP
.IP
64-(6741
01104624
A
A
v 3il989
4 1989
Inteinational Scaicb kcpon and Wnttcn Opuiion for Intcinaticnal
Applica(mn No PCT(JP2019(012496, da(ed Nov 12, 2019, 7 pages
JP 1-178412 A 7 1989
'"
0631821 4 2(1994 cited by examiner
U.S. Patent Nov. S,2022 Sheet 1 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 2 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 3 of 22 US 11,491,685 B2

l"i *
26
U.S. Patent Nov. S,2022 Sheet 4 of 22 US 11,491,685 B2

Fie, 2e
U.S. Patent Nov. S,2022 Sheet 5 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 6 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 7 of 22 US 11,491,685 B2

25
U.S. Patent Nov. S,2022 Sheet 8 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 9 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 10 of 22 US 11,491,685 B2

35
U.S. Patent Nov. S,2022 Sheet 11 of 22 US 11,491,685 B2

vt&:A't d io fit&
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U.S. Patent Nov. S,2022 Sheet 12 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 13 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 14 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 15 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 16 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 17 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 18 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 19 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 20 of 22 US 11,491,685 B2

Fig. 26
U.S. Patent Nov. S,2022 Sheet 21 of 22 US 11,491,685 B2
U.S. Patent Nov. S,2022 Sheet 22 of 22 US 11,491,685 B2

"36b». 36
 US 11,491,6)(5 B2
1
PRODUCTION METHOD FOR PREPREG A hot-melt pmccss tlui1 is onc of the methods ol'produculg
PREPREG TAPE, AND FII3ER REINFORCED prepregs is a method in which a matrix resin is melted and
COMPOSITE MATERIAL, AND PREPREG then applieil iiiuo rclcasc shccts, a laullllatix! stnlclurc is
PRODU(:TION DEVI(:E pmduced in lvhich a reintbrciug hber sheet is sandwiched
bctwimn the matux rcsul sheets at thc upper side and lower
CROSS REFERENCE TO RELATED side uf thc reinforcing liber shcct, and then, thc ulsidc ol'hc
APPLICATIONS reinforcing liber sheet is mlpregnatcd with thc matrix resin
by heat and pressure. There is a problem in that this method
'Elis is the U 8 National Plmse application of P(71'/ has many steps, cannot increase the production speed, and is
IP2019/032496. filed Au . 20. 2019, v:hich cLaims priority cils tlv
to Iapanese Patent Application No. 2018-155066. filed Au . For more eificient impregnation. for example. Patent
22. 2018. mid Japanese Patent Applicauon No. 2018- Litcraturc I has made a proposition. Thw is a method in
155077. Iilcd Aug. 22, 2018, the disclosures ol'each of these which glass liber is melted and spun, and tlm resultulg
applmations being incorporated harem by rclcrence in their spinnulg bundled in suand lbrm or rowug finn is allowed)
entireties for all purposes I to pass thmugh a liquid pool hi)ed with a thermoplastic resin
and having a conical flow path
FIELD OF THE INVENTION As another example. Patent Litemture 2 describes a
method in which a coating tihu is formed on both ihces of
1'he present im ention relates to: methods of producing a a shimt-like oblcct simultaneously, but this w a method in
prepre, a prepreg tape, and a fiber reinforced composite Io which a sheet-like object is allowed to pass tlumigh a
material, and to a prepreg production apparonis; and par- wcb-guide and coatcsl using a pipe type doctor blade in order
ticularly relates to a method and apparatus for impregnating to prevent ihictuation of the sheet-like object in the forma-
a reinforcing fiber sheet v ith a matrix resin unifomfly. tion of the coating film.
As a method of producing stop-like prepreg usiilg a
l3A('K(IROUNI& Oil Till I INVIIN11ON themloplastic resin, a horizontal type pultnision method is
Intown in which a suip-like rciulhrcing liber bundle is
Fiber remforced composite materials (FRP) in which a conveyed ul thc honzontal Ilirection (longitudinal dircctiun)
Iualrtx resin I:olltalluug a thcrulophlsitc Icaill ol a Ihcnuo- and is allowed to pass through a dm, where the strip-like
scuing resin is rcinl'orccd with a rcinlilrcing tiber are used in reinforcing fiber bundle is prm ided and inlpregnated with a
various fields such as aerospace materials, automobile mate- lo thernloplastic resin (Patent I iterature 3 and Patent I.iterature
rials. indusiual materials, pressure vessels, constniction 4). According to Patent Literature 3, a tape-)ike reinforcing
material~. housings, nledical applications. and sports appli- fiber is allowed to pass tllrough a cmsshead (in FICi. 2 in
cations. Carbon fiber reinforced materials (CFRP) are Patent Literature 3), and the tape-like reinforcing fiber
widely and suitably used particularly in cases where high bundle is provided with a rcaul immcdiatcly bekire o hnear
mcchmuca1 property and lightness are rcqutrosi. On lhc other ls dic in the crossheud. Patent Litcraturc 4 explains that a
hand, ul cases where cost has priouty over a mcchiuucal plunllity of strip-like reinforcing hber bundles are separately
property and hghtncss, glass liber reulforccd composite introduced into a die tifled lvith nlolten thermoplastic resin,
nlateri ala ((il 'Rp) are used I IRP is obtained by impregnatiag opened, impreenated, and laminated using o fixed guide (for
a reinforcing tiber bundle with a matrix resin to obtain an example. a squeeze bar). and finally withdrawn from the die
intermediate base materiaL wlfich is laminated and formed, so as one sheet of prepre .

and huther thermally cured if a thermosetting resin is used,

members composed of FRP are then produced. In thc PAT)!N1 I,I'll!RAI'I JRU
abolc-mentioned apphcations, phmar oblccls or obiccts
fornax) by folding planar objects are oflen ussxl, and two- Patent Literature I; WO2001/02895 IAI
dimensional sheet-like objects are inure widely used as Patent Literature 2. JP3252278B2
internlediate base materials of IIRP than one-dimensional Patent Literaturc3. JP H06-031821A
strands and roving-like objects, from the viewpoint of lami- Patent I,iterature 4 WO2032,'002417AI
nation efficiency and moldability achieved in producing
such members. SUMMARY OF THE INVENTION
In aildition, an auempt to cnhimcc production cfficimlcy o
for mmnbers composed) of FRP has recently promoted the However, thc method in Patent Literature I enables only
nlechallizatioll aild autoination of lamination ot sheet-like a stnlnd-like or roving-like object to be pmduced, and is not
intemiediate base matenals, and here. namlv tape-like applicable to producing a sheet-like prepreg at which the
intermediate base materials are suitably used. Normw tape- present invention is directed. In addition. Patent Literature I
like internlediate base materials can be obtained by slitting ls explains that. in order to enhance impre nation eificiency, a
broad sheet-like intermcdiatc base materials ulto tapes hav- thcnnuplastic resin fluid is aflow cd to strike against a side of
ing a desired width or imprcguatulg a narrow rculforcing thc strmld-like ur rovulg-like reinforcing liber bundle to
liber sheet directly Is ith matrix reams. acuvcly gcncratc turbulence in a conical flow path. This is
As two-dinlensional sheet-like intermediate base maten- considered to be intended to disturb pari of the arrangement
als, prepregs obtained by impregnating reintilrcing tiber io of the reinfilrcing fiber bundle so that the matrix resin can
sheets with matrix resins are widely used. Examples of flow in. but applying this idea to a reinforcing fiber sheet
reinforcing tiber sheets used for prepregs include UD bose conceivably causes the arrangenlent of the reinforcing fibers
ma/coals obtained ul shcct-hkc form by armnging remfilrc- to bc disturbed. rcsulung ul not only degrading thc grade of
ing libera unidircctionally and reinforculg liber fiibrws tliat the prcpreg but also decreasing thc mechanical propcny of
arc wolmt fabrics obtmned by orrim m remfilrcing libera ss FRP
nniltidirectionally UD hase materials are often used par- In addition, the sheer-like object in Patent I.iterature 2 is
ticu)arly in cases lvhere the mechanical property has puouty. a fihn, cloth. paper. foil. punching plate, network-hke sheet
 US 11,491,6115 B2

malcndl, or the like, Bnd &s not ultcndcd for a rculforcing healing thc matrix ream-impregnated reinlorculg liber
fiber sheet at v, hich the present invention is direcred. If the sheet in a noncontact nlanner:
tcclulology of Patent L&lcraturc 2 &s apphed 10 a rcinforculg whcrcul Ihc coalulg section includes a liqu&d pool and a
fiber sheet con&posed of carbon tiber. abrasion at the v eb- narrowed section &vhich are in conlmunicatioo ivith
guulc generates I'uzz, coucmvably makm &I ddlicull fi&r thc each other, wherein the liquid pool has a portion whose
reinforcing fiber sheet to nin In addition, the technology of izoss-sccnonal alod ih:crcdscs co&fill&IOUslv Blollg
Patent Literature 2 is intended for coating with resin. not for nuuung direct&on 01 Ihc reinforc&ng liber shccl, and
ill&pre n;it&on wherein the narmwed section has a slit-like cross-
According to the teclulology of Patent Literature 3. a section and has a smaller cross-sectional area than the
tape-1&kc reinlbrculg liber passes tluough a slit-1&kc guider
1&1
area of the top side of the liquid pool:
clip with no resin in the fore portion of a die in a cmsshead, wherein the noncontact heatin is started within a region
dnd accordulgly, thc fore poruon is morel&kely Io be clo ged of I m Ibom Ihe opcnulg of the narrowed section ul Ihe
with fuzz and also has no function for removina the fuzz„ nllllllllg ill&CCI&oil Of Ihc Ina&IIX &CS&ll-lmp&Cgl&a&Cd IChl-
conciivably making it ihllicult to run thc ldpe-like remfi&rc- forculg fiber shccl. and
wherein the below-mentioned lfonnula I is satisfied
ing fiber continuously for a long time. 'I'his tendmlcy is
assiuning that the surface temperature of the matrix
considered to be remarkable particularly with carbon fiber, resin-impre Bated reinforcing fiber sheet is P2 (" C.) at
which is more likely to generate fuzz. the completion point of the heating and that the tem-
In addition. the method of Patent Literan&re 4 makes it perature ol thc matrix resin stored in Ihc uls&dc of lhc
&nolo llkCIV 11&BI fU'IL 1 ~ ICU&ll&Cd ill 11 llqilul pool dullllg &ii
continuous production and that the fuzz clogs a pultrusion
coatulg section is M ('.j,
portion. There &s a problem in than ul perl&cular. ruiuling a lrornxao I&

strip-like reinforcing fiber bundle continuously at a high

speed causes the frequency of clogging with fuzz. to be very In addil&on, provided &s d method ol produculg a prcprcg,
h&CIUillllg:
high, and accordingly, enables production to be carried out
only at a very low speed and fails to increase productivity. allowing a reinforcing liber sheet to pass substanlmlly
In addition, a honzontal type pultrusion method makes it vertically doivnward through the inside of a coating
nimessary to semi Ihc dic hemlctically io prcvcnt liquid section storing a matrix resin to obtain a matrix resin-
ICBk;IgC ill&i llldkCS ll ll&SUfi&C&C&1110 COIICCI IIILZ dullllg
impregimted reinforcing fiber sheet in v hich the matrix
contimious production 1&urthennore in the horizontal type 10 resin is applied to the reinfilrcin fiber sheet, and
pultrusion method. inlpregnating the inside of a reinforcing cdrryulg out an add&uonal-&mprcgoauon process wluch al
ICBSI p&CSSCS thC IlullrlX &CS1n-ill&pl'Cgl&a&Cd &C&lifo&C&llg
fiber sheer &vith a matnx resin causes bubbles remaining in
the reinforcing fiber sheet to be discharged, by ascending liber sheet,
force, in a direction perpendicular to the nuu»ng direcrion of
wherein the coating section includes a liquid pool and a
thc reinlorculg liber shcct, aud accordulgly. Ihc dischar e ol ls narrowed section &vhich are in con&munication ivith
thc bubbles progresses ul such a manner llmt Ihe bubbles each other, wherein the liquid pool has a portion whose
cross-sectional area decreases continuously along a
pUsh rlwdv lhC lualllX rcslll ul-Colnlllg for llnplcgl&B!loll.
liecause of this. there is a problem in that not only the nuuung dirccuon of the reinforc&ng liber sheet, and
nlovement of the bubbles is inhibited by the liquid, but also wherein Ihc narrowed section has B slit-like cross-
the inlpregnation with the matrix resin is inhibited by the do scction and has d smaller cross-acct&orml area tlmn the
top side of the liquid pooh
bubbles. resulting in lov impregnation efiiciency. In tlus
regard, Pa&cut Literature 4 also proposes exhaustul bubbles wherein the distance N from the outlet of the coating
tluough a vent, but thc exhmistion takes place only near thc section to the starting point of the pressing in the
additional-impregnation process is I m or less; and
outlet of a die, and thc cfii:ct of thc exhausl&on &s considered
to be limitative whcrcin Ihc surface Iempcralurc P ('.) Ol'hc matrix
'tin&~, an efiicient method of applying a matrix resin to a resin-impregnated rmnforcing liber sheet bcforc thc
reinforcing fiber sheet such as a UD base material or a addit&onal-impregnation process sat&sties Ihe relet&on-
reinforcing fiber fabric. particularly an efficienr method of ship of Formula 2 &vith the tempemsture M (" (' of the
produculg a shee&-like prcprcg usul a UD base material has matrix resin stored in the coating section.
&101 bccll csuibllshcd I'cl. 0
.11 ul F ll'onnnlo )
An object ol'hc prcscnt invention rcldlcs to a method of
—

pmducing prepreg,
a and is to pmvide a production method ln addition. provided is a nlethod of producing prepreg„
a
and an apparatus for producing a prepreg, wherein genera- the method chamscterized by including allowing a reinforc-
tion of fuzz is suppressed, continuous production is possible ing fiber sheet to pass vertically dov, nward tluouogh a coating
&vithout clogging with fiizz. a reinforcing fiber sheet ls o. section to apply a matrix resin to the reinforcing fiber sheet;
cfiicicnlly in&pre@mlcd with a ma&Ox ream, Ihe production WhC&clll IhC Coallllg SCCI&011 lllchah:s
spccd can bc nuidc higher, tmd I'urthcnnore, Ihe resulting a 1&qind pool storing the matnx rcs&n aud havul a
rcinlbrculg liber shccl is inlubilcd from, for exiunple. being portion whose cross-sectional arcs coul&nuously
fillded and has an areal weight uniformly. decreases vertically downward;
'lhe aim e-mentioned problem is solved by a method of fo a narrowed section having a slit-like outlet in conunu-
producing a prepre accordmg to the present invenrion, nication ivith the lower end of the liquid pool: and
including the steps of: one or more bars included in the liquid pool and
allowing a rcultorcing liber shccl to pass subslanlially cxtcnding in lhe longitudinal d&rccl&on of thc slit-like
icrucally downward tluough thc ins&de oi' coating 0UIICI, Blul
SCCI&iul Stol lilg B ll&BI&1X &CS&ll 10 apply lhC n&B&r&X Icslll Ss whcrcul lhe rcinforculg liber sheet &s withdrawn from Ihe
to the reinforciilg tiber sheet to obtain a matrix resi&1- narrowed section &vhile the remfilrcing liber sheet is
impreg&mted reinforcing fiber sheet; and brought in contact with the bar(s) such that the holding
 US 11,491,685 B2
i
angle(sl fonncd bctwccn thc bar(s 3 imd saul rcuiforcing FIC& 15 is a dc&ail cross-sect&onal v&cw cxplmning thc
fiber sheet &s/are all 10" or more and 40" or less. internal structure of the coating section 42 accnrding to an
In edda&on. the method of producing a prepreg &ape embodiment other than ui FICi. 11
according to the present uivcntion is cliaracterizcd by FICi 16 &s a delml cross-scmlional view of the coalulg
includi&m shtting a prepreg obtained by the above-men- section 20/& according to an embodiment other than in I'IG
tioned method of producing a prepreg 4
In addition. the method of producin a fiber reinforced FICi 17 is a detail cross-sectional view of the coating
conlposite matenal according to the present invention &s section ZOC according to an embodiment other than in FICI.
characterized by &ncludin curing a prepreg obtained by the 16.
abolc-mentioned method of pmducm a prepreg or alii FICi 18 is a dc&ail cross-sixuonal vmw of thc coatuig
prcprcg tape obtanuxl by thc above-mentioned mcllx&d of section 20&/ according to ml embod&ment other than in FIG.
pnirhlclng;I prcprcg tape. 16
'Ilie method of pmducing a prepreg according. to the l&I(i 19 is a detail cross-sect&onal view of the coating,
present invention or the prepreg production apparatus section 20c according to an enlbodiment other than in FICI.
according to the present mvention makes it possible to 16.
significantly suppress and prevent clogging with fuzz Fur- FICi. 20 is a detail cross-sect&onal view of the coatin
thcnnore, thc method cnablcs thc reinforcing fiber sheet to acct&on 30 according to an embod&ment other &iran of the
be run continuously al a h&gh speed, imd makes it possible prcscul invention.
to enhance the pmductiv&ty of the reinfnrcing fiber sheet Ill(i 21 is a schematic diagmm depictmg an exmnple of
pmvided w&th a matnx msin and obtain a prepreg impreg- lo an embodiment of a prepreg production pmcess using the
nated with the matnx resin uniiiirmly. first production method according to the present invention.
FICi Z2 is a schematic diagram of an example of another
i3RII:I'ES('RIPI'ION Ol'RAY&IN(iS prepreg production process using the second production
ll&C&1&oil &ICCO&dlllg 8& ll&C p&CCC&ll 11&vi:&&&loll.
FIG I is a schematic cross-sectional view depicting a FICi 23 is a schcnuit&c diagram of au cxmnple of another
metlnld of producin a prepreg in an embodiment of a first prepreg production pmcess usulg the second pmduction
production method accordin to the present invention. method according to the present invention
FIG. 2a &s a schenuit&c cross-sectional view dep&cting a FICi. 24 is a schematic diagram of an example of another
method of produc&ng a prcprcg ul an embodiment of a prepreg production process using the second production
second production method according to the present inven- so method according to the present invention.
lion FICi 25 &s a schematic diagram of m& cxamplc of another
l1C& 26 is an enlarged detail cross-sectional view of the prcprcg product&on process usulg thc second product&on
portions of the coatin section and the additional-impreg- method according to the present invention
nation device 19 &n FICi. 1. l&I(i 26 is a schematic diagmm depictmg an exmnple of
FIG. Zc &s a dcta&l cross-simtioilal v&ew of a method ls an embodiment of a prepreg production pmcess using the
according to an mnboduncnl other than in FIG. 2a. ul wluch first production method according to the present invention.
method a release sheet 3 &s used. FICi Z7 is a schematic diagram depict&ng an example of
FIG 3 is a schematic cross-sectional view depicting a an embodiment of a coalmg secuon used &n a tlurd produc-
nlethod of producing a prepreg in an embodiment of a third t&on method according to the present uivcnl&ou.
production method accordin to the present invention. so l&I(i 28 is a schematic diagram depicting an example of
FIG, 4 is an enlarged detail cross-sectional view: of the an embodiment of another coatulg section used in a third
coatulg section portion ui FICI. 1. pmduction inethod according to the present invention.
FIG. 5 is a bouom sale v&ew of ihe coaung sect&on ui FIG.
4. as 1 iewcd in the d&rect&on A ui FIG. 4. DETAILED DESCRIPTION OF EMBODIMENTS
l1Ci 6a is a cross-sectional view depicting the structure of s Oli 1'III& IN&gi&N'I'ION
the inside of the coating section in I&l(i 4. as viewed &n the
direction B in FICI. 4. Preferred embodiments of the present invention will be
FIG. 66 is a cross-sectional view depicting the sueam of described with reference to the dressings. In this regard. the
thc mau&x res&n 2 u& llm clmrsncc ap 26 in FIG. 6a. fi&liow &ng descnp non illustrates cmboihmcnts ol thc present
FIG. 7 is an cnlargcd dc&ail cross-sectional vice of the o invent&on, thc prcscnt un en&ion is not to bc construed lo be
coalulg sect&on &n FIG. 3. 1&m&ted to thc cmbodmients. and venous mod&iicauom cml
FIG 8 is a detail cross-sectional view of a reinforciag be made to the invention to the extent that they do not depart
fiber sheet la in contact with a bar 35 in the liquid pnol 22. from the object and effect of the present invention.
FIG, 9 is a detail cross-sectional view of a bar 35 &Outfine of Method of Producing Prepregw
according to another embodiment. &s The present invention discloses tliree novel methods of
FIG. 10 is a mcw dep&cting an insisllauon exiunple of a producing a prcprcg. These producuou methods arc thc same
width regulauon mcchniusm. iu that allowing a rc&nforcmg liber sheet to pass subsuuit&ally
FIG. 11 &s a detail cross-simtioilal v&cw explmmng thc vertically downward enough the ins&dc of a coating sect&on
structure of the inside of the coating section in Ill(i. 7, as stonng a matrix resin afiards a matrix resin-impregnated
vieived in the direction l3 in the I&igure. (a re&nfi&rcing fiber sheet in which the reinforcing tiber sheet is
FIG. 12 is a deta&l cross-sectional view explaining the provided with the matrix resin. In these production methods,
internal stnicture of the coatmg section 41 accordiiig to an the following three production methods are used to further
cmbodimcnt otlmr than u& FIG. 11. enhance thc degree of unprcgnauon of lhc resull&ng prcprcg.
FIG. 13 is a v&cw dcp&cung an example of a bar both ends F&rsl, a Iirsl production mclhod accord&ng lo lhe present
ol'wluch each lrsve a w&dlh regulation member. ss invent&onw&llbeoutlincd with ref& rcnccto FICI 1 Acoalulg
FIG 14 is a view depicting width regulation members device 100 includes conveyance rolls 13 and 14 as a
accordi&m to an embodiment other than in l&I(i 13 outsing mechanisnl for mnnin a reinforcing tiber sheet la
 US 1 1,491,685 B2

in ihe substan»ally vertically downward direction Z, and a aficr thc coatuig device 101, it is possible to provide a
coating section 2() as a coatuig mechanism that is disposed plums)ity of cree)i 11 for unwinding reinforcing fibers I, an
betiveen the conveyance rolls and stores a matrix resin 2. arrangement device 12 for obtainiim a reinforcing tiber sheet
Also before and after the coatuig device 10)). it is possible la in which the unwound reinforcing tibers I are arranged
to provide a plurality of creels 11 for umvinding reinforcing unidirectionaily (arranged in the depth direction of the page
fibers 1. an arrangement device 12 for obtaining, a reinforc- in FICi. 3). and a wind-up device 17 for a prepreg Ir. and in
ing liber sluxt 1ii in which thc unwound reinfiircing libera 1 addition, the coating dcvicc 100 is cquippcd with a supply
arc arranged unidircctionally jarrtm cd ui the depth direc- dcvicc for a matrix resin, ihough thc supply dcvicc is not
tion of the page in lii(i li, and a ivind-up device 17 for a shown in the drawing In addition. the coating device it)l
prepre )r, and in addition. the coating device 100 is in can be equipped ivith a release sheet supply device 18 fiir
equipped with a supply device for a matrix resin, though the supplying a release sheet 3. if necessary In I'l(i 3. the
supply device is not shown in the drawin . An additional- release sheet 3 is applied to only one face of the prepreg Ir,
impregnation device 19 is further included be»veen the but can also be applied to both faces.
coatuig section 20 and thc conveyance roll 14. In the Iirst &Reinforcing Fiber Sheets.
production method, thm is a no»contact hcatuig device. It is Herc, cxamplcs of the reuilbrcuig liber I include carbon
also possible to apply a release sheet 3 to a prepreg, \ r which fibers, glass fibers, metal fibers. ntetal oxide fiber.;, metal
has undergone the additional-mtpregttation process at the nitride fibers, organic fibers (aran»de hbers, polybenzoxa-
noncontact heating device In Iil(i. 1. the release sheet 3 is zole fibers, polyvinyl alcohol fibers, polyethylene fibers, and
applied to only one face of the prepreg Ir. but can also be the like). and the like. Bnd carbon hbers are preferably used,
applied to both faces. 2C from the viewpoint of the mecharucal pmperty and lightness
Next. a second producuou method will bc outlmcd with of FRP.
rel'crcncc to FIG. 2u A coating device 100 mcludes: con- Examples of thc rmnforcing liber shcct 1» used ui thc
veyance rolls 13 and 14 as a nuining inechanism form»ming present invention include a unidirectionally arranged UD
a reinforcin hber sheet lir in the substantially vertically base material and a reintiircing tiber fabric as a woven
/,
doivnward direction and a coating section 20 as a coating fabric.
mechanism that is disposed between the conveyance mila A unidirectionally arranged UD base material as the
and stores a matrix resin 2 Also before and ai'ter the coating reinforcing fiber sheet Ia refers to a plurality of reinforcing
dcvicc 100, it is possible to prov»le a pluraluv ol'creole 11 fibers arranged unulirccuonally ui a plane, and thc plurality
for unwuiduig reuilbrcuig libera 1. an arrangement device of reinforcing libera do not nixcssarily huvc to bc integrates).
12 for obtaining a reinfoming tiber sheet lsr in wluch the ic for example, by intertangfing. 'I'hat is, the reinforcing fiber
unwound reinforcing fibers I are arranged unidirectionally sheet is termed so fiir convenience to represent a state in
)arranged in the depth direction of the page in Iil(i. 2). and v hich the reinfiircing tiber: are arranged, because the pro-
a wind-up device 17 for a prepreg Ic. and in addition. the duction method according to the present invention makes it
coating device 100 is equipped with a supply device for a possible that a sheet-like object impregnated with a matrix
matrix resin, though thc supply device is not shown in the ii rcmn is obtained when thc object has been coated with thc
drawing. An additional-uuprcgnation device 19 is further ma)Ox rcsut. Here, the rmnforcing liber sheet is not fimitcx)
includix) bctwccu thc coating section 20 mid the conveyance to dllv OllC llavlllg d paltlCI11BI tlllCkllCSS Or Widtll. Slid tllC
roil 14 The matnx resin-intpregnated reinforcing tiber sheet tluckness and the width can suitably be selected in accor-
)22 can also be provided with the release sheet 3 v hen dance with the purpose or application In the case of carbon
introduced into the additional-impregnation device 19. In dc fiber. usualiy approximately ).000 to 1,000.000 single fibers
this case, it is possible to mclude a release sheet supply assembled in tape form are called a "tow*i and such tows can
dcvicc 18 that supplies a re)case shcct 3 to both faces of a bc arrangml to obtain a reinlbrcuig liber shcct, but tous may
mau ix resin-unpregnatcd rmnforcing liber sheet 1b oh isuied bc huninatcd ui thc tluckncss direction. In tlus regard. )hc
immcdidtcly under thc coating scc»on 20. 11tc matux rcsin- reinforcing liber sheet is easy to hmidlc and accordingly
impregttated reinforcing hber sheet Iir can also be intro- preferable when the aspect ratio defined using the width and
duced and provided with the release sheet 3 using a con- tluckness is )0 or more. In the present mvention, one
veyance roll 15 and a conveyance roll 16. FICi. Za shov s that tape-like "tovv*'s understood to be one form of the rein-
the release sheet 3 is bein applied to each of both faces of forcing fiber sheet.
thc matnx resin-nuprcgoatcd rcinforcuig liber sheet Ib, but In addition, thc mctlxid used to form a rcinl'orcuig liber
thc re)case sheet 3 may be applmd to one face. Furthermore, c shcct Ia may bc a known method and is not limited to any
it is also possible to include a release sheet hwitui device particular onc, and it is prefi:rablc from thc vicwpouits of
lga or heatutg the release sheet 3 Fi(i. I shows that the pmcess efficiency and arranuement uniformity to prelimi-
release sheet heating device I gir is heating both faces of the narily arrange single fibers to form a reinforcing fiber
release sheet 3, but the device may heat only one face. bundle, followed by huther armnging the reinforcin fiber
Furtheunore, FICi. 2a shov s that a heating device in non- s. bundle to fonu a reinforcing tiber sheet Ia. For example. in
coll(dc) w'lilt tile release slice) 3 is usixi Bs tlic Ichaisc slice) thc case ol carbon liber. a **tow" thur is u tape-like rcudorc-
hcatuig device 18a. but a contact type of hcatuig device may iug liber bundle is v,ound on a bobbin us above-mentioned,
bc used. and a reinforcing liber shoe( as a UD base matcual can bc
Next. a third production method will be outlined v ith obtained by arranging the tape-like reinforcing fiber bundle
reference to I'l(i 3 A coating device 101 includes: convey- ic v ithdrav n front the bobbin. In addition, it is preferable to
ance rolls 13 and 14 as a running mechanism for run»in a have an arrangement mechanism for orderly arranging rein-
reinforcing fiber sheet Ia in the substantially vertically forcing fiber bundles withdmswn from the bobbins fit onto
downward direction Z, and a coann ace)ion 40 as a coating the crccls so that there can be no undcsirablc ovcrlappuig nor
mcchmusm that is disposed between thc conveyance rolls 13 fit)ding ui the rcuifiircuig fiber bund)ca in thc reinforcuig
and 14 mid stores a matux rcsui 2. 11ic coating scxtion 40 si liber sheet and no split bctwcmi the reinforcing liber
includes. therein, a group of bars 35 (35a. 35h, and 35r') btuidles As a reinforcing tiber arm»tgement ntechanism. a
extendiim in the depth direction in the page Also before and knowli roller, a conib type of arran ament device, or the like
 US 11,491,6(15 B2
10
can bc used. In add&non. )aycnng a plurahly of prchmularily into the 1&qusl pool aller ii is smoothed. Thc smooilung
arranged reinforcing tiber sheets is useh&1 fmm the viev- treatment method is not limited to a part&euler one, and
point of decreasing splits between the reintilrcing fibers In exanlples thereof include a method in wh&ch physical pres-
this regard, ihe cree)a are preferably provided &vith a tension sure is applied using opposin rolls or the 1&ke and a method
control nlechanism operated when the reinforcing fibers are in which reinforcin fibers are moved using air flow. A
withdmwn. As a tens&on control mechanism. a known one method in which physical pressure is applied is easy and
cml be used, and cxamplcs thereof include a brakulg mccha- convcnicnt. less likely io disturb lhc arrangemcni ol ihe
msm. In addiuou. tens&on can also bc controlled, for reulforcing libera, imd accordulgly prefi:rablc. More spec&li-
example, by adjusting a yan& guide cally, calendering or the like can be used 'the met)iud in
A reinforcing hber fabric as a reinfilrcina tiber sheet &n the &o which air flov, is used not only is less likely to cause
present invention refers to a sheet formed from multiaxially abrasion but also has the effect of widening a reinforcing
or randomly arranged re&nforcing fibers. Specific examples fiber sheet. and accordingly. is preferable.
thereof include not only ~oven fabrics. knitted fabrics. and &W&dening of Reinforcing Fiber Sheet&
Ihe like bui also lwo-dimcnsionally and nuill&axially In lhc prcscni uwent&on. it is also prefi:rablc from thc
anangcd reinl'orcu&g fibers m&d rmldomly omentcd remfi&rc- v&cwpoult of enabling a ilun prcprcg to bc produced clfi-
ing hbers such as non-woven fabrics, mats, and paper In tlus c&ently that the reinforcina fiber sheet is intmduced into the
case, the reinforcing fiber can be formed into a sheet by liquid pool afier it is treated filr &videning of the fiber bundle
utilizing a method such as binder-providing. interlacing, 'I'he treatment method of ividening of the fiber bundle is not
welding. or fusing. Examples of woven fabrics that can be lim&ted to a particular one, and examples thereof include a
used include not only basic fabric structures such as plain lo method in which vibration is applied mechanically, a method
wcaies. tw&ll. satin, and non-comp labncs but also buis iu wluch the rc&nforcmg liber bundle w cxpandcx) usulg air
structures. Icno weavcs, mult&axmlly woven lbbncs, mulu- fiow, and ihc hke. Exmnplcs ol methods ul wluch vibrai&on
woven fabrics, and the like. In a woven fabric fornled by is applied mechanically include a nlethod m which a rein-
combinina a bias structure and a Hl) base material. not only forcing fiber sheet is bmughi in contact with vibratulg rolls,
the Ul) structure mh&bits the woven fabric fmm being as described. for exanlple, in .IP 2015-22799 A As to the
defomled by a tension &n a coating and impregnating pro- vibration direction, vibration is prefemlbly applied in the
cess, but also the bias structure also causes quasi-isotropy, Y-ax&s d&rection (horizontal direct&on) or the Z-axis direction
and thus. &s a prcfcrable I'orm. In add&tion, a mult&-woven (vertical direction), assiuning thai ilm runnulg d&rection of
fabric is advantageous u& that thc upper face imd/or lower thc reinforculg liber sheet &s the X-ax&s. Ii is also prcfi:rablc
face of the v oven fabric and the stn&cture and properties of lo to use a combination of the horizontally vibrating rolls and
the inside of the woven fabric can be designed separately A the vertically vibrating rolls In addit&on, providing a plu-
preferable knitted fabric is warp knitting taking into con- nllity of pmjections on the surface of the vibration roll
sideration the shape stab&lity in the coatin. Bnd impre noting makes it possibie to suppress abras&on of the reinforcin
process, and it is also possible to use braid which is circuLar fiber on the roll, and accordingly is preferable. As a method
knit&fig. li iu wluch air fiow &s used. Ii&r example, a method dcsclibcxI
lhc iluckness of thc re&nforc&ng liber fabric is not Inn&tcd iu SEN-I GAKKAISHI, iol. 64, P-262-267 (2008) can be
to any part&euler value prov&dcd thai ihe value &s wiilun a &.ISCiL
ran e enablin the effects of the present invention to be &Preheating of Reinforcing l&iber Sheet&
obtained. The thickness needs only to be determined taking In the present invention, introducing the reinforcmg fiber
into considerat&on the required FRP perfomlance and sta- So sheet into the liquid pool after heating the sheet suppresses
bility of the coat&ng process. The thickness is preferably I a decrease in the temperature of the matrix resin and
nuu or less, more prcfcrably 0.3 nun or less. &akulg ulto cnhanccs thc v&scosliv'nlfonuliv'f thc nu&tnx lcsul, Bnd
considcrat&on thc passab&1&ty t)nous& thc narrowed section. accordingly, &s prefcrablc. The reinforc&ng liber shcci is
A reinforcing liber fabnc su&table in accordance with thc prcfcrably heated up io or io ihe v&c&n&ty of ilm tcmperaturc
purpose is commercially available un the market or can be of the matrix resin, and examples of various heatulg means
pmduced. and examples thereof are listed as below-men- that can be used tilr this purpose include air heatmg. infrared
tioned. Examples of woven fabrics include: "TORAYCA Iy** heat&ng. far-infrared heating. laser heating, contact heating,
cloth CO(i142. C06347B, C05642, and the like. manufac- heat medium beati»g (steam). and the like. Among others. an
tured by Toray Industncs, Inc., and woven Iablics mami- iul'rarcd heat&ng dcvicc is easy and convcnmni and cml
faciurixl by Hcxccl Corporation, ulcludulg. *'HcxForcck" o d&rectly heat the rcullbrculg liber shcct, and accorihngly, can
Fabrics and '*Pnme Tcxa", such as 84. G0801, XAGP282P, ach&cvc cfiic&eni heating up io a des&red tcmperaturc even ai
43195 G093&J (i0803, 43364, XS(ip196P. S(ip203CS, a high nuuling speed, and is preferable.
X( 1400, 48200, 48287, and 46150: "Iajetex)t" liabrics, &Matrix Resin&
such as GB201. Ci0986, and Ci0926; hybrid Ibbrics of carbon A matrix resin used in the present invention can be used
fiber and glass fiber. such as (11088, Ci0874. (i0973, and Ss as a ream composition containing any of the below-men-
43743. Bramidc liber Ihbncs. such as 20796 mid 21263. and tioned vBllous rcshlw pBrtlcics, htuik:nels, Bnd f&uthcr ciul-
Quartz woi cn fabncs, such as 610 and 593. Exiunples of taiuulg any ol'various kinds of add&uv as. A prcprcg obis n&cxi
non w oi cn fabncs, mats, aud paper include "TORAYCA x" according io thc present invmltion &s &n a state in wluch a
mat i)030. l3050, IIY03, and the like, inanufactured by 'I'oray re&nfilrcing liber sheet is inlpregnated &vith a matrix resin,
industries, Inca "('ARI301 I(il f1:&I*''I'.0-030, Cl39-030, io and the reinforcing fiber sheet can be d&rectly laminated and
ZX-020. and the like, manufactured by Oribest Co., Ltd, molded as a sheet-like prepreg to afi'ord members composed
and the like. of FRP. The degree of impre~tion can be controlled in
&Smootlung ol'cu&lire&ng F&bcr Sheet& accordance with ihc dcs&gn ol'hc coat&ng sect&on and
hl ihc plcscnt ulvcnnon, ulcrcasul ihc siilfBcc snloolh- tluuugh an aikliiional-impregnai&on process carried oui al'ler
ness ol'he re&nforc&ng liber sheet can enhance the un&for- si coauug A matrix rcsul can suitably be sclcctcd in accor-
nlity of the coatmg amount in the coating section I'r tlus dance v ith the application. and a thernloplastic resin or
reason. the re&nfilrcing tiber sheet is preferably introduced thernlosetting resin is generally used 'I he matnx resin may
 US 11,491,6)15 B2
12
bc a moltml rcsul melted by heating or a matrix resul which group capable of reacting with an epoxy group Prcfcrably.
is a matrix resin at room temperature In addition, the matrix compounds having an anlino group, an acid anhydride
resin may be formed into a solution or varnish using a gmup, or an azido group are suitable Specifically, various
solvent. isomers of dicyandiamide and diaminodiphenyl sulfone are,
Examples of matnx resins that can be used include matrix and amino benzoic acid ester types are, suitable. Accordin
resins generally used for FRP. such as thermoplastic resins, to specific description. dicyandiamide pmvtdes excellent
thcnnosettulg resins, and photo-curable rcsuls. II'hese are storage stabihty of prcprcg. and accordingly, is used by
liquids at room temperature, they may be directly used. If prCfhrCIICC. Ill addi/loll, VallouS ISOIIICIS Of dlaltllllixllphCII)'I
they are solids or viscous liquids at room temperature, they sulfone atford cured objects having good heat resistance, and
nlay be heated to decrease the viscosity. Inay be melted to be in accordingly, are most suitable for the present invention As
used as a nlelt, or may be dissolved in a solvent to be used amino benzoic acid ester types, trimethyleneglycol di-p-
as a solution or varnish. aminobenzoate and neopentylglycol di-p-aminobenzoate are
Examples of thermoplastic resins that can be used include used by preference and imve lower heat resistance but have
polymers having, ut thc pnnctpal chmn, a bond selected cxccllcnt tensile strengih, compared with diaminodtphcnyl
from a carbon-carbon bond, an mntde bottd, ml inudc bond, Sldloile, dlld BCCOIdlllglV, dlt: OSI:0 St:Iccli VCI)'11 BCCordallCC
an ester bond. an ether bond, a carbonate bond. a urethane v ith the application Iqeedless to say. a curing catalyst can
bond, a urea bond, a thioether bond. a sulfone bond. an also be used, if necessary In addition. a hardener or a curing,
imidazole Ixmd. and a carbonyl bond Specific exanlples catalyst and a complexing agent capable of forming a
include polyacrylate, poiyoiefin, polyiunide (PA). Bramid, complex can be used together. from the viewpoint of
polyester, polycarbonate (PC), polyphenylenesulfide (PPS), 10 enhancing the pot life of a nlatrix resin
polybenzunidazolc (PBI), polyinudc (Pl), polyethcnmtde In thc present invention. a mixture of a Ihcrmoscttulg
(PE I), polysulfilne (PSU), polyethcrsul line (PES), remn and a thcrmoplasuc resin is also suitably used. A
polyetherketone (PI IK), polyetheretherketone (PE)I IK), nuxture of a thermosetting resin and a thermoplastic resin
polyetherketoneketone (Pl IKK). polyaryletherketone atfords hetter results tlmn a thermosetting resin used singly
(PAI:K). polyanlideimide (PAI), aod the like In fields 1'his is because a thenuosetting, resin and a thermoplastic
requiring heat resistance. such as aircraft applications. PPS, resin have antinomic characteristics: that is, a thermosetting
PES. PI„PEI. PSU„PEEK, PEKK, PAEK. and the like are resin is generally disadvantageouly bnttle but can be molded
suitable. On the other hand. in industnal mid automobile dt low prCSSolc'11 Bll duklCRIVC. Slid Coll/IBIII)', B thcrlno-
dpphcauons. PA, polycstcr, PPS. a polyolclin siwh as poly- plastic resin is generally advantageously tough but ddlicult
pmpylene (Pp), and the hke are suitable in order to increase lc to nlold at low pressure in an autoclave, and accordingly,
molding etficiency 'I'hese nlay be polymers„or oligonlers or using these in mixture can effect a balance between pmp-
monomers may be used. because of the low viscosity and erties and moldability. Such a mixture to be used preferably
low temperature coating. Needless to say. these may be contains more than 50 mass "4 thermosettin resin, from the
copolymerized depending on the purpose. or various kinds viewpoint of the mechanical property of FRP obtained by
ol'hem can be mixixl to be usixi as polymer blends/alloys. Ii Ctirlllg pic'pic'g.
Examples of thcrmoseuing resins ulclude epoxy resins, &Polymer Partmlc&
nuilCllllldc rCSIIIS, poly'ltllltIC rc'SIIIS. IL'Slits hiivlllg Bll IICCI)'- In thc present ulvcntion, use of a matnx resin containulg
lene ternlinal, resins having a vinyl terminal, resins having polymer particles is also prefemble because the use can
an allyl terminal. resins having a nadic acid terminal, and Clif;IIICC tile toligiltlCSS Bint i tap;ICI ICSistallCC Of ttlC oh tBIIICd
resins bavin a cyanate ester terminal. These can be used do CFRP. In this case. the glass transition temperature (Tg) or
genemlly in combination tt ith a hardener or a curing cata- melting temperature (Tm) of polymer particles which is 20"
lyst. In addition, these thcrmoseuulg resins can suitably bc C. or morc lugher tlmn thc temperature of a matnx resin
used in nnxturc. makes it caswr to retain thc lonn ol Ihc polymer particle in
As Ihcmlosetung resins suitable for lhe prcsenl invention, thc matnx resin, and accordulgly ts preferable. Thc Tg of
epoxy resins are suitably used in that epoxy resins have polymer particles can be measured under the folloiving,
excellent heat resistance. chemical resistance, and mechani- conditions using a tenlperature-modulated DSC As a tem-
cal property. In particular, amines, phenols, and epoxy resins perature-modulated DSC device, QI000 manufactured by
whose precursor is a compound having a carbon-carbon TA Instruments. Inc. is suitable, and this can be used on the
double bond are prefi:rablc. Spccilic examples mclude, but basis oi calibration camcd out using lugh-punty uldium
arc not lani/ed to epoxy resins whose prccursors are unines, O under a iutrogcn atmosphcrc. Thc mcasurcment conditions
such as venous isomers of tetraglycidyl dtanunodtphcnyl- can bc based on a tcmpcrdture ramp rate of 2'ymin., and
nlethane, triglycidyl-p-aminophenol, triglycidyl-m-anliml- the temperature-modulation condition can be based on a
phenol, and triglycidylaminocresok epoxy resins lvhose cycle of/IO seconds and an iunplitude of I" C The reversible
precursors are phenols. such as bisphenol A epoxy resins, components are separated from the total heat flow obtained
bisphenol F epoxy resins, bisphenol S epoxy resins. phenol 11 under these conditions. and the temperature at the midpoint
uovohic t:pox)''csllls, alai cxcsol novtilac cptixv lcsllls, of thc stcqt signal can bc rcgdrdcd as Tg.
epoxy resins whose prccursors arc compounds hat in a In addition. Tm cml be mcasurtxt usutg a conmlon DSC at
carbon-carbon double bond, such as alicyclm epoxy resins, a tcmpcrdture ramp rate of 10'./nun., mtd the tcmperaturc
and the like. I3romated epoxy resins resulting from bronlat- at the peak top of the peak-shaped sigttal corresponding to
ing these epoxy resins are also used. Iipoxy resins whose ic melting is regarded as Tnl
precursors are aromatic amtnes and v;lfich are typified by In addition. the polymer particles are prefembly insoluble
tetraglycidyl diaminodiphenylmethane are most suimble for in a matrix resin. and as such polymer particles, suitable
thc present invention because the epoxy rcsuw have ood ones dcscnbcd in, Ibr example. WO2009/142231 as a rel-
hciu rcslstdllcc alai good Bdllcslvcllcss to rclllfolclllg libel s. erencc can bc used. More spccilically, polyimtules and
lltcnnosctting rcsuts arc prcfcrably used in combulatton Si polyimidcs can bc pret'crably used, and polyiuntdes that
with hardeners ltor exanlple, for epoxy resing a hardener have excellent toughness and accordingly can significantly
cml be used if the hardener is a compound having an active enhance the impact resistance are nlost preferable. ixamples I
 US 11,491,685 B2
13 14
of polyamides that can bc suitably used uicludc polyinnidc in cases whcrc 0 rcinforcuig liber fabnc is used, il is only
12. polymnide I I. polyamide 6, polyarnide 6(i, polyannde necessary to replace the creel 11 in Irl(i. I with an unwinding,
6'12 copolymers, and a polyamide modified to have a senu device for a reinforcin fiber fabric and replace an arrange-
IPN (nlacromolecular interpenetrating network structure) ment device 12 in Iil(i I ivith nip rolls so that the fabric can
with an epoxy compound (semi IPN polyamide) described in be v ithdrawn. A prepreg 10 can be obtained by further
Example I of IP HOI-104624A. As to the shape of tlus allowln the matrix resin-impregnated reinforcing fiber
thcnnopldslic resin particle, thc pariiclc may bc a spherical shcct Ib lo pass through lhc additional-impregnation device
particle. a nonsphcricdl paruclc, or a porous particle, and the in thc lirsl and second production methods or by further
spherical shape is particularly preferable in the production allowmg the sheet to pass throuah the coating section in the
nlethod according to the present invention in order not to 10 tlurd pmduction method lite prepreg IC and the release
decrease the resin flow property in addition. the spherical sheet 3 may be simultaneously wound up using a wind-up
shape is a preferable aspect in that the spherical shape has no device 17. In particular. in cases where part or all of the
starting point for stress concentmtion and aflords hi h matrix resin 2 contained in the matrix resin-lmpre nated
impncl resistance. reinforcing liber sheet Ib is soll present on thc surface of thc
Examples ol'ommercially available polymnide particles matrix rcsrn-rmprcgnaled reuilbrcutg liber sheet Ib mid has
that can be used include SP-500, SP-I 0, 'I'R-], 'I'R-2. Y42P- high fluidity and adhesiveness ivhen the matnx resin 2
4g. 342P-g0 (which are all manufactured by 'loray Indus- reaches the conveyance roil 14. the release sheet 3 can
tries. Inc.). "Orgasollt" 1002D. 2(N)1HD, 200IIIXD, prevent the part of the nlatrix resin 2 on the surface of the
2002D, 3202D, 3501D. 3502D (which are ail manufactured matrix resin-impre~ted reinforcing fiber sheet I b from
by Arkema K.K.). "Grdamid:xr* TR90 (manufacnlred by so being transferred to the conveyance mll 14. Furthermore, the
Emser Wcrkc. Inc.), "TROGAMIDgr* CX7323, CX9701, melhod can prcvcnl adhesion between parts of Ihc matrix
CX9704 (manu l'ectured by Degussa AG), and thc like. These remn-impregnated reinforcing liber slicct Ib mid provides
polyamide particles may be used singly or in combination of easy handling in the post-process 1 he release sheet is not
nvo or more kinds thereof linuted to a particular one as lon as the release sheet
In addition, polymer particles are prefensbly retained in achieves the above-mentioned effect. and exaniples thereof
the interlayer resin layer of CFRP in order to impart hi h include not only a release paper sheet but also an organic
toughness to the interlayer resin layer. For this. the number polymer fiim v:hose surface is coated with a release agent,
average particle size of thc polymer parucles is prefhrably in ditd tlic like.
the range from 5 to 50 tun, morc preferably ui thc range from Next, w rth rcfhrencc lo FIGS 4 to 6, 0 stop ol'roviduig
7 to 40 pnl. still more preferably in the range from 10 to 30 so the reinforcing fiber sheet I a with the matrix msin 2 will be
um. laving a munber average particle size of 5 pm or ntore
I described in detail iri(i 4 is an enlarged detail cross-
makes it possible that the particles do not intnide into the sectional view of the coating section 20 in lil(ig I and 2a
reinforcing fiber bundle. but are retained in the interlayer The coating section 20 has ivall constituent members 21a
resin layer of the obtained fiber reiniiirced composite mate- and 216 that are opposed to each other with a iven gap D
rial. Havuig a number average parnclc size ol 50 pm or less ss in betw ceo, and betwemi lhc wall constituent mcmbcrs 21a
makes ii possible Ihal Ihc thickness ol Ihe malnx ream layer and 21b. 0 liquid pool 22 whose cross-sectional area
on lhc surface ol thc prcprcg is made suitable. and evmtlu- dimrcascs continuously in Ihc i crtically downward direction
ally that the fiber ntass content in the obtained ('is RP is made I (that is, in the ninnina direction of the reinforcing fiber
suitable sheet) and a slit-like namswed section 23 positioned beloiv
&kiscosity of Matrix Resin bein Applied& 40 the hquld pool 22 (on the discharge side of the reiniiircing
A matrix resin used in the present invention preferably has fiber sheet 1a) and having a cross-sectional area smaller than
dn optundl i iscosity sclccted from lhe vwwpoint ol'proccss- thc cmssscctional arcs ol'the top side of thc liquid pool 22
dbihly and stability Spcciiically. n is prcfhrablc liter thc (thc introductron side of lhc reinforcing liber sheet 1a) arc
itid iris i iviii boiiig dppliixl isa s 0 viscilsilv'ii lite i dirge froiti formixh In FIG. 4, Ihc rmnforcing liber shcct 10 is arranged
I to 60 Pa s because such a viscosity makes it possible that in the depth direction of the pane
drip of the liquid at the outlet of the rmrniwed section is In the coating section 20, the reinforcing fiber sheet la
suppressed and that the lugh-speed running properties and introduced into the liquid pool 22 nina in the vertically
stable runnmg properties of the reinforciltg fiber sheet are downvvard direction Z, and, at the same time. is accompa-
cnhanccd. As used herein, 0 viscosity rcfcrs lo onc mcasurcd nied by thc matnx rcsui 2 surrounding the reinforcing liber
al a slrain rate of 3.14 s al a malnx rema lcmpcralurc in the 0 shcct Durutg this, thc accompanying matnx resin 2 is
liquid pool. As a mcasurcmcnl device. a viscoclaslicily gradually comprcssci( and thc prcssure of thc matnx resin
nleasnrement device such as of a pamllel disc type or a 2 increases tov,ard the loiver portion of the liquid pool 22,
conical type can be used because the cmss-sectional area of the liquid pool 22
&Coating Step& decreases in the vertical doiinward direction Z (in the
A step in iihich a UD base material is used as a reinforc- s. running direction of the reinforcing fiber sheet 1a). When
ing liber shcct will bc dcscnbcd with refercncc to FIC. 1. thc prcssure in Ihc lower poruon of the liquid pool 22
Thc method ol'providing thc reinforcuig tiber sheet 1a with incrcascs. il is more difiicull for thc accompanyuig liquid
the matrix resin 2 in the coating device 100 is a method in flow to flow toward thc lower portion any I'urther, and thc
which a plurality of the reinforcing fibers I unwound front accmnpanying liquid floivs in the direction of the wall
the creels 11 are arranged unidirectionally (in the depth ro constituent members 2 I ri and 21b, and then inipeded by the
direction of the page) thmu h the arran emenr device 12 to v all constituent members 21a and 21b„resulting ln flowin
obtain the reinforcin fiber sheet Ia. and then. rhe reinforc- upward. As a result, a circular stream T is formed along the
iiig liber slicct Iii ls iillowcd 10 priss lhroiigli lite ciialiitg plane of the rcinforcmg liber sheet 1a and thc wall surfaces
sccnon 20 in thc substanually vertically dovutw ard direction of lhc wall constituent mmnbers 21ir and 21b ut thc liquid
Z to provide both faces of the rcuilhrcuig fiber sheet 10 with ss pool 22. Thus, even if thc shcct-like reinforcing liber Ia
the matrix resin 2 1 his makes it possible to obtain a matrix brings fuzz in the liquid pool 22. the fuzz moves along the
resin-inlpregnated reinforcing fiber sheet lb In this regard, circular stream 1; and cannot appmach the lower portion of
 US 11,491,685 B2
li 16
the liquid pool 22, w herc thc liquid prcssure is larger, or thc section as above-mentioned. In addiuon, thc cross-ace/tonal
narmived section 23. I'unher as below-inentioned, bubbles shape of the uppermost face of the narroived section 23 is
stick to the fuzz, and accordmgly. the fuzz moves upv ard preferably made to conforni to the cross-sectional shape of
along the circular stream 1, and passes near the liquid the lowermost face of the liquid pool 22, from the viewpoint
surface at the top of the liquid pool 22. This also makes it of the ninnin properties of the reinforcin tiber sheet Ia and
possible not only that the fiizz is prevented thorn clogging the flow control of the matrix resin 2„but. If necessary, the
thc lower poruou of thc liquid pool 22 and thc narrowed cross-sectional shupe ol Ihe uppcmto st fucc of Ihe narrow est
sccuon 23. but ulso Ilrat the retained fuzz is easily collcctcd section 23 may be made shghtly larger.
through the liquid surface at the top of the liquid pool 22. In this respect, the reintii reine fiber sheet I a in the coating
Iiurthermnre, when the reinforcing fiber sheet la is nui at a In section 20 in Fi(i 4 nuts in the completely vertically
high speed. the liquid pressure further increases, and accnrd- I
downward directinn (at 90 de rees to the horizontal face),
ingly, the fuzz elimination effect becomes higher. As n result, but, v ithout limitation to this, ntay run in the substantially
this makes it possible to pmvide the reinforcin fiber sheet vertically downward direction to the extent that the fizz
la with the ma(Ox resin 2 at a higher speed, and enlmnces collection eflhct and thc bubbles discharge eflhct can bc
productivity signiticanlly. I obtained, and that Ihc reinliircing tiber sheet la can run
In addition, the increased liquid pressure has the etfect of stably mid continuously
making it easier for the reinforcing, fiber sheet Ia tn be In addition, the total amount of the matrix resin 2 applied
impregttated with the niatnx resin 2. 'I'his is based on the to the reinforcing liber sheet tir can be contmlled in the gap
property (Darcy*s law) accordin to which the degree at D in the narroived section 23. For example, in cases where
which a porous object such as a reinforcing fiber bundle is io the total amount of the matrix resin 2 applied to the
impregnated with a ma lux res us is uicreascd by Ihc prcssure reutforcing liber sheet la is dcsircd Io be larger (thc areal
Ol tltC itiatrix rcslll. Titis call also CllllilllCC tltC llltplegllalioll weight is dcsircd to be larger), the w ul1 constituent mcmbcrs
etfect because running the reintiircing fiber sheet la at a 2 I a and 21b inay be disposed in such a manner that the gap
higher speed increases the liquid pressure further. In tlus D is wider.
regard, the matnx resin 2 is mipregnated tltrough gas-liquid lit(i 5 is a bottom side vieiv of the coating section 20, as
repLacement with bubbles remaining in the reinforcin fiber viewed in the direction A in FI(t. 4 In the coating section 20,
sheet Ia, and the bubbles are dischar ed from the gapa in the side wall members 24a and 24b are provided to prevent the
rcinlbrcuig fiber sheet la by thc hquid pressure and asccud- matrix rcsui 2 I'rom Icakuig by both ends of Ilm rcinforcuig
lllg Iolcc iit Illc OllCilu'I(lost ilirCCiioil (iii 111C vCltlcallv fiber sheet la in the nrrangemcnt direction, and the outlet 25
upward direction) of the fibers I Iere. the bubbles are dis- io of the narroived section 23 is formed in the space surrounded
charged without pushing away the in-corning matrix resui 2 by the v all constituent niembers 2 iii and 216 and the side
fiir impre nation, and accordingly, also has the etfect of nnt v all members 24a and 24b I Iere, the outlet 25 is slit-like,
inhibiting impregnation. In addition, part of the bubbles are and the cross-sectional aspect ratio (Y/D in FICi. 3) may be
discharged in the out-of-plane direction (in the nomtal set in accordance ivith the shape of the reinforcing fiber
dirccuon) from thc surface ol'hc remfiircing liber shee! la, is shcct lii wluch is dcsircd Io bc provided with thc matrix
and the bubbles are elunuiatcd rapidly by thc liquid prcssure remn 2
and ascmtding lorcc in Ilm vertically upward direction, and FICi 6a is a cross-scctioiml view depicting thc structure of
accordingly, are not retained in that lower portion nf the the inside of the coating section 20. as viewed in the
liquid pool 22 which affords a high impregnation efl'ect, direction l3 I Iere, to niake the view easier to see, the wall
ivhereby the effect of promotin the discharge of the bubbles su constituent member 21b is onutted. and in addition. the
efficiently is also achieved. These effects enable the rein- reinforcing hber sheet Ia is depicted as if the reinforcing
forcing liber shcct la to bc efiicicnily nuprcgnatcd with thc fibers I are arranged with a clearance bctw cen the libera, buk
matrix rcsut 2, and, as a result, make it possible Io obtaut a iu reality, it is prefcrablc Io arrange the reinforcutg libera I
lngh quality prepreg lb impregnated uniformly with thc wiIh no clearance bctw ccn Ihc libera. from Ilm viewpoint of
matrix resin 2. the grade of the sheet-like prepreg and the mechanical
I'urther. Ihe increased liquid pressure allows the reinfnrc- pmperty of FRV
in fiber sheet Ia to be automaticafly aligned with the center FICi. 6b depicts the stream of the matrix resin 2 in the
of the gap D. and the reinforcing fiber sheet Ia is not directly clearance gap 26. When the cleamsnce gap 26 is large, n
abraded agauist tlm wall surlhccs of Ihe liipiid pool 22 and circular stream R of thc matnx rcsut 2 ui thc cd c is
thc narrowed section 23, whcrcby thc etlbct of suppressing u gcneratcd in Ihc depicted dirixuon This cirmilar strcmn R in
thc generation of fuzz herc m also aclucvcd. This is because, the ixlgc becomes an outw ard flow (Ra) in thc lower portion
when miy external disturbance or the like causes the rein- of the liquid pool 22, and accordingly. results in tearing apart
forcing fiber sheet la to approach either side in the gap D, the reinforcing fiber sheet (causiim split of the sheet-like
the matrix resin 2 is pushed and compressed in the resulting fiber bundie) or expanding the distance between the rein-
narrower gap on the approached side. and accordingly. the s. forcing fibers, and because of this, there is a possibility that
liquid pressure further uicreases on the approached side, arrangement nonuiul'ormity is caused in Ihc rcinforcuig
pushuig Ihc reinforcing liber sheet la back to Ihc cmitcr of fibers in Ihc rcsultutg reinlhrcuig liber shcct prcprcg. On thc
the gap D. other hand, Ihc circular sucam R bccomcs au uiward flow
'lite narrowed section 23 is desigtted to have a sntaller (Rb) in the upper portion of the liquid pool 22, and accord-
cross-sectional area than the top side of the liquid pool 22. Io ingly, the reinfnrcing fiber sheet Iii is compressed in the
As understood from FICI. 4 and FIG. 6a, the smaller cross- v idth direction. resulting in edge folding of the reinforcin
sectional area is simply due to the fact that the len th in the fiber sheet in some cases. In a device„such as typified by
dirccuon perpendicular Io thc pseudo-plane of the remfiirc- Patent Literature 2 (JP3252275BZ), Ihr coauug both faces of
ing liber slmct is smaller. that is, thc ihstmicc between the an intcgmtcd sheet-lite base matenul (pnrticularly. a film)
wall constitumtt mcmbcrs is narrower. Tins is utIended Io ss with a matrix resin, such a circular stream as caused in Ihe
achieve the impregnation efFect and the automatic alignment edge in the clearance gap 26 afiects the quality insignifi-
effect thmugh increasing the liquid pressure in the narrnwed cantly, mid accnrdingly. has attracted no attention.
 US 11,491,6)15 B2
17 18
In I iew of this, w nlth regulation for makuig the clearance takes place, thc reuflhrcing liber sheet 1a is pressed a must
gap 26 smaller is cerned out in the present invention, the bar. the inside of the reinforcing fiber sheet Ia is
whereby the generation of the circular stream in the edge Ic impregnated with thc matnx resin 2 drawn uuo thc spht
preferably suppressed gpecifically, the width I, of the liquid betwecit the reinforcing fiber sheet I ii and the bar, and at the
pool 22, that is„ the distance L between the side plate same time. bubb)ca contautcx) in thc rcuilorcing liber shce1
members 24a and 24b is preihmbly adapted to satisfy the ia are discharged out through the opposite face of the
bciov'-nlcntioncd rcliinonshlp with ihc wnlfli W of thc reinforcing hber sheet Ia from the face in contact with the
reuiforcuig liber shcct measured muncdiately under the bar in such a inmuier that the bubbles are squeezed out by the
narroived section 23 bar. This makes it possible to impregnate the inside of the
I.as+i(l I
rcuiforcing liber sheet Ia with the matnx resin 2 unifiinnly.
In addition. the bubbles discharged out of the reinforcin
This suppresses the eneration of a circular stream in the
fiber shcct lii move upward by an ascmiduig lhrcc, and arc
edge and makes it possible to cuppress split and ed e folding
of thc reinforcing liber shcct 1a mid tu obtaui thc proprcg Ib further dicchar ed out of the liquid pool 22, and thus, there
in which the rein('orcuig libera I arc umformly arranged over is uo such tlung as accumulation of bubb)ca around thc
the full ividth (W) of the prepreg Ib and which is of high gmup of bars 35 liurthemiore. the reinforcing fiber sheet la
grade mid has high stabihty liurthermore, this tecluiology which has passed through the Lrzoup of bars 35 runs in the
applied to a prepreg can not only enhance the grade and vertically doivmvard direction /. and, at the came tiine, ic
quality of the prepre but also enhance the mechanical accompanied by the matrix resin 2 surrounding the reinforc-
property and quality of FRP obtained using the prepre The Io iug fiber sheet. During tins, ihe accompanying matrix resin
relanonship bctwccn L mid W is murc preli:rably L W+2 2 is gradually compressed. Snd the pressure of the matrix
(mm). and tluis, Ihc spit and edge fokluig of Ihc rcinforcuig rcmn 2 uicrcascs toward thc lower portion ol'the hqunl pool
fiber sheet can fiirther be suppressed 22, because the cross-sectional area of the hquid pool 22
In addition, it ic prefemble to make adjustments so that the decreases in the vertical downward direction / (in the
lower limit of I is equal to or greater than W — 5 (mm). front outsing direction of the reinliircing fiber sheet la') When
the viewpoint of enhancing the Iuiifounity of the dimension the pressure in the lower portion of the liquid pool 22
in the width direction of the prepreg lb increases. it is more diflicult for the accompanying liquid
In tins regard, this width regulation is prcfi:rably carried flow to flow toward thc lower portion any I'urthcr, and thc
out at least in thc lower portion of thc hquid pool 22 (Ihc G accompanyuig liqunl flows ui thc dirccuou ol'hc wall
position in isI(i. 6u). front the viewpoint of suppressing the io constituent members 2 I ii and 21b, and then Inipeded by the
generation of the circular stream R in the edge due to a high v all constituent menibers 2 in and 21b, resulting m floiving,
liquid pressure in the lower portion of the liquid pool 22. upward. Ac a result, a circular stream 1 ic formed along the
Furthemiore. this v idth re ulation is more preferably car- plane of the reinforcing fiber sheet Ia and the wall surfaces
ried out in the whole region of the liquid pool 22. whereby of the wall constituent menibers 21a and 21b in the liquid
thc gmicration of thc circular strciun R ui die edge can be ic pool 22 Thus, even if thc reinforciug liber shcct Iu brings
supprcsscd substantially completely, and, as a result, the )i izz In thc hquid pool 22 or ei cn il'hc contact bctw iwn thc
spht and cdgc lhlduig of thc reinforcing tiber sheet can be rcuiforcing liber shcct Iu and dic group ol'bars 35 gcncratcs
suppressed substantially completely fuzz, the fuzz moves alon the circular stream 'I: and cannot
In addition. the width regulation may be carried out only approach the lov,er portion of the liquid pool 22, where the
to the liquid pool 22 if it is carried out only from the co liquid pressure is larger. or the narrowed section 23. Further
viewpoint of suppressing the circular stream in the edge in as belov,-mentioned. bubbies stick to the fuzz. and accord-
Ihe clearance gap 26, but 11 is prcfi:rablc to carry out thc ingly, thc fuzz moves upward alon thc circular strciun T.
w idth regulation also to thc narrow cd section 23 ui Ihc s unc and passes near the liquid surface at Ihc top ol'Ihc hquid pool
wav, foui thc vn:cvpouu ol silpprcssulg excessive apphca- 22. Tlus also makes it possible not only that the fiizz is
tion of the matrix recm 2 to the sides of the prepreg lb prevented fmm clogging the lower portion of the liquid pool
In the third production method according to the present 22 and the narmived section 23, but also that the retained
invention„ the coating step Is bacically the same as in the first fuzz is easily collected tluough the liquid surface at the top
and second pmduction methods. but the third production of the liquid pool 22. Furthermore„when the reinforcin
method Is charactcnzed in that unprcgiiation is advanced by liber shcct 1a is run at a lugh spccd. thc liquid prcssure
one or more bars mounted in thc coanng scwtion. Tins will o liirthcr incrcascs, and accorduigly, thc fuzz elimination
be described in detail below. clfcct bccomcs lughcr. As a result, this makes 11 possible to
Referrin to I'I(i 3. a remfiircing fiber sheet I u is brought pmvide the reintiircina tiber sheet la with the niatrix resin
in contact with a gmup of bars 35 in the coating section 2(), 2 at a higher speed, and enhances productivity significantly
cvherein the bars extend in the depth direction in the page. In addition, the increased liquid pressure has the eflect of
Bubbles contained in the Inside of the reinforcin fiber sheet ss impregnatin the inside of the reinforcing fiber sheet 1u with
1a arc thus squeezes) out aud discharged. cnablmg thc Inside thc matnx resin 2. This is based on tlm property (Darcy's
of thc rmnforcing liber sheet Ia to bc impregiwtcd wuh a law ) according to which thc degree at wluch a porous obi act
mauix resin morc eflicicntly Il'accessary, a relcasc sheet 3 such as a rcinliircuig liber bundle w unprcguated with a
can further be apphed to the prepreg I c in the same manner matrix resin is increased by the pressure of the matrix resin
as in the first and second production metlxidc and then io I:ven if the reinforcing fiber sheet lii is insufficiently
wound up. impregnated cvith the matrix resin 2 at the mup f bare 35,
Next. the impregnation mechanism in the coating section the sheet is impregnated cvith the matrix resin 2 again in the
will be described with reli rcncc to FIG. '7. In Ihc coating lowci sccfion of thc fluid piiiii 22, thus ulakulg u possible
sccnon 4ffi thc rmnforcing liber shcct 1a uttroduccxl mto the to obtaui a prepreg Ib thc degree ol'mpregnation ol'luch
liquid pool 22 runs In thc vertically doccnward direction Z, sc is high. In addition, tins can also cnhancc the nuprcguation
and, at the same tinie, is brought in contact with the bars 35a, etfect because ninning the reinforcing fiber sheet la at a
356. and 35C in this order in the matrix resin 2 When tlus higher speed increases the liquid pressure further
 US 11,491,685 B2
19 20
Further. thc incrcascd hqual pressure allows fixe rcmfixrc- rcsux 2 drawn into lhc split between thc rcinforcuxg liber
ing hier sheet I xi to be automatically aligned with the center sheet lii and the bar 35, thus depleting the matnx resin, the
of the ap D. and the reinforcing fiber sheet la is not directly reinfixrcing fiber sheet I ix chafes directly against the bar 35,
abraded a auxst the wall surfaces of the liquid pool 22 and and thus causes the possibility of fuzz genemxtion to mxpidly
the narrowed section 23. v hereby the efl'ect of suppressing become higher. If fuzz is generated and deposited on the face
the generation of fuzz here is also achieved. This is because, at which the reinforcing fiber sheet Ia is in contact with the
when any extcmul ihsnirbrmcc or thc like causes Ihc reux- bar 35. the runnuxg of thc rmnforcing liber shcct Ia is
forcing liber shcct Ia lo approach euhcr side m fixe gap D, disturbed, making it unpossiblc to obtain a uniform prepreg
the matrix resin 2 is pushed and compressed in the resulting lb, and thus, the holding aimle ix formed between the
narroxver gap on the appnxached side, and accordingly. the Ia reinforcing fiber sheet I xi and the bar 35 is prefemxbly small
liquid pressure fiirther increases on the approached side, sufficiently not to deposit fiizz Specifically, the holding
pushing the reinforcin fiber sheet In back to the cenrer of
the gap D.
In addition, thc total amount of Ihe matnx resin 2 applied
lo thc reinforciug liber shimt Ia can be controlled ux Ihc dp
D in the narrowed section 23 lior example, in cases where
the total mnount of the matrix resin 2 applied to the
reinforcing, fiber sheet la is desired to be larger (the areal
weight is desired to be larger), the wali constituent members
21a and 218 may be disposed in such a mmmer rhat rhe gap zo
10'r
angle ix fomxed between the reinforcing hber sheet 1st and
the bar 35 is preferably

resin.
40'r less, more preferably 20" or
less On thc other hand. the holduxg angle o needs to be
iiiorc to acliicvc sufficiciil iiliprcgiirilioii willi llxc iiialixx

Ilere, lil(i 7 shows an example in which the cross-

sectional shape of the bar 35 in the coating section 40 is
circular. but without limitation to this, the cross-sectional
shape of the bar may be other than circular. For example, the
D is wider. slmpc may bc a rectimgle hai ing rounded comers as ux FIG.
In Ibis respect, Ihc rcuxlorcuxg liber sheet Ia in Ihe coal uxg 9(A), or an clhpse as in FI(i. 9(B). However, from Ihc
section 40 in lil(i. 7 nuts partially in the completely verti- viewpoint of inhibiting fuzz,. the face in contact with the
/
cally doxvmvard direction (at 90 degrees to the horizontal reinforcing fiber sheet lix preferably does not have any sharp
face), but, xvithout hmitation to this. may nui in the sub- corner and has a snxooth curve.
stantially vertically downward direction to the extent that the In addition, the inside of the bar 35 does not need to be
fuzz collection effect and the bubbles dischar e efi'ect can be dense. and the bar may be. for example. a pipe the inside of
obrduxcsJ, and liat the reinforcing liber shcel la can run which is voxl. In adihuon. the cross-section of thc bar is not
stably and continuously. In adihlion. fixe rcmfixrcing fiber linutcd lo any particular diamclcr (or charactenslic length).
sheet lix chaimes m the ruxxning direction xvhen brought in io 'I'he larger the diameter of the bar 35, the longer the length
contact v ith the group of bars 33. and this change in the along which the reinforcing fiber sheet I u is in contact ivith
direction needs only to be substantially vertically downward the bar 35 'lixe longer length increases the possibility of hivz
to the extent that the bubbles discharged out of the reinforc- generation. and thus. the diameter is preferably small suf-
in fiber sheet In are not accumulated around rhe roup of ficiently not to cause the bar 35 to be deformed by the
bars 35. xs tension of thc rmnforcing liber sheet la. In addition, from
Next. thc arrmxgmncnt aud shape of fixe bars will be the viewpoint of inlubiluxg Ihc dcformution of the bar 35, Ihc
descnbcd in detail. FI(i. 7 shows rm example ux whwh the material ol'he bar is prclbrably a metal havuxg high still-
mup of bars 35 in the coating section 40 i ~ composed of ness, such as stainless steel.
three bars, 35rx, 35b. and 35c. and the number of bars is not liurtherinore, the surface of the bar 35 preferably has a
limited to this but needs only to be one or more. In addition, do smooth finish. Tius is intended to make it more unlikely that
all the bars in the coating section 40 in Fi(i. 7 are arranged fuzz is generated when the reinforcing hber sheet ln is
so as lo sink inside thc matrix resin 2, and, w ilhoul linulalion brought in contact v,ilh the bar 35.
lo tins, il is only accessary Ihal al least one or morc bars arc Here, using, as thc bar 35. a roll rotatablc in the coatuxg
anuxxgcd so as to suik inside thc matrix rcsux 2. Howcvcr, a section 40 also makes il possible to obtaux thc matrix resin
lar er nmnber of bars in contact with the reinforcing tiber d inxpregnation etTect. but bringing the remfixrcing fiber sheet
sheet Irx in the matrix resin 2 cause the matrix resin la in contact with a roll rotatable in the coating section 40
impregnation effect to be hi her, and tluis, it is prefemble causes part of the reinforcing hber sheet Ia to be wound
that a plurality of bars are armsnged so as to sink inside the around the roil oxving to the viscosity of the matrix resin 2,
matrix resin 2. and in some cases, males il impossible for thc reinforcuxg
FIG. 8 is a detml cross-sectional view ol' reinforcing o liber slmel I xi lo run, mxd thus. the bar 35 is prcfcrably a fixcxJ
liber shccl ld in contact with a bar 35 in lhc malnx rcsux 2. member which dues not rotate.
'I'he reinforcing fiber sheet la and the bar 35 are in contact In addition, Fl(i 3 shows that a guide mll (conveyance
with each other at a holding angle o I!ere„ the Imlding angle roll) )3 is provided vertically above the coating section 40
(x refers to an an le made between an arc and the center and that the reinforcing fiber sheet Ia rumung horizontally
point Pc of the bar 35„wherein the arc is between the point s. is brought in contact with the guide mll 13 so as to change
Pl at whici thc reuxlhrcing liber shcs:I 1d is brought in its running direction lo the vertically downward dirccliun.
contact with thc bar 35 and thc pomt P2 al wluch thc and then, is guided mlo thc coaxing section 20. Such a case
rcinlbrcuxg liber shimt la comes ofi'rom lhc bar 35. Herc, iiitikcs il possible Io lower llic 3 cl1ical liciglil ol llic codliixg
the larger the holding angle om the longer the distance along device 100, and is preferable from the viewpoint of decreas-
which the reinfixrcing fiber sheet la is in contact with the bar (o ing the constmction cost of a building in xvhich the coating,
35. and the more easily the inside of the reinforciitg fiber device 100 is installed.
sheet 1 xi is impregnated with the matrix resin 2 drawn Into When this takes place. the bar 35C located at the hi hest
thc split bctw can lhc rcinforcuxg liber sheet la and the bar position in Ihc group ol'ars 35 is prcffirably brought in
35. but al tlu: same time, the lugher the possibilily tlml the contact with lhc opposite face of Ihc reinforcing liber shccl
reuxforcuxg liber shixl la chafcs against the bar 35 to ss Ia from Ihc face brought in contact with thc guide roil 13.
enerate fuzz. In particular, if the inside of the reinforcina This is because the perimeter diiTerence of the reinforcing
fiber sheet I xi is completely impregnated with the matrix fiber sheet la nuxning on the guide roll 13 causes a slight
 US 11,491,6)15 B2
21 22
spccd difli:rcnce in the thickness dirac iion, and if the bar 35rr Allcmatively, the width rcgulauon mcchaiusm can bc
is brought in contact with the same face of the reinforcing pmvided in the below-mentioned manner in the third pro-
liber shcct Ia as thc guide roil 13 is. thc sporal diflbrence is duction method I'ICi 11 is a detail cross-sectional view of
further accumulated, thus causing the reinforcing tiber sheet the coating section 40 in lr(Ci. 7. as viewed in the direction
1a to become slack in thc coating sivuon 40. LC For explanatory purposes. the wall constituent member

(Width i&egulation Mechanism& 21b is omitted. The ~cup of bars 35 in FICi. 11 are in the
In the description of the first production method and the for(it of a colo(nil hay(rig (I uiiiloml 1:ross-sect(oil. Who(i a
second pmduction method. the above-mentioned has reuiforcing fiber shee( 1a is brought in contact with the bars
described a case where the side wall members 24a and 24b 35 while running in the vertically downward direction in /
iri the coatmg section 40 in lr(Ci. 11. not only the inside of the
serve lhr the purpose ol'width regulauon, bulr as shown in
reinforcing fiber sheet rr is impregnated with a matrix resin
I
FIG. 10, it is also possible to provide width regulation
2 drawn into the split between the reinforcing liber sheet 1rr
mecharusms 27rr aud 27b bctwccn thc side wall members
and the bar 35. but also the matrix resin flows and bleeds
24a and 24b and to carry out width regulation using such from both ends of the reuilbrcuig liber shcct 1a ui thc
mcchmusms This is prefi:rablc because thc capabihty to direction E ui FIG. 11. In cases where a unidirectional
freely change the width regulated by the ividth regulation material (IJD base material) in which rein forcmg fibers I are
mechanisms makes it possible to use one coatin section to unidirectionally arranged is used as a reinforcing fiber sheet
pmduce diflerent matrix resin-impregnated reinfiirciag fiber I, the fibers in both ends of the reinforcing tiber sheet la are
sheets having various widths. Here. the relational»p between carried av:ay on the flow. and extend in the direction E in
the width (W) of the matnx resin-imprc ox(ted rcuiforcing FICi. 11. ivith the result that the ividth of the reinforcing fiber
fiber sheet inunediately under the narrowed section and the shcct Ia is changed or tluil the dmisity ol'hc libera in bolt
w iihh (L2) rcgulatcd by thc width regulauon mechanisms at ends of thc reinforcing liber sheet Ia w decrcascd, makuig
the bo(tom ends of the width regulation mechanisms is it impossible to obtain a prepreg lb liaving unifiirm quality
prefembly I 2aW+10 (mm), more preferably [,2 W+2 Alternatively. in cases where a remfiircing fiber fabric is
(mni) In addition, it is preferable to make adjustments so used as the reinforcing fiber sheet la, both ends of the
that the lower limit of LZ is equal to or Irreater than W-5 reinforcing tiber fabric is pulled by the flow of the matrix
(nun). more preferably equal to or greater than W (nun), resin 2. and the v,idth may undeslmbly be chan ed. In a
from the iiewpoinl of c((fencing thc unilbnmly of thc worst case, both cods ol'thc reinl'orcing liber slmr:I Ia come
iliilleilslon ln Ilia w I 0 lll ilii clio(1 ol lie illa Irlx resin i(lip( cg-
1 oif from thc group of bars 35. posing thc possibility thai thc
nated reintiircing hber sheet prepreg lb. 1'he shape and io sheet can nui no longer
material of the width regulation mechanism are each not lrl(i 12 is a detail cross-sectional view of the coating,
liniited to a particular one. and a plate-like bush type is easy section 41 according to an embodiment other than in I'l(i
and convenient. and accordingly, preferable. In addition, 11 The coatin section 41 in FICi 12 includes a group of
allowing the width regulation mechanism to have a width bars 36 having width regulation members at both ends
smaller Ihmi the disuincc between lhe wall coiwlilucul is thereof ins(cad ol'he group ol'ars 35 lrsving a unifirnn
mcmbcrs 21a and 21b in the upper ponion, that is, near the cross-ace(ion. In thc coanng section 41 ui FIG. 12. a
liquid surface (as seen in FIG. 10r thc wide refi:rs tu the reuiforcing liber shccl 1a is brought in contact with Ihe
vertical length of the width regulation mechanism in the gmup of bars 36 while naming in the vertically doivmvard
/
"Mieiv seen in the direction" ) is preferable because such a direction '/, and the reinfiirciim hier sheet Ia is mhibited
ividth makes it possible not to impede the horizon(al flow of so from extending in the direction E in FICi. 12. mal ing it
the matrix resin. On the other hand, the shape from the possible to maintain the density of the fibers of the rein-
middle portion to the lower portion of lhe wide regulation forcuig liber sheet 1a unifounly In addition, both ends of thc
mecharusm is prcli:rably in confornuty (o lhc mlcmal el(ape reinforcing liber sheet 1a will not come ofl''rom the group
of lhe coaluig sccuou bccausc such confonmly can make 11 of bars 36. Thc wiihh rcgulauon mcmbcr may be a disc-like
possible to suppress the retention of the matrix resin in the men(her having a large diameter and attached to each of both
liquid pool and suppress the degradation of the matrix resin. ends of each bar, as shoivn in I'l(i. 13, or niay be each of(wc
In this sense„ the v idth regulation mechanism is preferably parallel plates betv,een which a plurality of bars are sand-
inserted into the narrowed section 23. FICrb 10 slmv s an v iched, as shown in FIG. 14. Alternatively„as shown in FICi.
cxiunple of a plate-like bush 27 as thc width regulation 15, side plate members 24 ol'a hquid pool may bc in contact
mcchmusm, and shows mi example in wluch Ihc portion o with thc group ol'bars 36 so that lhc side plate mcmbcrs 24
from the middle poruon to thc lower poruon of lhc bush is can bc width regulation members. Iu cases whcrc the wide
in confiirmity to the tapered shape of the liquid pool 22 and regulation member shown in I'l(i 13 is used, the diameter
in which the portion is inserted into the narrov ed section 23. d2 of the disc-like niember at each of both ends of the bar
Fl(1 10 shows an example in which L2 is constant from the preferably satisfies the relationship, d2&dl+I (mm). This is
liquid surface to the outlet, but the width to be regulated may s. intended to prevent the reinforcing liber sheet Ia from
sary dcpmiding on the site lo Ihc cxlenl tlial Ihc purpose of coming olf from both cods of thc bar. Iu addition, thc
the width rcgulatiou mechiuusm is liillillcd. Thc width thickness W3 of the disc-1(1 e member needs only to bc lar c
rcgulauon nu:chan(am can bc lixed in Qtc coating section 20 sidlicicntly no( to dcl'oun thc disc-like member pushed by
by an arbitrary method, and fixing the mechanism of a the reinforcing fiber sheet rr. Bpecifically. W3 is preferably
I

plate-like bush 27 at a plurality of sites in the vertical ro I flu(1 oi'liore

direction can make it possible to suppress variation of the In the coating section 41 in FICi. 12. the spacing W2
re ulation iiidth due to the deformation of the plate-lil e v ithin the width regulation members of the gx&up of bars 36
bush 27 caused by a lugh hquul prcssure. For example, using is prcfcrably equal to or shorler than the width Wl of Ihe
a suiy for Ihc upper portion and inscrling lhc lower portion slit-like cutie(. This is because, if thc spacing W2 between
into Ihc coating sccuon makes it easy lo regulale Ihc widlh Ss the width regulation members of thc group of bars 36 is
by the width regulation mechanism, and accordingly, is wider than the width Wl of the sht-like outlet, the reinforc-
prefemble ing fiber sheet la having a width widened by the group of
 US 11,491,685 B2
23 24
biirs 36 pdsscs lhrorigli llic slit-like'ulh:I liaviiig B iiarrowcr thc taper, thc morc preferable, and specifically, the miglc is
width. and thus, both ends of the reinforcing, fiber sheet la preferably an acute angle (90'r less) 'this makes it
chafes against the slit-like outlet, posing a fear of fuzz possible that the effect of conipressing the matrix resin 2 in
generation Alternatively, if the spacing W2 between the the reginn ZZa (tapered portion) in which the cross-sectional
width regulation members of the group of bars 36 Is too area of the liquid pool 22 decreases continuouslv is
narrow with respect to the width Wl of the slit-like outlet, enhanced, and that a high liquid pressure is made easier to
thc narrow reinforcing fiber sheci 1a which has passed obtain.
tlirough the group of bars 36 is rapully widened at the FICi 17 is a delml cross-scxlional view of the coaluig
slit-like outlet, and thus, the arrangement of fibers at both section Zflr" cording to an embodiment other than in lil(i. 16
ends of the reinforcing fiber sheet la are disturbed in some In The coating section 21)c is rhe sante as the coating section
cases Specifically, if the difference between the spacing W2 20b in FI(i 16 except that wail constituent niembers 2 le and
between the ividth re ulation members of the group of bars Zif constitutin the liquid pool 22 fomi a two-tier taper. In
36 and the width Wl of the slit-like outlet is more than 10 this m mner. the region 22a in it hich the cmss-sectional area
nun, thc arrmigmncnt of libera at both amis of the rcuiforcing of the liquid pool 22 decrcascs continuously may be con-
liber sheet la are disturbed in some cases. In Ii hl oi'hcsc, stituted by a multi-tapered portion composed ol Iwo or morc
it is preferable that the spacing WZ between the width tiers In this respect, the opening angle 0 of the tapered
regulation niembers of the group of bars 36 and the width portion nearest the narrowed section 23 is prefembly an
VVI of the slit-like outlet satisfy the relationship, 0 Wl- acute angle, fmm the vieivpoint nf enhancing the above-
)V2&10 (mm). The relationship is more preferably 0 Wl- mentioned compression efl'ect. Also in this case. the height
)V2&6 (nun)„still more prefembly Wl-W2=0 (WI =WZ). Ic H of the region Z2a along ivhich the cross-sectional area of
&Shape of Liquid Pool& the liquid pool 22 dccrcascs continuously is prel'crably 10
As dcscnbcd above ui detail, it is unporlanl in lhe present nun or more. Thc vertical height H along which the cross-
invention that allowing the cross-sectional area to decrease sectional area decreases conrimiously is more preferably 50
conrimiously in the running direction of the reiniiircing fiber nun or more. I laving a multi-tier tapered portion as the
sheet in the liquid pool 22 increases the liquid pressure in the region 22a in which the cross-sectional area of the liquid
nuuiing direction of reinforcing fiber sheet, nnd here. the pool 22 decreases continuously, as in FICi. 17, makes it
slmpe of the cross-sectional area decreasing conrinuously in possible to maintain the volume of the matnx resin 2 that can
Ihe runiung dirccuon of llm rcuilorcuig liber slmel is nol bc stored rn Ihc liquid pool 22, and ut thc smnc lime, lo
linnled io a particular ouc as long as lhc slmpc allows thc drxrcasc the angle 0 oi'hc tapcrcd portion nearest thc
liquid pressure to increase continuously in the nrnning ic narrowed section 23 'I'his increases the liquid pressure
direction 'I'he shape may be a tapered (linear) one or shov caused in the lniver ponion of the liquid pool 22. and can
a curved form such as a trumpet shape in the cross-sectional further enhance the fu77, elimination effect and the impreg;
view of the liquid pool In addition, the cross-secrionnl area nation effect of the matrix resin 2.
decreasing portion may be continuous over the full length of FICi. 1S is a detail cross-sectional view of the coatin
thc liquid pool, or thc liquid pool mdy contmn a perl in ii section 20d according to mi embodiment other than ui FIG.
winch the cross-sectional area docs not dccrmisc or con- 16. Tlm coaluig section 20d is thc same as thc coaluig
tranly increases, lo the cxlcnt thar Ihc oblccl and eilec! Of the section 20b in FIG. 16 except that wall constituent mcmbcrs
present invention can be achieved. 'I'hese ivill be descnbed 21g mid 216 constituting rhe liquid pool 22 form a tier. In
in detail beloiv with reference to I'l(iS 16 to 19. tlus manner, allnwin the lowermost portion of the liquid
FIG, 16 is a detail cross-sectional view of rhe conring do pool Z2 to have the region 22a m v, hich the cross-sectional
section 20b according to an embodiment other rhnn in FICI. area decreases continuously makes it possible to obtain the
4. Thc coating sixliou 20b is Ihe same as lhe coaluig section clfi:ct of rncrcasing lhe liquid pressure, wherein thc cfl'Ect is
20 m FIG. 4 cxccpt that wail constituent members 21c and an object ol lhe prcscnl uivcnlion. and uccordingly, Ihc other
21J constituung the liquid pool 22 are difii:rent in shape As part ol tlic liquid pool 22 iiidv'iicluilc B ri gioii 22c iii % liicli
in the coating section 20b in I 'l(i 16, the liquid pool 22 may the cross-sectional area decreases intermittently Alloiving
be sectioned into the region 22a in ivhich the cross-sectional the liquid ponl 22 to have such a shape as in lil(i 21 makes
area decreases continuously in the vertically downward it possible that the shape of the re ion 22a in v.hich the
direction Z and the region 22b in which the cross-secriorml cross-sectional area decreases continuously is maintained,
arcs does not dccrwrsc. Iu tins respccb Ihe vertical height H and at the same nmc, that thc depth B of thc hquid pool 22
along whici the cross-sectional area decrcascs conlinuously o is ciilargcd lii iiicicdsc tlic vohiiiic ol llio iiirilrix lcsiri 2 llial
is prcfcrably 10 mm or morc. Thc vertical height H along can be stored. As a result, even ui cases whcrc thc matrix
which the crnss-sectional area decreases continuously is resin 2 cannot be supplied into the coating section 20d
niore prefembly 50 mm or more. 'I'his assuredly aflbrds a cmitinuously, the matrix resin 2 can continue to be provided
distance along v,hich the matrix resin 2 accompanying the to the reinfiircing fiber sheet Ia for a ion time, w hereby the
reinforcing fiber sheet la is compressed in the region 22a in Ss productivity of the reinforcing fiber sheet prepre 1b can be
wluch thc cross-sectional area ol'hc liquul pool 22 CillidiiCCd.
dixreases continuously. whereby Ihe liquid prcssure gcncr- FICi 19 is a detail cross-sixuonal vmw of thc coatuig
dtcd in thc lower portion ol'he liquid pool 22 can bc section 20e accorduig lo mi cmbodimcnt other than in FIG.
increased sutficiently I'his consequently makes it possible to 16 'lite cnating section Z(le is rhe sante as the coating section
obtain the etfect of allowing the liquid pressure to prevent ic 20b in lil(i. 16 except that wail constituent menibers 21i and
fuzz from clo ging the narrowed section 23 and the eflect of 211 constituting the liquid pool 22 form n tnimpet chape
allowing the liquid pressure to induce the impregnation of (curved shape). In the coatin section 20b In FICi. 16, the
thc reinforcing liber sheet Za with Ihe matnx resin 2. region 22a in wluch the cross-sectiorml arcs ol'he liquid
In cases where, as in thc coatuig section 20 in FIG. 4 and pool 22 decreases connnuously is tapcrcd (luicar), bul,
thc coatuig section 20b in FIG. 16. thc region 22a m wluch si without lrmilation to Ibis. may be, for cxrunple, in Irumpcl
the cmss-sectinnal area of the liquid pool 22 decreases shape (curved shape) as in lil(i 19. Ilowever, the lower
conrimiously is tapered, the smaller the opening angle 0 of portimi of the liquid pool 22 and the upper portion of the
 US 11,491,6))5 B2
2i 26
narrowed section 23 Brc prcfcrably coiuicctcd smoofidy. tion dcvicc 19 is included immcdiatcly under thc coatuig
'I'his is because any step at the boundary between the lower section. and carrying out the additional-impregnation pro-
portion of the liquid pool 22 and the upper portion of the cess makes it possible to obtain a prcprcg lc adlusted lo a
narmived sectinn 23 causes the reinforcing fiber sheet la to desired degree of impregnation 13ecause of this. the distance
be caught by the step, where fuzz will undesirably be N from thc ouficl ol thc coating sixuou to thc starling pouu
enerated. In cases where. in this manner, rhe region in of additional-impregnation is I m or less N is preferably 0 5
winch lhc cross-sectional arcs ol Ihe liquid pool 22 m or less.
dcxrcascs continuously is in trumpet shape, lhc opening In the first pmduction niethod, a noncontact heating,
angle 0 betiveen the virtual tangent lines of the lnwermost device Is disposed as an additional-impregnation device,
region 221i in which the cross-sectional area of the liquid lu enabluig thc additional-impregnatiou process to bc cerned
pool 22 decreases continuously is preferably an acute angle.
out by noncontact heating, as shown in FICi I In this case,
In this re ard„ the above description illustrates an example
thc lempcralurc of Ihe matrix resin contained ui Ihc matrix
in which the cross-sectional area decreases smoothly. bur the
cross-scciioiial area of thc liquid pool ui lhc present mven- resin-intpregnated reintiircinu fiber sheet lb can be
uon docs nol necessarily aced to decrcasc smoofidy, to thc increased to lov,er the viscosity of the resin so that impreg-
extent that the oblect of the present invention is nnt nation can be advanced tluough capdlarity phenomena. For
impaired this purpose, il is unporlmii that Fonuula I is salisliod
11Ci 20 is a detail cniss-sectional vieiv of the coating
assuming thai thesurlace iemperaturc of thc matrix rcsin-
section 30 according to an embodiment other than of the imprcgniucxl reinforcuig fiber sheet is P2 ('.) at thc iimc
present invention. Differently from an embodiment of the 20 of cnmpletinn nf the heating and that the temperature of the
matrix resin stored in the inside of the coating section is M
present invention, thc liquid pool 32 in FICE 20 does not
contain a region in which thc cross-sectional arcs decrcascs ('),
contimiously in the vertical doivnward directinn zk but the
li I 2
liquid pool 32 is conhgured such that the cross-sectional
area decreases discontinuously and suddenly at the boundary P2 (" (' is preferably M+30 (" C ) or more, in which case
33 with the narmwed section 23. This makes it more likely the impre nation is advanced more easdy„and this is pref-
that the reinforcing fiber sheet Ia causes clogging at the erable. In this case, the distance from the outlet of the
niirtots cil scclioil coating section to the aikliiional-impregnauon starting pouu
&Ruiuung Mecharusm& is lhc distance N2 from Ihc oufiet ol thc coaluig section lo
Known rollers or the like can suitably be used as a ninning 10 the heating starting point of the heating device of a tloncon-
mechanisni fnr conveymg a reinforcing fiber sheet and the tact type (see I'l(i 26)
prepreu according to the present inventinn In the present 1ixamples of nnncontact heatutg means that can be used
invention„ the reinforcing fiber sheet is conveyed vertically include infrared rays, far-infmsred rays. laser. heat media (for
downward. Bnd accordingly, the rollers are prefembly dis- example. steam and the like)„and the like. Infmsred msys are
posed aboic and below the coating sccuon, which is Is most convenient, imd thus. arc prefi:rablc. The hcaluig
belwcxn Ihc rollers. distance is not linuled to any particular value provided tlial
In addinon, 11 is pret):rablc ui Ihe prcscnt uivenlion dial the matrix resin-Imprc~rutcd rcinlbrcing liber slmct can be
the nuuting pathway of the reinforcing fiber sheet is as linear heated to a desired temperature. 1he heating distance is
as possible in order to suppress arnsngeinent disturbance and preferably I m or less in a sense that such a distance makes
fuzzing of the reinforcing fibers. Additionally. in a step of so it possible to simplify the device. The heatin distance is
conveyin a sheet-like integrated object that is a laminate of preferably 0.5 m or less.
a prcprcg and a release shccl, it is prclhrable Ihat lhc ruruung Iii Bdditioil, IISC Of II IIOIICOIIQICI hcallilg ilCVICC ICBQS 10
pathway of thc shcct-like integrated object is also as luicar Ciltryiiig Olil Iul picSSiilg Oii QIC IIIBlilx I'Csiil-lillplegiianx!
as possible, bixausc B bend, if any, ui thc conveymg step reinforcing liber sheet. and thus. causes, for example, thc
generates wrinkles due to a perimeter difference between the surface tension nf the matrix resin to disturb the reinforcing
inner layer and the outer layer in some cases. I'rom tlus fiber layer in some cases 13ecause of this, the additional-
viewpoint, nip rolls are more preferably used in the nuu»ng impregnation process is carried out by noncontact heating,
pathway of the sheet-like inte rated object. preferably folloived by pressing so that the shape of the
Which of S-shaped arrmigcd rolls and nip rolls should be prcprcg mid thc shape and arrangemcnt ol'he reinforcuig
used can suitably be dctcnnincd ui accordance with the 0 liber layer can bc nuidc suitable. Exiunples ol'rcssuig
produciion conditions and Ihe product characlensucs. means that can be used uiclude nip rolls, S-shaped arrangcxt
-Additional-lmpregnatiion& rolls, and the like
In the present im ention. impregnation progresses m the Next, in the second pmductinn method. an additional-
coating section, and after this, an additional-impregnarion impregnation device including a pressln means can be
process can be carried out to further advance impregtafion. 11 used, as shown in FICi. 25 and FICi 20. In the second
Iii QIC prCSOIII ltivCtilloil, piilliCUlallv Ill CBSOS Whole tllC production metlxid, Ihe dislmice N from Ihc outlet ol'hc
malrix resin 2 heated lo a lempcmuire lugher than room Coiiliilg SCClioil 10 thc slarliiig pi1iiit Of tile prcsslilg Ill QIC
tempera lure is applied to the reinforcm tiber sheet 10, thc additional-uuprcgnanon process is I m or less, and allowuig
tenipemture of the matrix resin-intpregnated reinforcing the surface temperature p (" (' of the ntatrix resm-impreg;
fiber sheet lh immediately under the coating sectinn 20 is io nated reinfnrcing fiber sheet before the additional-impreg;
hi her than room tempemsture, Becmise of this, the prepreg nation process to satisfy the retationslfip of Formula 2 with
which has gone out of the coating section and rhen unme- the temperature M(" (1) of the matrix resin stnred in the
dialely undcrgonc au additional-imprcgnalion process is nol coaling section males ii possible lo make Ihc device com-
cooled to room tempcraturc. and Quis, it is made possible to pacl or simplily Ihc hcaung device and, at Ihc Brune time, lo
omit or simplil'y a heating dcvicc, such as a hol plate, for ss obtain a dcsirid dcgrcc of unprcgnation.
reheating the ntatrix resin-impregnated reinforcing fiber
sheet lb. In the present mvention, an additiional-impregna- M-!0 P irouuula 21
 US 11,491,685 B2
27 28
lhc tcmpcraiurc M ('.) of thc matnx rcsui storcx) in thc additional-unprcgnanon process, making ii difiicult to con-
coating section 20 can be measured using a thennocouple. tinue the additional-impregnation process. I)ecause of this,
'I'he surface temperature P (" (' of the matrix resin- setting 'I'nd K in a range that satishes the below-mentioned
impregi&ared reinforcing fiber sheet before the additional- liorniula 3 inakes it possible to obtain a high degree of
impregnation process can be measured using a radiation impregnation and further to inhibit the matrix resin from
themtometer. In tins re ard. the emissivity varies depending protrudin . and thus, is preferable
on thc measunng oblcct, but an cnussivity of 095 Is
E lo rnx+ fl
— II'onnvio 'I)
uniformly used I'or mcasuremcni. The surface temperature P
(' ) of the matrix resin-impregnated reinforcing fiber sheet I'he heating device for heating the release sheet 3 is not
Ii& is measured at a measuruig position located at a distance in linuted to any particular device, and exaniples of various
of 10 cnt ivhich starts toward the coating section 20 front the heatin means that can be used include air heating, infrared
starting point of the pressing in the additional-impregnation heatin . far-infrared heating, laser heating. contact heatiitg,
process. In some of the cases where the distance N from the heat medium heatin (steam), and the like.
outlet ol thc coaung section to ihe starting point of thc In tlus regard, Ihc surlhcc temperature P ('.) of thc
prcssulg ul thc Bikhilonill-unptcguatiou ptoccss is less than I matrix rcsut-Impregnated reinlbrcu&g liber sheet 15 bcforc
10 mn, such a measurement is diflicult in terms of manipu- the additional-intpregnation process, the surface tempera-
lation. and a measuren&ent is made of the surface tempera- ture T (" C.) of the release sheet before being applied to the
ture P (''.) of the matrix resin-impregnated reinforcing matrix resin-intpregnated reinforcin fiber sheet. and the
fiber sheet 15 located as near the startin point of the surface temperature K (' 1) of the matrix resin-impregnated
pressing as possible In this re ard, the measuring point is Io reinforcing tiber sheet before having the release sheet
thc center ol'hc matrix resin-impregimicd rcuiforcuig liber apphcd thereto can bc measured using a radiauon thermom-
sheet 1b ui thc w nlth direction. Onc example ol'a fliermom- eter. Thc enussnity &aries depending on Ihc mcasunng
eter usable for measuren&ent is an infrared mdiation ther- object, but an emissivity of 0 95 is unifi&rn&ly used for
ntonteter AD-51& I I A (with the emissivity set to and tixed at measurement. In one example. a measurement can be made
0 95; mamifactured by A3'ID Company. I,imited) usiag an infrared radiation thermometer AD-51&I)A (&vith
In the first production method and the second pmduction the emissivity set to and fixed at 0 95: manufactured by
met)a&d. additionally impregnating the matrix resin-impre- AkD Company, Limited). The surface temperature P (" C.)
natcxl reinforcing liber sheet 1b inuncdiatcly under thc of the matrix resin-impregirdicd reuilbrcutg liber slum& 1b
coatuig section 20 Is referred to as an additional-impre Im- bcff&rc undergoing thc additional-impregnauon process and
tion process so to be distinguished fmin the impregnation &o after having the release sheet 3 applied thereto cannot be
pmcess in the coating sectiim, and a sheet obtained by the directly measured. and tlnis. the surface teniperature of the
additional-impregnation process is referred to as a prepreg applied release sheet is measured as P (" C ) In carrying out
1c. the measurement. the measurin position of P is located at
In addition„as shown in FICi. 2c. applying the release a distance of 10 cm winch starts to&sard the coating section
sheet 3 makes ii possible to prevent thc matrix resui from &I 20 from the startuig pouu of the pressutg in the additional-
contamurdting tlm rolls and ihc device which are brou ht In impregnation process. In some ol'he cases where ihe
contaci with Ihc matnx rcsui-Imprcgirdtcxl rcudorcm liber distance N Irom ihe outlci of Ihc coaung section io ihe
sheet I and the prepreg I c in the pmductimi pmcess in the
I& starting point of the pressing in the additional-unpregnation
present invention and to enhance the running properties of pmcess is less than 10 cln or ilt some of the cases where the
the matrix resin-impregnated reinforcing fiber sheet lb and do distance from the starting point of the pressin in the
the prepreg 1c. and thus, the release sheet 3 can be applied additional-impregnation process to the position at which the
io thc matnx resin-unprcgnated rcuilhrcmg fiber sheet 15 matrix resin-impregnated reinforcing liber sheet Is brought
bcforc the sheet undcrgocs thc additioiml-unprcgnation pro- in contact with Ihc release sheet Is less flrdn 10 cm, thc
cess. In cases w herc thc matrix rema 2 hmited io a icmpcra- mcasurmncnt is ddliculi m terms ol'anipulation, but thc
ture higher tlmn roon& ten&perature is applied to the rein- measurement should be made at a position as near the
forcing fiber sheet I a. the release sheet 3 to be applied in the starting point of the pressing as possible Regarding the
present invention may be heated before the release sheet 3 measurement position of the surface temperature T ('.) of
is applied to the matnx resin-impregnated reinforcing fiber the release sheet 3, the measurentent is made at a distance of
sheet lb. Heating thc relcasc shcci 3 bali&re applyuig the 10 mn which starts tow ard ihe rclcasc ah&xi supply device 18
sheet can prcvcnt thc surface temperature of tlm mainx o from a position ai winch ihc release shcci 3 w brought in
resui-Imprcgnatcd reinforcutg tiber sheet 15 brou ht In contact with the matrix resin-imprc Bated reinforcing liber
contact ivith the release sheet from significantly decreasing, sheet I I&. In this regard. the measuring point is the center of
enables the de ree of Inipregnation to be inhibited front the release sheet 3 in the ividth direction flhe surface
decreasing. and thus. is preferable. Heating this release sheet temperature K ('.) of the matnx resin-impregnated rein-
3 thus befi&re applying the sheet makes it possible to omit or» forcing fiber sheet 1 b be fore having the release sheet applied
simplify ihc hcaung devwc ut thc additioi&nl-unprcgnaiion thcrcto is uicilsutcd ai a nlcdsurlug position locatixl Bi
dcvicc. In cases where thc surface temperature T ('.) Of thc illsidncc ol 10 cnl which siBI'ls tow iird flu: coBtlug section 20
rcleasc shcct bcforc being apphcx) io thc matrix rcsin- from a position ai v,luch the shcci lb Is brought in coniact
impregi&ared reinforcing hber sheet is too lmver than the v ith the release sheet 3 In cases ivhere the distance from the
surface temperature K (" C ) of the nmtrix resin-impregnated io outlet of the coating section to the position at w:hich the
reinforcing hber sheet 1b before having the release sheet matrix resin-impregnated reinforcing fiber sheet 11& is
applied thereto, the effect of omitting or simplifying the brought in contact &I ith the release sheet 3 is less than 10 cm,
device Is low. Convcrscly. ui cases whcrc ihe surlacc tem- thc nlcasolcnlcnt shoukl bc u&Jill: Bi a position ds near tis
perature T ('.) of thc relcasc sheet before bcuig brought In possible io the position ai wluch the matnx resin-impreg-
contaci with Ihc matnx rcsui-Imprcgirdtcxl rcudorcm liber Si nated rcuiforcing fiber shcci Is brought In contiwi with ihe
sheet is too high, the niatrix resin protrudes from the matrix release sheet In this regard. the nteasuring point is the center
resin-intpregnated reinfbrcuig fiber sheet Il& during the of the matrix resin-intpregnated reinforcing fiber sheet I 5 in
 US 11,491,6115 B2
29 30
lhe wnllh direction In this regard, lhe surlacc lcmpcralurc achieve a dcsircd degree of unprcgnution. Allcmatively. il is
P2 (" (hl of the nlatrix resin-impregnated reinforcing fiber also possible to use such "S-wrap rolls" as described in
sheet at the conlpletion point of heating in the first produc- WO2010/150022, v,hcrcin a prcprcg shcct mus in S-shape
tion methnd can also be measured using a mdiation ther- through the S-v, rap mlls In the present im ention. ")-wrap
mometer in the same manner. The surface temperature of the rolls*'rc simply reli:trcxl to as '*S-shaped arranged rolls".
prepreg is measured at a measuring position 10 cm down- Iii(i I m WO2010i150022 describes an exanlple in which a
stream from a nonconuicl heating device. prepreg sheet runs in S-shape. but the contact length
In lhc second production melhod, lhe pressing method in between the sheet and the roil may be adjusted in U-shape,
the additional-impregnation device 19 is not limited to any V-shape. or A-shape as long as impregnation can be carried
particular method Preferable exmnples thereof include a la
out. In addition. opposing contact rolls can be added in cases
nip mll niethod which makes it possible to decrease the roll v here the impregnation pressure is increased to enhance the
diameter. set pressure. and contact leilgth along wl»ch the
dcgrcc of impregnauon. Furthermore, as dcscnbcd in FIG. 4
prepreg is in contact with the roil and makes it possible to
male the device smaller, and an S-shaped arrmigcd roll in WO2015/076981. it is also possible to attempt to increase
method which cuubles a wide pressm arcs to bc securid, the production speed of prepreg by arrmiguig a conveyor
thus makin it possible to obtain a take-up capability as well belt opposite to "S-wrap mila" and thereby enlmncing,
as achieve impregnation. In cases where the pressing impregnation efiiciency. Alternatively, ns described in
method is a nip mll niethod. an impregnatimi load obtained WO2017/068159, .IP2016-203397A. and the like, it is also
by dividing a force applied to a nip roll by a prepreg width possible to enhance impregnation efficiency by subjectin
is preferably 0.1 N/nun to 40 N/mm or less. In cases where io prcprcg to ultrasomcation to heat the prcprcg rapidly bcforc
tlic lurid is loo low, thc dcgrcc of unpregiiation is low In impregnation. Alternatively. as described in JP2017-
some of thc cases where thc load is too high, thc matux resin 164330 h, it is also possible to use an unpregnation device
pmtrudes in the width direction, or the width of the prepreg in which a plurality of "squeeze blades" are vibrated by an
is excessively widened, making it impossible to obtain a ultrasonic generator Alternatively, as descnbed in .IP2013-
prepre bavin a target areal weight 22868A, it is also possible to fold a prepreg up and carry out
In addition. in cases where the matrix resin 2 heated to a impregnation.
temperature higher than room temperature is applied to the &Degree of impregnation&
rcinlbrcuig liber slmct Io tmd, at thc smne lime. where a roll Thc slate of unprcgna non w ilh a main x resin ui a prcprcg
is uscxI Ibr pressuig in the additional-miprcgnalion process, obtained by a producuon method according to thc prcscnt
the mll preferably has a heatmg mechanism 'I'his makes it io invention can be checked by cleaving a sampled prepreg and
possible to inlubit the surface temperature of a matrix visually observing whether the inside of the prepreg is
resin-impregnated reinfiircuig fiber sheet Ib from decreas- itnpregnated. More quantitatively, the impregnation can be
in and to obtain a hi Jt impregnatin property. In addition, evaluated. for example. by n peeling method. Measuring the
the additional-unpre nation device may have a heating impregnation ratio of the matrix resin by a pacing method
device to bc used before prcssuig. Heatuig die ma/Ox ii can bc camid oul in lhc lollowiug manner. Tlial is. a
resui-imprcgnatcd rmnforcing liber shccl Ib belbrc prcssutg sampled prcprcg is sandwiched bctwccn adhcsivc tapes,
il uicrcascs thc tcmperaturc of lhe malrix rcsui, and these arc pimled ofi; and the reinforcuig liber lo which lhe
decreases the viscosity of the matrix resin in the matrix matrix resin has stuck and the reinforcing tiber to which the
resin-inipregnated remfiircuig fiber sheet I/z, tints achieving matrix resin has not stuck are sepamted I'hen, the ratio of
a high impregnating property. but it is necessary to pny So the muss of the reinforcing fiber to which the matrix resin
attention to the possibility that the device will be a large hns adhered with respect to the mass of the whole reinforc-
scale onc. To enhance lhc imprcgnaling properly, lhc vis- iug liber shccl that has bimn used can bc regarded as an
ciÃilv of llic iiialrix i'csiii iii llic itianlx resist-iitiprcgiian:il impregnation ratio of lhc matrix resin based on a peeluig
rcinlbrcuig liber shccl Ib needs only lo bc low belbrc thc method. From the viewpoint of hmulhng a prcprcg, it is
pressing in the additional-mtpregttation pmcess I'or tlus preferable that the degree of inipregnation is 80% or more
purpose. the viscosity of the matrix resin in the matrix based on a peeling method
resin-Impregtated reinforcing fiber sheet 1/z before the &High Tension Take-Up Device&

rulc of 3.14 s 'n

pressing is preferably 80 Pa s or less, as measured at a strain
tlus regard, il is difiicuh lo directly
mcasurc the vmcosily of Ihc malnx reaui ui the malnx O
In the present invention, it is preferable that a high tension
take-up dcvicc lbr withdrawuig lhc prcprcg from Ihc coaluig
section is disposed dow nstrc;mi ol'hc coating simlion ui lhe

14't
resui-imprcgnalcd reuifiircuig liber sheel 16 belore the
pressing. and tints, the viscosity of the matrix resin is
prefembly 80 Pa s or less as measured at a strain mate of 3
the above-mentioned surface temperature P (" O.j of the
matrix resin-impregnated reinforciilg fiber sheet before
miiering into lhc addiuonal-unpregnauon process.
Any onc of thc below-mentioned devices can bc suitably
sclcctcd as auotlmr additional-impregnation device. For
example. as described in .IP2011-132389A and WO2015/
ss
process. Tliis Is bcciiiisc liigli filctioii force arid sliialliig
stress are generated betiveen the reinforcing fiber sheet and
the matrix resin in the coating section, and accordingly, it is
preferable that high take-up tension is generated down-
stream in the proces~, in order to overcome the high friction
force and lhc shcanng stress and withdraw Ihc prcprcg. As
a lugh tension lake-up device. Oip rolls. S-shaped arranged
rolls, mid thc like can be used, and in miy case lhereol.
einhancing friction force between the mila and the prepreg,
060299, impregttation can be promoted by preheating a io can prevent slip mid achieve stable nuuting 1O achieve this,
laminate of a sheet-like carbon fiber bundle and a resin on it is preferable to arrange a high friction coefiicient material
a hot plate and sufficiently sofiening the resin on the on the surface of the roll. increase the rup pressure. or
sheet-like carbon liber bundle, followed by usm a device iucrcasc lhc pressing prcssure of the prepreg agmnst lhe
for pressing with iup rolls wluch are also healed. Thc hot S-shaped arranged rolls. The S-sliapcd arranged rolls make
plate icmpcralure and nip roll surface lempcralure lor prc- Si il possible to morc easily control fnction lorce ou lhc basis
heating. the linear pressure of the nip rolls, and the diameter of the mll diameter and the contact length, and accordingly,
and number of the nip mila can suitably be selected so as to are more preferable. from the viewpoint of preventing slip
 US 11,491,6)15 B2
31 32
&Rclcase Sheet Supply Device and Wmdcr& or once cut and split uilo approxunatcly 30 cm narrow
A release sheet supply device and a winder can suimbly be prepregs and then slit again into prepregs having a desired
used in producing prcprcg or FRP using Ihe present mvnt- v idth.
tion As such a device, any known one can be used, and in Ilere, in cases where the above-mentioned plurality of
dny case, it is prcli:rable from thc viewpomt of ruiuung thc coating sections for narrow prepregs or prepreg tapes are
sheet stably that such a device includes a mechanism fi&r juxtaposed, the respective independent release sheets may
making it possible to feed an unwinding or wind-up tension bc supplied. or a plurality of prcprcg shccls may bc lami-
back to the unwinding or wind-up speed nated on one broad relcdsc sheet that has bimu supphcd. The
width direction edges of the prepreg thus obtained can be cut
Prepreg Width&
ott'and supplied into an A'I'l. or Al'P device In this case the
A prcprcg that is a kind ol'recursor ol'RP is one fi&mt
I I I

major part of the edges to be cut off is fmm the release sheet,
of the reinforcing fiber sheet obtained in the present inven-
and accordingly. the antount of the matrix resin component
uon,;md accordingly, a case whcrc Ihe present invntlion is
(the resin component in the case of CFRP) sticking to the slit
applied to 11ZP applications will be described below, cutter blade can bc decrcascd. resulting in bcutg also advan-
w hcrcui the reinforcutg liber sheet is rcfbircd Io Bs pit pt
I
tagix&us in that the cleaning cycle for Ihc slit cuucr blaihc can
'lhe width of a prepreg is not limited to a particular one, be extended
and the ividth may be broad, tens of centimeters to approxi- &Matrix 13esin Supply Mechanism&
ntately two meters, or may be tape-like, several millimeters In the present invnition. the matnx resin is stored in the
to tens of ntiliimeters The width can be selected in accor- coating section. but it is prefemsble to replenish the matrix
d;mce with thc application. In recent yntrs, a device called resin suitably because the coatmg progresses The mecha-
ATL (Automated Tape Laying) or AFP (Automated Fiber tttsnl for supplvttlg thc ct&alitlg si:cion w lib d niatrix Iesttl is
Placement) ui which narrow prcprc s or prepreg tapes are not limitnl to a particular onc. and a known device can be
automatically laminated has widely been used to make a used. Supplying the coating section with a niatnx resin
prcprcg huninauug step more cfiicienl, and Ihc width is also cmttinuously makes it possible not to disturb the liquid
prefembly adapted to such a device A11, often involves use surface at the top of the coating section and to stabilize the
ol'narrow prcprcgs havutg a width of approximately 7.5 cm, running of the reinforcing tiber sheet, and accordingly. is
approximately 15 cn&. and appn&xiinately 30 cm, and Alip preferable. For example, the matrix resin can be supplied by
ofien involves use of prepre tapes having a width of tls OWII w Ctghl BS II ilrt& trig forCI: Ifotlt B VCSSCI Sloritlg lhi:
approxinmtely 3 mm to approximately 25 nliu. tnillriX rCS111, Of SuppliCII COI11111UOUSI&'Sltlg II plttnp Or lhC
A method of obtainin a prepreg having a desired width
iu like As a pump. a gear-pump. nibe pump, pressure pump,
and the like can suitably be used in accordance with the
IS IX&t lhlttliXI to a patllcUIBI OIIC. Btlil B IUCIhoil 111 WRICh II
pmperties of the matrix resin. In addition, in cases where the
broad prepreg having a width of approximarely I m to
matrix resin is solid at room temperature, a melter is
approxunalcly 2 m is slit uito narrow prcprcgs can bc us&xi.
preferably provided at the upper portion of the stomsge
Alternatively, in order to simplify or omit the slitting step, vcsscl. In iuldition, a continuous cxtrudcr and Ihc bkc can be
Ihe w id lb of Ihc coauug section used in Ihe prescnl invnt! ion IISCIL AS It& lhC SUpply'tlti&Util Ol lhc IIXIIIIX rCS111. a
cmi be adjusted so as to be a desired width front the mechaiusm Ihr ertablmg lhc matnx resin to bc suppltcxt
beginning. For example. in cases where a narrow prepreg cmttinuously in accordance v ith the coating mnount is
having a v idth of 30 cn& is produced ti&r A'll, the width of preferably provided so that the liquid level of the matrix
the outlet of the coatin section can be adjusted in accor- do resin in the upper portion in the coating section can be as
dance with tlu: Ihnuer width Further ui order Io produce tlus constant as possible. For this. for example„a mechanism in
prepreg etficientty, it is preferable to produce a product which Ihc liquid lcvcl dnd thc coating sixuou weight arc
haVitlg d w tilth Of 30 Crit, drill IUXlapoSttlg a plUIIllttV of SIICh motulorcd and fi:d back Io d supply device is conceivable.
production apparatuses enables prep&re s to bc produced iu a &On-Linc lVIunitonng&
plurality of lines usmg the same nuiniog devices. convey- In addition, a mechmiism for allowing the coating amount
ance devices. various rolls. and winders to be monitored on-line is preferably pmvided in order to
In addition, prepreg tapes can be obtained by forming a monitor the coating anu&unt. The on-line monitorin method
reinforcing fiber sheet from approximately one yam to tltree is not limited to a particular one. Bnd a knov n one can be
yarns ol'ape-like reutlhrcutg tiber bundles and allowing the used. For example, as a dcvicc Ihr tluckncss mcasuremcnl,
Icsulnttg rcitilorctttg liber sltccl Io pass thloilgh lhi: coBlittg fi&r example. a 1&-ray gauge cmt be used. Iu Ilus case. Ihe
sccuon the width of wluch is adjusted to afi'ord a desired tape coaling amount can be cslimalcd by measunug thc thickness
width I or prepreg tapes, particularly the accuracy of the of a reinfi&rcing tiber sheet and the thickness of a prepreg and
tape Ividth is often required, from the viewpoint of control- analyzing the ditference betv een the thicknesses 'I'he coat-
ling cross-ihrectional overlappin between the tapes. ing amount monitored on-line can inunediately be fed back
Because of this. It is preferable to control the coarin secrion» to the coating section. and utilized to adjust the temperature
outlet width more stnctly, and in Ibis case, it is prcibrablc of thc coating sccuon and the gap D in thc narrowed section
that lhc aboi c-mcntioncd L, L2, mid W satisfy tlm relation- 23 (sec FIIL 2). Ncnlless lo suy, tlm coating Imiount
ship(s) ol L W+I mm and/or L2 W+I mm. motuloring can be used as defect monitonug As to thc
&Slit& tluckness measurement position. for example. in lilli. 12,
'lhe method of slitting prepreg is not limited to a particu- io the thickness of the reinti&rcisg tiber sheet 416 can be
lar one. and a knov n slitting device can be used. A prepreg measured in the vicinity of the diverting mll 419. Bnd the
may be slit after the prepreg is once wound up and separately thiciotess of the prepreg can be measured in the vicinity of
mounted in a slitting device, or. Io obuiin ctlicicncy. a shllutg the lugh tension lake-up device 444. Iu addition, on-lute
slap may bc disposed continuously after a pr&3&rc produc- deli:ct monitonng is prcfi:rdbly earnest out using iniidrixh
tion step without once winding up Ihc prepreg. In addition, ss ttnlt-itlftdfCIL CBIUCIII (tnlagC Iltully'Sls), Still lhi: ltkC.
the slitting step may be a step in Ivhich a I in or more broad A prepreg pmduction apparatus according to the present
prepre is directly slit into prepregs having a desired width, invention includes a runniim mechanism for allowing a
 US 11,491,6115 B2
33 34
rcinlbrcuig liber shcct lo run subslanually vcrtmally down- 446, and then, &s v Ound up ui a w&nder 464, whereby B
ward; a coating mechanism for applying a matrix resin to the sheet-like integrated object 472 composed of prepreg and a
reinforcing, fiber sheet to obtain a matrix resin-impregnated release sheet can be obtained as a product I lere, the depic-
reinforcing, fiber sheet; an additional-impregnation ntecha- tion of a matrix resin supply device and an on-line moni-
nisni for at least pressin the matrix resin-impregnated toring device is omitted in FICi. 21. FICi. 22 &s a schematic
reinforcing fiber sheet: a release sheet supply mechanism for din@ala showing an example of a production process/device
supplv'nig d tel i due shcct 10 Bpplv 11&c rc'Icasc slice& 10 &8 Icasl iu Ihe second production method accord&ng to thc present
one face Ol'he mnlnx rcsui unpregnalwl shccl before invent&on. A plural&ly of rcinlbrcuig liber bobb&ns 412 arc Iil
carrying out an add&tional-unpregnation process on the onto creels 411. m&d the reinforcing fibers pass by the
n&atrix resin intpregnated sheet: and a heating, mechanisnt Ia diverting guides 413 and withdra&vn up&vard. I lere, a braking
for heating the release sheet; wherein the coating mechani ant mechanism provided in the creel enables the reinforcing
can store a coating liquid therein and further comprises a fiber bundle 414 to be withdrawn at a constant tension. A
liquid pool and a narrow ed section which are in conununi- plurality of the reinforcing fiber bundles 414 that have been
cauon w &th each other, w barmn the hqu&d pool has a portion withdrawn are orderly arranged by a rc&nforcing liber
whose cross-acct&onal arcs dccrcases con1&m&ously along a arrangement dcv&ce 415 lo fomi a re&nforcu&g liber sheet
running direction of a sheet-like reinforcing fiber bundle, 416 Ilere, lqli 22 depicts only three yarns of reinforcing,
and wherein the narrowed section has a slit-like cross- fiber b&u&dies, but in reality, one yant to hundreds of yarns
section and has a cross-sectional area smaller than the top are possible, and adjusunents can be made to afii&rd a desired
side of the liquid pool; v herein the additional-impre nation prepreg width and fiber areal weight. Then. the reinforcin
mechanism is arran ed such that the starting point of the io fiber sheet passes through a tiber bundle widenmg device
prcssuig i&i &lie rukht&0&ial-ni&plcg&&BI&on p&occss &5 I &i& or 417 and a smoothing dcvicc 418, passes by a ihvcrtuig roll
less from thc coating mccharusm, and wherein thc prcprcg 419. Bnd is convcycd vertically downward. In FIG. 22, Ihe
pmduction apparatus has a release sheet heating mechanisnt re&nforcing fiber sheet 416 is linearly conveyed between the
bet&veen the release sheet supply mechanism and the devices frnm the reinforcing tiber armsngement device 415 to
h'lip&agua&&oi& nlccltai»sm the diverting roll 419 In this regard, the tiber bundle
Belo&v, the present invention will be described in detail widenin device 417 and the smoothin device 418 can be
&vith reference to a specific example in which a prepreg &s skipped suitably. or omitted depending on the purpose. In
produced usu&g a coatuig dcv&ce in Ihe prcprcg production add&lion, Ihc arrangemcnl order of thc rmnforcing liber
apparatus. In llus rcgnrd, Ihc folio&su& dcscnpt&on &s an arrangement device 415, the liber bundle w&denuig device
example. and the present invention is not constnied to be &o 417, and smoothing device 418 can su&tably be changed in
lin&ited to the aspect described below accordance v, ith the purpose I'he reinforcing fiber sheet 416
11Ci 21 is a schen&at&c diagram showing an example of a nu&s vertically do&vmvard fron& the divert&ng rol1419, passes
production process/device in the first production method through the reinforcing fiber preheat&ng device 420 and the
according to the present invention. A plurality of reinforcing coat&ng section 430 to obtain a matrix resin-impregnated
liber bobbuis 412 arc Iil onto crccls 411. Thm&. a braking &s reuiforcing liber shim& 421. Release shimts 446 unwound
mcchmusm prov&dixl u& lhc crcvl c»shies the rc&nforcing from release shiv& supply dcviccs 442 arc appl&cd to bod&
liber bundle 414 to bc w&thdrawn at B const&mt tens&on. A faces of lhc matnx resin-impreg&rated reu&lbrcuig liber shccl
plurality of the re&nforcing fiber bundles 414 that have been 421, which passes thmugh an additional-unpregnation
withdmsv n are orderly armsnged by a reinforcing fiber device 440. and reaches a high tension take-up device 444
arrangement dev&ce 415 to form a reinforcing fiber sheet ao In FIG. Z2. the release sheets 446 are applied to both the
416. Iqere, FICi. 21 depicts only three yama of reinforcing faces. but such a release sheet is optionally not applied, or
liber bundles, but &n real&ly, onc yarn 10 inuidreds of yanw applied 10 only onc lace. In Ibis regard, Ihc relcasc sheet 446
are possible, and adl usuncnts c m be made to sword a des&red may bc hcatcd by a rclcasc sheet hcaung dcv&cc 422. For thc
prcprcg width und liber areal wc&ghm Then, thc rcuiforcing coanug ace&ion 430, m& arb&lrary coaung sect&on shape cun
fiber sheet passes through a tiber bundle &videning dev&ce be adopted to the extent that the object of the present
417 m&d a smoothing device 418, passes by a diverting roll invention can be achieved. I:xampies include such shapes as
419. and is conveyed In FICi 21. the reinforcing fiber sheet in FIGS. 4 and 16 to 19. In addition„bushes 27 can be
416 is linearly conveyed between the devices from the provided as in FICi. 10, if necessary. In addition, bars can be
reu&forcuig liber urrungcmenl device 415 lo lhc d&verlmg roll provulcd &n Ihc coaung section as &n FIG. 7 For Ihe
419. In this regard, thc liber bundle wulening devwe 417 and a ddd&lnu&al-hi&p&cg&iat&0&i dcv&cc, dny deva:c co&il&guldnon
thc sn&oodung device 418 can bc skipped su&tabiy, or omit- can be adopted lo Ihe ex&cut that tlm oblecl ol Ihc present
ted depending on the purpose. In addition, the armsngement invention can be achieved In I'IG 22, an addit&onal-im-
order of the re&nforcing tiber arrangement device 415, the pregnation device inciudin heated n&p rolls 452 is depicted
fiber bundle ividening device 417. and smoothin dev&ce as an additional-impregnation dev&ce 440. Allowing the
418 can suitably be changed in accordance with the purpose. sheet to pass tluougt the additional-impregnat&on device
Thc reinforcing liber shia& 416 nuw vcrtmally downward makes &t possible lo obtam a prepreg/release shcct (shcet-
from thc diveniug roll 419, and passes through lhe reinfi&rc- 1&ke u&tcgratcd objccti 472 hating a lugh dcgrce ol'uprcg-
ing liber prchcauug device 420 mid thc coating siml&on 430 nal&on. In FIG. 12, heated nip rolls 452 are dep&cted as Bn
to obtain a matrix resin-impregnated reinfbrcina fiber sheet exan&pie of a pressing, method. but needless to say, smaller
421 'I'hen. Ihe matnx resin-impregnated reinforcing tiber io heated 8-shaped arranged rolls may be used depending on
sheet 421 is allowed to pass tl&rough a nonconmct heating the purpose.
device 423 disposed at a distance of N immediately under Then, the sheet-like integrated object is cooled on a
thc coating sect&on 430, so Ihal lhc impregnation &s cool&ng dcvicc 461. is taken up by a take-up dcvicc 462,
advanced. Furlhcrmorc. a release sheet is applied to the fi&llowcd by peeling Ofi'hc release shia& 446. and then, &s
sheet on a divert&ng roll 445, and the shccl-1&kc mte rated ss wound up in a wuider 464. whereby a sheet-hke &ntcgratcxt
object is cooled on a cooling device 461, is taken up by a object 47Z composed 0 f a prepreg and a release sheet can be
take-up device 462, followed by peeling oif the release sheet obtained as a product.
 US 11,491,685 B2
3i 36
Here. the depiction ol'a matnx resin supply device and an olf al Ihc outlet lace of Ihc narrowed scchon so tlial thc
on-line nionitoring device ts omitted in FICi. 22. matrix resin could not leak through the outlet of the nar-
FIG. 23 is a schmnatic diagrmn of another example uf a rowed section
preprea production process/device using the second produc- In the third production method. a coating section in
uon method. FIG. 23 is dillbrent from FIG. 23 in that thc symmetrical biock shape as in FICi 7 v as used. The liquid
reinforcing fiber bundle 414 withdrawn from the creels 411 pool 22 was a tapered flow path whose cross-sectional area
is directly formed into the reinforciilg fiber sheet 416 in the dimrcascd continuously. Ihc height H ol'hc hquid pool 22
reinforcing, fiber armsngement device 415. and conveyed was 100 nun, thc operung;mgle 0 of thc tapcrcd porhon was
30', and the gap I) of the narrowed section 23 was 0 2 nun
linearly through the fiber bundle widening device 417 and
thc smootlung device 418, followed by uitroducing the
I it (in slit-like shape, having an aspect mstio of 100) Stainless
steel-made blocks were used as the wall constituent mem-
reinforcing fiber sheet 416 upward. Such a conf aration
bers Zla and 216 forming the liquid pool 22 and the
clullllldtcs lhc ncccssllv 10 lllstall Illc devices lu Ihc uppt.'I
narrowed section 23. Stainless steel-made plates were used
places and can simplify the instalhstititl of platfilnns and the as side plate mcmbcrs 24. Furlhcnnorc, to melt the epoxy
hkt: significantly rcsui, a ribbon hcatcr was wound around thc periphery of thc
11Ci 24 is a schematic diagram of another example nf a v all constituent members 21 and the side plate members 24,
process/device for producing a prepreg using the present ,'uld tbc tcuipci lull'c of thc cpoxl''csul 'ls 'I lnatl'Ix I'cshl was
invention. In ill(i 24, the crasis 411 are installed upstairs, ad)usted to t)0" G with a teniperature bemg nleasured using,
and the ninning pathway of the reinforciilg fiber sheet 416 a thennocouple.
is lhrthcr lineanzcd. 20 &Release Sheet&
FIG, 25 is a schematic diagrmn of another exlunple of a A rclcasc paper shcct luiving a width of 100 nun was uscxf
process/dcvicc for producing a prcprcg usulg Ihc present as a rclcasc sheet. A rclcasc sheet heating dcvicc was used
invention. Ibis illustrates an example in which heated in ixample 5 and Coniparative iixantple 5 'I'he release sheet
I

S-sluiptxl arrangcxf rolls 455 arc used also as a Iugt tmision heatin device used was a heat aun 1 he release sheet was
take-up dcvmc. Thw also has an advmltagc ui that thc whole heated with the heat un tvhich was placed at a position 30
preprea production apparatus can be made very compact In cm toward the release sheet supply device from a position at
this example, contact rolls 436 are arranged to increase the which the matrix resin-imprecated reinforcin fiber sheet
degree of impre~ation, but such contact rolls Bre optionally was brought in contact with the rclotsc shccl. The distance
tint Blrallgcd dl whlcil Ihc 110th glut uris dirt:cled lo lllc release slice'I was
In tlfis regard, the first production method, the second lo ad)usted so that the teniperature of the center of the release
produciion method, and Ihe Ilurd pmduclion mclhod accord- sheet in the v, idth direction could be 00" ('t a position 10
ing to the presmit invenuon can be used suitably also in cm tov 3rd the release sheet supply device from a position at
combination. v hich the matrix resin-impregnated reinforcing fiber sheet
v as brou ht in contact ivith the release sheet. In this regard,
EXAMPLES ls lllC pcSItlon 111 w lllCh lhC ulatrlX ICS111 llllpl'cgllBB il It lllloIC-
ing liber sheet was brought in contact with thc relcasc shccl
In this EXAMPLES section, Examples I to 3 correspond was sct so as to bc 30 cm toward the high Imision take-up
to the first production method. I ixamples 4 to 5 correspond device froin the outlet of the coatin section
to the second production method, and lixamples 6 to 15 &Additional-Impregnation l)evice&
correspond to the third production method. 40 In the hrst production method, a noncontact heating
Prepreg Production Apparatus& device used was an infrared heater. The length of the heating
A prepreg production apparatus used was a device con- section was sct to 0.5 m.
ligured as descnbcd ui FICi. 26 liir the lirst production In Ihc second produchon method, two heated rup rolls
method, ui FIG. 22 for thc second produchon mcthoik and werc used for prcsslllg ln thc iukhtlotlBI-llllprcgllBIloll pro-
in I'ICi. 3 for the third production method (the description of 4 cess, as shown in Fl(i 2Z. In this regard, the nip rolls nearer
a matrix resin supply section is omitted) I lere. none of a the coating section tvere disposed such that the distance N
widening device. a smoothing device. and a cooling device from the outlet of the coating section to the starting point of
was used. the pressing in the additional-inipregnation device was 0.5
&Coating Sccuon& m, mid thc nip rolls nearer thc high tension take-up device
In thc lirst production method and Ihe second production 0 werc disposed such Ihat the distance from thcsc nip rolls Io
method. a coating section of thc type 20c ui the fiiml lllC SIBrtlllg polllt Of IIIC prCSSlllg Oil thc tllp IOIIS IICtllcl lhC
depicted in ill(i 17 tvas used as a coating, section. 1he coatin section was 100 mm. 'the dimneter of the nip roll
coating section was made of stainless steel. Iiurthernlore, to was 50 mm. 111e nip ml1 had a heater therein, and was heated
heat the matrix resin, a ribbon heater ives wound around the such that the surface temperature w as 100" C The nip force
periphery of the coating section so that the temperature and s. of the nip roll during pressing was set to 400 N.
tiscosity of the matnx rcsui could be adlustcd while thc &Reinforcing Fiber Shecti.
ICIllpCI'rlllllc w Bs lllcdsllrcil Willi B IIICIOIOCouplC. In Bddllloll, A prcprcg was produced using tlucc yartts ol'carbon liber
the ruruung dirixuon of Ihe rcinliircing tiber sheet in thc ("TORAYCA i** TSOOS (24K), manufactured by Toray
liquid pool was the vertically dow mvard direction, and the Industries, Inc.) as reinforcing hbers
liquid pool was tapered in two tiers 1'he opening, angle of to &Matrix 1(Csin&
the first-tier taper was 17", and the taper had a height (I.e., Matnx Resin A (Thennosettin Epoxy Resin Composi-
H) of 100 tmn, and the opening angle of the second-tier taper tl till)
was 7'. In adihtion, plate-like bushes 27 confirmed to the 0 nllXIIIIC'f till CptiXV ICslll (B tlllXhllc Of rill BlollldllC
llllt:Illdl shapC Of lllC COBtlllg SCCIIOII WCIC pltivuh:0 IIS mninc type ol'poxy resul and a bwphenol type of
wiihh regulation mecharusm, as dcscribcd ul FIG. 10. L2 ss epoxy resin), a hardcncr (diaminodiplmnyl sullbnc),
was 20 mm, and the gap D of the imrniwed section was 0 2 mid polyethersnlticae The viscosity of this thermoset-
nim In addition, the space external to each bush was closed ting epoxy resin 1 was measured usmg the ARI ig-Ci2
 US 11,491,685 B2
37 38
manufactured by TA Instruments. Inc. at a mcasurc- thcrcto was the surl'acc iempcralurc of thc width direction
nlent frequency of 0 5 I lz at a temperature ramp rate of cenlcr point at a distance of 10 cm low urd thc coating ace non
I 5" (','minute and was found to be 3675 Pa 1 at 40" (', from a position at winch the release sheet was brought in
855 Pa s at 50" (', 80 Pa s at 70"(, 5] Pa s at 75'(', contact with the matrix resin-intpregnated reinforcing fiber
sheet
and 15 Pa s at 90" C.
cEva)nation of De ree of Impregnation&
A sampled prepreg was xsndwiched belwcmn adhesive Example I

tapes. these were pcclcd olf, mtd thc reufibrctng tiber to

which the matrix resin adhered and the reinforcing tiber to I(einforcing fibers were ivithdrawn fmm reinforcing fiber
bobbins fit onto creels, three reinfilrcmg fiber yarns were
which the matnx resin did not adhered were separated. I'hen, Ia
arranged in Ihc v tdih direction by a reinforcutg liber
the ratio of the mass of the reinfiircing fiber to which the strtulgcntcni ilcvicc to lotus a reinforcing fibi:1 shcct, anil lhc
matrix resin stucl with respect to the mass of the whole rcsulltng rcinlitrcutg liber sheet was utlroduccd utto a coat-
reinforcing hber sheet that was used was regarded as a ing section storing a matrix resin A heated to 90" (1. so that
dcgrcc ol'mprcgnauon 01'hc matrix resin basu! on a the nlatrix resin A was applied to the sheet. I'hen, the nmtrix
pcchng ntcthod. I
resin-impre usted reinforcing tiber sheet v as withdrawn
A de ree of impregnation of 90%v or more ives rated as
from the coating section, a noncontact heating device was
I:xcellent, 70% or ntore and less than 90%i ss (iood. and less disposed such that the distance N2 fmm the outlet of the
than 70%a as 13ad. coaling section lo ihe nonconlacl heaung device was 0.5 m,
cEva)nation of Prepreg Ciradew and lhc sheet was healed by utfrared rays such thai P2 was
A santpled prepreg was laminated/cured to obtain a corn- 10 130"
C., i e., P2 — M 40 (" (1). and then, pmvided with a
post(a plate. and the cross-sccnon 01 Ihc compostle plate was release paper, ivhereafter the resulting sheet was wound up
obscrs txt lo Iind disturbance in thc rcinforcutg fiber layer.
-Measurement of gurface 'I'empensturew by a vinder I'he nulning speeds of the reinforcmg fiber
sheet and the prepreg were 10 m/minute The degree of
1'he surface temperature P2 (" (1) of the matrix resin-
impregnation of the obtained prepreg was evaluated and
impregnated reinfilrcmg hber sheet at the coinpletion point

('.)
of heatin the surface tempemsture P (" ('.) of the matrix
„

resin-Impre~ated relnforcmg fiber sheet before the addi-

uonal-tmprcgnunon process, thc surface lcmperalurc T
ol'he rcleasc shccl, and thc surlhce icmpcralurc K
of the matrix resin-impregnated reinfisrcing fiber sheet

sured usin an infrared radiation thermometer AD-5611A

('.)
before having the release sheet applied thereto ivere ntea-

(with the emissivity set to and fixed at 0.95: manufactured

by A&D Company, Limited). The measurement was made
with thc infrared Ihcrmomcter placed SS cm aparl from the
sample to be measured. P2 tn the Iirsi production method
wss a measured imnpcralure of thc center ol lhc malnx
sc

ss
found to bc 92%. which was rated as Good. In addition, thc
cross-sccfion of lhc lanunatcd/cured i:Ontposilc was
observed, revealing that no disturbance was found in the
carbnn fiber layer and that the grade of the prepreg was
good

Examples 2 and 3

With the temperature P2 at 115" C (P2 — M 25 (" C ) in

Example 2) and at 95'. (P2-M=5 ('.)
in Example 3),
prepregs were obtained in the same manner as in Example
I, mtd the dcgrces ol'mpregnation werc cvalua lcd and found
to be 83% and 75% respectively, which werc both rated as
resin-inlpregnated reinforcing fiber sheet 10 cm downstreant Good In addtnon, thc cross-section of ihe laminated/cures)
of the noncontact heating device Ibe surface temperature P cmnposite was observed. revealing tlmt no disturbance was
('1) of the matrix resin impregnated reinforcing fiber sheet so found in the carbon fiber layer and that the grade of the
before the additional-impregnation process in each of prepreg was good.
Exmnple 4 and Comparauvc Example 6 ut thc second
production method w as mes surest as thc surface lcmpcra! urc ('omparative lxample
I I
of Ihc width direction center al a distance of 10 cm loward
the coating section front the starting point of Ihe pressing on With the temperature P2 at 85" C (P2 — M= — 5 (" (1)), a
the nip roll nearer the coating section 'I'he matrix resin- prepreg v:as obtained in the same manner as in Example I,
impregnated reinforcing fiber sheet before the additional- and the degree of impregnation was evaluated and found to
impregnation process in each of Example 5. Comparative bc 65%, which was rated ss Bad
Exmnple 2. and Comparauve Example S hsd a release sheet
apphcd thereto, und thus, thc lcmperalurc measured as the o Comparative Example 2
surface iempcraturc P ('.) of thc sheet was the surface
temperature P of the ividth direction center of the release A noncontact hcalulg ili:vlcc was nlounti:il such thai lhc
sheet. v herein the center was located at a distance of 10 cnt distance N2 Irom thc outlet of Ihc coatutg section lo thc
toward the coating section from the starting point of the noncontact heating device was I 3 m, and the mnnutg speed
pressing on the nip roll nearer the coating section. Further- ss of the prepreg was set to 10 ngnumtte. resulting in decreas-
morc. in each of Exnmple 5, Comparative Example 4. and ing the surface tenlperature of the matrix resin-impregnated
Comparanvc Example 5, ut each of wluch thc relcasc sheet reinforcing fiber sheet before being introduced into the
was used, the tempcraturc measured as Ihe surface tcmpcra- noncontact heating device. and thus. the capability of the
ture 'I'" C ) of the release sheet befisre being brought in inlrarcd healer of thc nonconlacl hcatutg dcvtcc was nol
contact with the matnx resin-mtpregnated reintisrcing tiber ic sullictcnl for rchcaung, fmlutg to increase llm Icmpcralure
sheet was the surface temperature of the width direction P2 to 90" C 1'his cmtsed the de@ac of impregnation to be
center point at a distance of 10 cm toward the release sheet less than 70%, ivhich was rated as 13ad
supply dei tcc I'rom a posttton at wluch lhc release shcml was
brought in contact with thc malnx resin-impre twicd reut- Comparative Example 3
forcing liber shcct. Thc lcmpcralure measured as the surface ss
temperature K (" (' of the matrix resin-impregnated rein- An experiment vvas carried out in the sante ntanner as in
forcing tiber sheet before having a release sheet applied ('Omparative I/xanlple 2 such that the distance N2 fmm the
 US 11,491,685 B2
39 40
outlet oi Ihc coauug section lo the nonconlacl healing device tapes werc imprc usted suilicimltly, and accorduigly thc
was 1.3 m. but except that the nmning speed of the prepreg resin sticking to the cutter blade of the slitter v as a little.
was 0 5 nfiminute, with the result that a longer time for
rehearing v as enabled to be secured, thus enabling the Comparative itxample 4
tempemsture P2 to be Increased to 90" C., but observing the
cross-section of the I am inat ed/ cured composite revealed t1 mt Aprepre was obtained in the same manner as in Example
some disturbance was found in thc carbon liber layer and 5 except liat a rclcasc shccl healing device was not used.
that Ihe prepreg grade was nol good. Then, the release paper was pccled oil'using a relcasc shccl
'I'Ai31 I'. I

"
C ndttions N2 t!.1 nl 0 m
PS M+4! C M+26'Cl M+.' M — .
1st
' less than VI 'I C.
Rttttlttttg SPoetl lt! ntttnutute 10 tntnunute 0 s tntllltltlt'te
h tlu:ttton Itnpregnstion 97 6." less titan 70
If m. Ii. t o
Ginl

20
lixafupie 4 (upper) wind-up device 463 to obtain a sheet-like integrated
object. The degree of impregnation of the obtained prepreg
Reinforcin fibers were withdraivn from reinforciag fiber was evaluated and found Io be less than 70%. which was
bobbins fit onto creels. tluee reinforcing fiber yama were rated as Bad. In this regard, the surface temperature P of the
arranged ln thc width ihrection by a reluibrcuig fiber matrix resin-impregnntmi rculforcing liber sheet bcforc
arrangement device to fomi a reinforcing fiber sheer. Bnd the entering the additional-impregnation device v as 35" C. as
Icsillnug rcini'orcing liber shcct was introduced into a coat- measured on thc rclcasc sheet. Ihc surface tcmpecdturc T of
ing section stoung a matrix resin A heated to 90" (' so that the release sheet was 23'..
and thc suri'acc tcmpcralure K
Ihe matrix resin A wns applied lo thc sheet. Tllcn, a malux of the matrix resin-inlpregnated reinforcing fiber sheet
resin-inlpregnated reinforcing fiber sheet v as withdrawn 30 before having the release sheet applied thereto was 80" C
front the coatin section: an additional-impregnation device Example 5 and Compamstive Example 4 venfied that
was disposed such that the distance N from the outlet of the heatln the release sheet inhibited the matrix resin-impreg-
coatingsection to the starting point of the pressing in the nated reinforcing fiber sheet from bein cooled. making it
additional-imprcgna lion device was 0.5 m; Ihe matrix rcsui- is possible to obtain a prcprcg luivuig a dcsircd dcgrcc of
lulprcgu'111011.
impregnated reinforcin fiber sheet was allowed to pass
lluough Ihc addluonal-unpregnauon dcvicc such thai thc
Comparative Example 5
sheet ives pressed at a nip pressure of 400 N by two heated
iup rolls sct to 100'u and 0 prepreg was tluis Obtautcsl and A lllalllx fCSBI IChlforChlg fibCI SIICCI ivan OblalllCd ul lhC
wound up by a winder 'I'he ninning speeds of the reinforcing sante manner as in 1ixalnple 5 except that ilo pressing was
fiber sheet and the prepreg were 20 ni/minute. The degree of carried out by the nip rolls. 'I'he degree of impregnation of
impregnation of the obtained prepreg was evaluated and the obtained matrix resin-inlpregnated reinforcing fiber
found to be 80'io or lllore, which was rated as flood. In tlus sheet ives evaluated and found to be less than 70%. Ivhich
regard, Ihc surfnce Imnperaturc P oi thc malmx resin-un- v as rated as Bad.
pregnated reinforcing fiber sheet before enterin rhe addi- 4 Example 5 and Comparative Example 5 venlicd Ihal
tlouill-uuplcgllBI100 device was 70'. pressing is ncednxI to obtain a dcsircd dcgrce oi'mpregna-
tion m the second production method
Example 5
Comparative Example 6
Aprcpreg was obtanuxl ui thc same mniuicr as ui Example o
4 cxccpi that a relcnsc shccl was applied lo lhc prepreg, A prcprcg wns produced in thc same maiuicr as in
wherein Ihe surface tenlperature of the sheet ives heated so I:xanlple 4 except that an additional-inipregnation device
as to be 90''efore the sheet entered the additional- was disposed such that the distance N front the outlet of the
ofi'sing
impregnation device. Then, the release paper ives peeled

d sheet-hke uilegrated oblixl Thc dc rcc oi'impregnation of

the obtained prepreg was evaluated fmd found to be 80% or
coatln section to the starting point of the pressing in the
a release sheet (upper) wind-up device 463 to obtain o. additional-impregnation process was 1.5 m. The degree of
impregnation oi'hc obtained prcpreg was cvaluatcd and
found to be less Ihan 70%o, which was rated as Bad. In tlus
111010. 9;111Ch WBS I'IIICB Bs Good. Iu lhlS Ieglird. thC SilrIBCC rcgdrd, tile sill face lclupcldullc P of tlm matrix rcsui-im-
tenlpemture P of the nlatrix resin-impregnated reinforcing pregnated reinforcing hber sheet before the additional-im-
fiber sheet before entenng the additional-impregnation fo pregnation process ives 50" ('.
device was 75" C. Bs measured on the release sheet. the Example 4 and Comparative Example 6 veriiied that the
surface tempemsture T of the release sheet was and 90'..
distance N of more than I m from the outlet of the coatin
thc surface tempcralurc K 01'hc urdtrlx resin-unpre~lated section to thc slnrtuig poult of thc pressing ln thc additional-
Icullol'culg fibcr sltccl bcfolc llavulg lhe Iclctisc shcel impregnation process caused Ihc surfnce tcmpecdturc of Ihe
applied thereto was 80'. 61 matux resin-imprc usted reinforcing liber sheet to bc low,
I Iere. the prepregs obtained in ixample 4 and lxample 5
I faihng to afford a prepreg bavin a desired degree of
I

were slit to obtain 7 nlm wide prepreg tapes 'I hese prepreg hupregflaliofl.
 US 11,491,685 B2
41 42
1AI)i,t'. 2
Con&ps&at ve Cnmpnat ve Cmnpa(at ve
Ex(unple 4 Ex.unple ( Exnnple 4 Exannsle 6 Exunple 6

C nc(tines 8 OSn& 0 S n1 m

I...
Items
I .I n
p

I p pm!ma
Rat o
M —

s!7!! o
0'

mn«
('m
XI
K +
—

ta!s„»n
1
10'
'

I
vx
K
—

—
.

.. Iten 70es
'
s7 ('

I
M —

+ 10
1
'

.. tt m 70'!6 I
N
1
—

...tbu
40'.
70'a,

Example 6 'IAI31,1. 3

Us&ng the coaung sccuon 20 u& FIG. 7 accordin to an Comp(uatv*

1 Example 6 rx(unple 7 Ex.unple 7
cnlbodhncnt of lhc present u&vc'Bi&on, a Blot&On epoxy'csul
was applied to a carbon tiber sheet. 'I'tune stainless steel- Pc&fn&mu&p gau&ibc( I'b(ce none ne
nlade polished bars having a diameter of 10 mm and a length
of'onalil
ns Ba&5
710! 10" boa
of 40 nun were used as a group of bars 35. The holding f(n. s. " '!

angles between the carbon fiber sheet and the bars 35a, 35b,
20
and 350 &vere formed so as to be 10", 20", and 10" respec-
ui sly. and all thc bars werc sunk u& the ma&Ox rcsul 2. In Next, Table 4 hats thc results of the cxpcnmm&t in wluch.
addition, tlu: bar 350 loca&cut at the lu hest posulon was using the coating section 41 in I!1(i 12 according to an
bnIO ht in contact with the opposite face of the carbon tiber embodiment of the present invention, a nlolten epoxy resin
sheet fronl the face brought m contact with the guide roll 13. v as applied to a carbon hber sheet to produce a sheet-like
The group of bars 35, v hich had 0 uniform cross-section in prepreg. In this regard, the ninning speed of the carbon fiber
the longitudinal direction as in FI(i. 11, did not include a sheet vvas set to 20 &u/minute in any of the Examples. The
width regukxtion member. In addition, the width Wl of the dc&a&1 w&ll be explained below.
sl&t-lite outlet was 20 rrun. Thc degree ol'mprcg&x&t&on of
thc resulting prcprcg was quanutauvcly cvaluatcd by a Example 8
10
peeling method Measuring the degree of impreg&&ation of
the coatina liquid by a peeling method can be carried out in Using the coating section 41 shown in I!1(i 12 according
fiie followin manner That &s, a sampled coating liquid to the present invention, a molten epoxy resin was applied
impregnated reinforcin fiber sheet is sandwiched between to a carbon fiber sheet. A group of bars 36 used were
adhesive tapes„ these are peeled otf. and the reinforcing fiber stau&leab sleet-made bars having d&sc-l&kc w&dth regulat&on
to wluch thc coaung liquid has stuck and thc rcu&forcing
ii members large ln diamclcr at both m&ds therix! f, as shown in
liber to which thc cont&ng hqunl has not stuck arc scparataxt. I! 1(i. 13. I he diameter d I of the group of bars 36 was 10 nun,

Thml. thc ratio of the mass of thc reinli&rculg fiber to wh&ch die diameter d2 of the ividth regulation member was 14 nun,
the coating liquid has stuck to the mass of the whole the spacmg W2 between the width regulation members was
reinforcing hber sheet that has been used can be re arded as 20 nun. and the thickness W3 of the width regulation
a de ree of impregnat&on of the coating liquid ixnsed on a member was 2 mm. The bar and the width regulation
peeling method. 'I'he degree of impreglmtion of the obta&ned members werc an u&tcgra led obtect Into w iuch onc pol&shcxt
preprcg &n Example 7 was 73%. bar was carved and produced. The youp of bars 36 were
arran ed in the same n&armer as the bars in the coatin
('omparative I ixample 7 section 4(t (I ixample 7) according to the enlbodunent in I 'l(i
7, and the holding an les bet&veen the carbon tiber sheet and
Next, all the group of bars 35 were removed from the the bars 36a. 36b. and 36c werc fi&oned so as to bc 10", 20',
coating section 20 accordin to the embodiment in FIG 7, and 10'espect&vcly. In add&uons thc w&dth Wi of thc
and the coating section, which did not &neet the requirenlents slit-lite outiet was 20 mm, and satisfied the relationship
ot the present ulvention, was used to apply a molten epoxy 0 WI-W2at0 (WI=W2). Next, the degree of unpre nation
resu& to 4 carbon tiber sheet. Thc degree of unpregnatlon of 60 of the obtained sheet-like prepre was measured by a
the obtained sheet-1&ke prepreg was mcasurcd by a peeling pectin method in addition. to evaluate the quality of the
method, and fiiund to be 50%. obtained prcprcg, the prcprcg was vmually obscrvixt. A
prcprcg &n wluch Ihe carbon libera werc arrtmgcd so as to
Example 7 form a uniform thickness and have no gap over the full width
vvas rated as "Excellent**: a prepre the thickness of
s. (20 nun)
Next. ucmg the coating sect!On 43 in I!1(i. 27 accord&ng to which was partially umulifonll (the surface was irregular)
an embodiment of the present invention. a molten epoxy but m which the carbon tibers had no gap over the full width
resu& was applied to a carbon liber sheet. Difibrently from was rated as "Good", and 4 prepreg &n wluch pan(s) ol'hc
the coaung sect&on 40 according lo thc embodiment ul FIG. carbon libera had a gap. &luis hai ing a poruon(s) contailung
7. only one polished bar Imving a dimneter of 10 mm and a only an epoxy resin, or a prepreg the surface of which was
""
length of 40 tmn was used as a bar 35. The holding angle fuzzy was rated as "Fair'*. The degree of impregnation of the
bet&veen the carbon fiber sheet aod the bar 35 was fiirmed so prepreg obtained in ixample 0 was 73%. and the carbon I

as to be 20" in addition. the bar 35 ives sunk in the coatiag fibers were arranged so as to form a uniform thickness and
1&qu&d 2. The dcgrcc of Impregnation of the obtai&md shcct- have no gap over thc liill width (the qunl&ty was "Excel-
likc prepreg warn mcasurix! by a pimlu&g method. a&xl fi!und lcnl ).
to be 60%o. The absolute value of the degree of impregnarion 6i Here. in the prepre obtained in Example 7, part of the
was low, but the comparison with Gompamtive Example 7 carbon fibers had a gap. portions of only an epoxy resin were
verities the effect of the bar. present consecutiiely in the ninnin direction, and in addi-
 US 11,491,685 B2
43 44
uon, fuzzing was Ibund at both cods of the propre ul thc part oi'hc prcprcg v as not uniibnu ln Iluckness (the surface
wiihh direction (thc quahty was "Fmr"). v as irregular), but the carbon hbers had no gap over the full
v idth (the quality ives "(iood").
Ilxarnple 9

Next, lvith the width Wl of the slit-like outler in Example

8 clmnged to 30 mm, a molten epoxy resin was applied to a
carbon fiber sheet 'I he present Iixample also satisfied the
rclntionslup OuWI — W2 10. Thc dcgrcc oi'mpregnation of Exlunple 12
thc prepreg obtmned ln Example 9 was 71'!o, and part of the I
With thc position of Ihe group oi'ura 36 ad)usted such
1 1

prepreg was not uniform in thickness (the surface was

irregular)„but the carbon fibers had no gap over the full that thc holding angles between Ihc curbon liber shimt and
width (the quahty was "(Iood"). the bars 36u. 366. and 360 were formed so as to be 40", 80",
and 40" respectively, a molten epoxy resin was applied to a
Example 10 carbon fiber sheet. 'I'he carbon fiber sheet was observed
fluttenng signilicantlv at or near the top liquid surface in the
NexL with the width Wl oi Ihe slit-hkc outlcl in Example hquid pool 22 wlule runmng. Thc dcgrcc of unpregnauon of
8 changed to 40 nun, n molten epoxy rcsul v;as applied Io a the obtained prepreg was measured by a pcchng method, and
carbon fiber sheet. The present Example did not satisfy the found to be 90'!o or more. In addition. the prepreg obtained
relationship 0&WI-W2&I 0. The degree of impregtafion of v as visualiy observed and checked for quality. revealing that
the sheet like prepreg obtained in ixample 10 v as 72%, part
I 20 part of the carbon fibers had a gap. that portions of only an
of the carbon fibers had a gap. and portions of only an epoxy epoxy resin lucre present consecutively in the nulning,
legal v;crt: prcscnt consccnllvcly'l lhc rnnnnlg direction direction, and ln addnlon, tlui1 fuzzing was found all over Ihc
(Ihc quality was "Fnir"). surface of thc prcprcg (thc quality wus '*Fair" ).
'IAI)l,li -I

fxample 6 L'xmnple S Example 0 Lx.unple ltl

P rfotnune Wtdtb Regulstton Vn 1'es Yes Yes

C 0 5 5 6! 11 0 st 5 tv I — 1V2 u nnn It 1 tmn 20 mm
E aluatton Itnptngttattntt Rtl'ttn 72'
Oust t, mt

Next. 'I'able 3 lists the results of the experiment in wluch, lixample 13

using thc coating section 41 in FIG. 12 accordmg to an 35
cnlbodhucnt of lhc present Hive'alton, a nloltcn epoxy'egal With the diameter dl of the group of bars 36 clmnged to
ives applied to a carbon fiber sheet to produce a prepreg. The 20 mm, a molten cqtoxy resin was applttx) to a carbon liber
perfi&rnling conditions common to all these Examples were sheet Thc diameter d2 of the width regulation member was
that the nlnning speed of the carbon fiber sheet v as set to 20 set to 24 nun. In addition, the position of the group of bars
m,'minme, that the group of bars 36 used were bars having 40 36 v as adjusted such tint the holding an les between the
w iihh rcgulatlou mcmbcrs in thc same shape as ul Example carbon fiber sheet and the bars 360, 3677, and 36C were
8. that the width Wl oi'hc sht-like outlet was 20 nun, and formed so as to be 10', 20'. and 10'espectively. The degree
that the relations)up OmWI — W2& was satisfied. The detail of unprcgnation oi'hc obtained prepreg was measured by 0
lvill be explained below. pimhng method. and found to bc 84%. In addition, Ihc
45 obtained sheet-like PrePreg ives visually observed and
Example 11 checked for quality, revealing that part of the prepreg was
not uniform in thickness (the surface was irregular), but the
With the position of the group of bars 36 adjusted such carbon fibers lmd no gap m er the fill width (the quality was
thai Ihe holdulg angles bctwimn Ihe carbon liber shecl and '*Liood").

TABLE 5

0'040'i) 'tl
'he
bars 36n. 36b. and 36O were formed so as to be 20'. 40",
and 20'espccuvcly, a molten epoxy resin was apphcd Io a
carbon fiber sheet I'he carbon fiber sheet was observed
fluucung at or near thc top liquid suri'ace in Ihc hquul pool
22 sometimes lvhile nnuung. The degree of impregnation of
thc obtained prcprcg was mcasurcd by a pcclulg method, and
found to be 82%. In addition, the obtained sheet-like prepreg
was visuafly observed and checked for quality, revealing that
Pel'I 5

Cnnd t ons
tet tt

E 'sist:stints
nttlts

60
Bu IDauuet*t dl
I ueest H Id ttg
attgln
Dnpremiattott Rytto
ttttass
0 e Ill
.unpt

If t nun
S L ampl

tttttt

lixample 14
11 E»ampl

ttlttl
SD

Next, usuig thc coating section 44 in FIG. 28 according to

the present invention, a molten epoxy resin was applied to
a carbon fiber sheet The mnning speed of the carbon tiber
sheet was set to 20 m/minute. The performing conditions in
the present ixampie were the sante as in I ixample 8 except
I
12

20't1"
I.» 11

mnt

f!4
I
 US 11,491,685 B2
4i 46
Ihal thc group of bars 36 werc broughl in conlacl with thc cqurpmcnl applrcanons, housing applrcnlrons, civil cn i-
opposite Ihce of thc carbon liber sheet lrom lhc face brought neering and construction applications, and the like.
in contact t(ith the group of bars 36 in Example 8. In the
present Example. the bar 36a located at the hi hest position REFERENCE SIGNS LIST
was bmuaht In contact with the same face of the carbon fiber
sheet as the face brought in contact with the guide roll 13. I Remforcing Fiber
Thc cnrbon liber shccl la was obscrvcd fiuttering at or nmrr Ia Rcuiforctng Fiber Sheet
the top liquid surlhcc In thc liquid pool 22 somenmcs while Ih Matrix Rcsui-imprcgndlcd Reuitbrcuig Fiber Slum(
numing. The degree of impregnation of the obtained sheet- Ic Prepreg
like prepreg was measured by a peelilig method. and found I I I
2 Matrix Resin
to be 70% In addition. the obtained sheet-like prepreg was 3 Release Sheet
visually observed and checked filr quality, revealing that part 11 ('eel
of lire pit.plcg was trot Uliiloitli iii Ihlcklicss (llic silllacc wits I 2 AlrilligClllulil Di:VICC
irrcgular), but the carbon libera had no gap over thc full 13, 14. 15, 16 Convcyancc Roll
rvidth (the quahty was "Ciood'*). 17 Wind-up Device

TAI31,1! 6

Example S B7 unpre 14

P rfornune
I:misIu .
Contact Face of Bar:it
Bish (t p (tu

Ou, Its
7.

*
"'o'u,
Oppoairc Side fiom Fa c in

llmt
Sune Side 55 Fa 5 rn

Example 15 18 Rclcasc Shrml Supply Device

I gu Release Sheet I leatin Device
Usmg lhc coatuig section 41 ui FIG. 12 accordui lo an 19 Additional-inipregnation l)evice
embodiment of the present invention, a molten epoxy resin 20 Coatin Section
was applied to a carbon tiber sheet. 'I'he perfilnning. condi- 20b Coating Section in another embodiment
tions ivere the same as in I:xample 9 except that the nrnning 20C Coating Srx:non in another mnboduncnt
speed of the carbon fiber sheet was cet to 5 m/minute. The 20J Coating Section in another mubodnuenl
degree of impregnation of the obtained prepreg w:as mea- 20e Coating Srx:non in another mnboduncnt
surixl by a pceluig method. Snd ui addition. to evaluate the 2 lu, 2 lb VVall Constituent Merubers
quality of Ihc obtained prcprcg. Ihc prepreg was visually 2 lc, 2 Id Wali Constituent Members havmg another slmpe
observed. A prepreg in which the carbon fibers v ere 21c. Zlf Wali ('onstituent Members bavin another chape
arranged so as to form a uniform thickness and have no gap 21g, 21h Wall ( 'onstituent Members having another chape
over the fidl width (20 nim) tvas rated as "I'.xcellent", a 21/. 21/ Wail Constituent Members having another shape
prepreg the thickness of w hich was partially ununiform (the 22 I Iquid Pool
surface was irreguLar) but in which the carbon fibers had no «, 22ir Region ivhose cmss-sectional area decreases continu-
gap o(cr thc full width was mted as "Good". Imd a preprcg ously ui Liquid Pool
in winch pan(s) of the carbon libera had a gap, thus having 22b Region whose cross-sectional urea docs nol decrease
a portion(s) containing only an epoxy resin„or a prepreg the in Liquid Pool
2ZC Region whose cross-sectional area decreases inter-
surface of ivhich was fuzzy w:as rated as "Iiair" 1'he degree
mittently in I iquid Pool
of impregnation of the sheet-like prepreg obtained in 23 Narrowed Section
Example 9 was 90% or more, and the carbon fibers were 24, 24a, 246 Sale Plate Members
arranged so as to form a umfomt thickness and have no gap 25 Outlci
over lire lull widlll (lllc qurlhlv was Exccllclil ). 26 Clearance Clap
27 Plate-lii e Bush
'I'A1311( 7 27u, 27h VVidth Regulation Mechanism
3(l (.'oating Section
himp& 11 I, pr I(
31ir, 31b Wall consntumil members
Perform n Runrun 20 irrinunute ( m mnmte 32 Liquul Pool
Condit&onr Spccd 33 Region v:hose cross-sectional area decreasea intermit-
E elect&on llnprcallarloll - 9&p
tently in Liquid Pool
lt'c1115 Ratio o.
I&a&155
35a, 356. 35c 13ars
Ou:
36u, 36h, 37& 13ars in another emlxidinient
I I
7
40 Coating Section in another embodiment
41 Coatrng Section in another embodiment
43 Coating Section in another embodiment
INDUSTRLAL APPLICABILITY dc
44 Coatin Section in another embodiment
100 ('cating Device
1'he prepreg obtained by the production method accordiag ltll ('oating Device
Io lhc prcsmit uivmiuon can widely be applied as FRP B Depth of Liquxl Pool 22
typilied by CFRP, in acrospacc apphcatrons. applications for C Height up Io Ihc liquid surface at the lop of Liquid Pool
structural matenals and interior materialc such as for auto- 4( 22
mobiles. trains. Snd ships, precsure vessels, industrial mate- D Ciap of Narrowed Section
rial applications, sports material applications, medical li Width Direction of l,iquid Pool
 US 11,491,685 B2
47 48
G Posiuon at wluch width regulation Is cairted out whclc'lu thc uoucoutact hcdthlg ls sldllixi wilful d region
I I Vertical I ieight along which the cross-sectional area of of I ul fioul du opcuulg of saul ulllrovvcd sccnou ul lhc
I iquid Pool 22 decreases continuously rurufing direction of said matrix resin-impre nated
I. Width of I iquid Pool 22 reulforcing fiber sheet,
N Distance from Outlet of ('oating, Section to Startiag wherein beloiv I'omiula I is satisfied assuming that a
Point of Pressing in Adihtlonal-impregnation surface temperature of said matnx resin-impregnated
N2 Distance from Outlet of Coating Section to Stattutg reinforcing fiber sheet is P2 ('.) ut a compleuon poult
Point of Heating by Noncontact Type Heating Device Of thc heating and that a tcmpcruture ol'aul matrix
R. Ra, Rb Vbltex Stream in the Edge resin stored in the inside of said coatin section is M ("
1''irculatin Streanls C.).
Width of Reinforcing I'iber Sheet Prepreu lb. as
measured unmcdialcly under Narrowed Section 23 .v/ p il'nsnsulu li

Y Width of Narrowed Section 23 wherein said coatin section comprises, in said liquid
Z Rulumlg Dirimuou Vertically Downward Dlrccuon) of
I pool, 0 width rcgulauon mcchalusm Rlr regulating a
Reinforcing Fiber Sheet 1o width of said rcinforculg liber shcct, and whcrcin a
0 Opening An le of Tapered Portion relationslfip between a width (W) of said reinforcing
411 ('eel fiber sheet immediately under said narrowed section
412 Reinforcing lliber 130bbin mid a width (1,2) regulated by said width reguLstion
413 Ducrting Guide mechmlism at a lolver end of said width reguLstion
414 Reinforcing Fiber Bundle mechanism sauslics
415 Reinfbrcin Fiber Arrangement Device
416 Reinforcing Fiber Sheet I iV+0( (nun l
417 I'iber 13undle Widemng l)evice 2 1'he method of producin a prepreg according to claim
410 Smoothing Device 1, tiirthcr comprisulg a step of pressing said matrix rcsin-
419 Dii crtlng Roll imprcgnatcxl reinforcing liber sheet after thc step ol'heatulg
420 Reinforcuig Fiber Prelmdtulg Device in a imncontact manner.
421 Matnx Resin-impregnated Reinforcing Fiber Sheet 3 The method of producing a prepreg according to claim
422 Release Sheet Heating Device I, wherein the obtained prepreg has a degree of mipregua-
423 Noncontact I testing Device tion of 70')I or more based on a peehng method.
430 ('Cating Section 4 A method of producing a prcprcg tape, compnsulg
440 Additional-Impregnation Device shluug a prepreg obtained using the method ol'produculg a
442 Release Slmct Supply Device prepreg according to cLsim 1.
444 Iqigh Tension Take-up Device 5 A method of producing a hber reinforced composite
445 Diverting Roll material, coinprising curing a prepreg obtained using the
446 Release Sheet method of pmducing a prepre according to claim I
452 I teated Nip Roll 6 Thc method of producing a preprcg accorihng to claun
455 Hcalcd S-shaped Arranged Roll ls
1, whercul said nonconlacl healing Is select(xi from thc
456 Coullii:I Roll group of infrared heatin . far-infmsred heatin, laser heatin
461 Cooling Device and steam heating.
462 Take-up Device 7 1'he method of producin a prepreg according to claim
463 Release Sheet (Upper) Wild-up l)evice I, v herein a heating distance in the noncontact heating is I
464 Winder dc
ul or less.
471 Prepreg (Reinforcing Fiber Shee( Prcprcg) 8 A prepreg producuon apparatus. composing.
4'72 Prepreg/Rclcasc Sheet (Sheet-hke Integrated Object)
a ruiuung mechanism for allowing a reinforcin fiber
sheet to run substantially vertically dov nward;
lllc luvcutlou clauuixi ls: a coating mechanism for applying a nlatnx resin to said
1 A method of pmducing a prepreg, coinprising the steps remforcing fiber sheet to obtain a matrix resm-impreg;
ol: ilanxl rcuiforculg liber sheen and
allowing a rmntbrcing liber sheet lo pass subslanlially a healing mechanism lor heating said matrix rcsul-Im-
vertically downward through an inside of a coating pregnated reinforcing fiber sheet„
section storin a matrix resin to apply said matrix resin wherein said coatin nlechanism can store a coating liquid
to said reinforcing fiber sheet to obtain a matrix resin- therein and includes a liquid pool and a narrowed
impreguated reinforcing fiber sheet; and section which are in communication with each other,
heating said mutnx resin-impregnated reullbrculg fiber whcrcin saul liquid pool has a poruou whose cross-
sheet ul a uoncontact mmulcr, scctional arcs dimreases continuously along a runnulg
wherein said coatin section comprises a liquid pool and direction of a sheet-like reinforcing tiber bundle.
a narmwed section which are in communication with s. wherein said portion of the liquid pool is formed by wall
each other. said liquid pool having a portion lvhose constituent member: having a vertical height of 10 nun
cross-sectional area decreases contimmusly along a or more that are opposed to each other with a gap in
numing direction ol'aid rcullbrcing liber sheet, bclwimn to generate d circulation flow ui Ihc hquld pool
wherein saul portion ol'hc hquid pool is formed by wall fol rculoval ol lhLZ dud/ilr Ol prcvcunou ol cloggulg
constituent members having a vertical height of 10 nun fuzz.
or more that are opposed to each other with a gap in "" wherein said narrolved section has a slit-hke opening that
betlveen to generate a circulation flow in the liquid pool can be used to uide said matrix resin-impregnated
for removal of fiizz and/or for preventiicu of cloggiag reinforcing fiber sheet out, and wherein an area of the
I 0 z L. Opening ls smaller thml an area of a top side of said
0 hcrcin said narrow cd section has u sht-like cross-section liquid pool and has a gap so that said reinforcing liber
and has a smaller cross-sectional area than an area of a ss sheet is automatically aligned.
top side of said liquid pool and has a gap so that said wherein said coating mechanism ln said hquid pool
reinforcin fiber sheet is mitomatically aligned. further comprises a width regulation niechanism
 US 11,491,685 B2
49
between sale mall members for regulatm a wtdth of
saitl rcinlbrctng tiber sheet, and
wherein said heattng mechanism is a noncontact hearing
means„and is disposed so as to be started wirhin a
region of 1 m from said opening of said narrowed
section in the nutning direction of said matrix resin-
impregnatcd rcinforcutg liber sheet.
9. Thc prcprcg producuou apparatus accorrling to claun 8,
wherein said noncontact heating is selected from the group
of infrared heating, far-infrared heating. laser heating and
steato lteatlrlg.
1(l. 1he prepreg production apparatus according to claint
8. whcrmn a hcatutg distance ut the noncontact hwttut is 1
Ilt ol 1csw