FIBER BUNDLE DRAWING APPARATUS, METHOD OF DRAWING FIBER BUNDLE, AND METHOD OF MANUFACTURING FIBER COMPOSITE MATERIAL

Abstract

There is provided a fiber bundle drawing apparatus that can draw a fiber bundle traverse-wound around a bobbin and having a laterally-elongated cross-sectional shape while maintaining the cross-sectional shape, and cause the fiber bundle to travel along a fixed course. The fiber bundle drawing apparatus includes: a bobbin holder configured to hold the bobbin in a rotatable state; a turning mechanism configured to receive the fiber bundle drawn from the bobbin, and to turn and deliver the fiber bundle, thereby reducing change in course of the fiber bundle in a direction parallel to a center axis of the bobbin; and a twist prevention mechanism provided between the bobbin holder and the turning mechanism in a path of the fiber bundle in the apparatus, and including a support portion and a rotation suppression portion, the support portion coming into contact with the fiber bundle, the rotation suppression portion being disposed to face the support portion with a gap through which the fiber bundle passes, the gap having a distance greater than or equal to a thickness of the fiber bundle and less than or equal to a width of the fiber bundle.

Claims

1. A fiber bundle drawing apparatus drawing a fiber bundle from a bobbin around which the fiber bundle is traverse-wound, the fiber bundle drawing apparatus comprising: a bobbin holder configured to hold the bobbin in a rotatable state; a turning mechanism configured to receive the fiber bundle drawn from the bobbin, and to turn and deliver the fiber bundle, thereby reducing change in course of the fiber bundle in a direction parallel to a center axis of the bobbin; and a twist prevention mechanism provided between the bobbin holder and the turning mechanism in a path of the fiber bundle in the apparatus, and including a support portion and a rotation suppression portion, the support portion coming into contact with the fiber bundle, the rotation suppression portion being disposed to face the support portion with a gap through which the fiber bundle passes, the gap having a distance greater than or equal to a thickness of the fiber bundle and less than or equal to a width of the fiber bundle.

2. The fiber bundle drawing apparatus according to claim 1, wherein the twist prevention mechanism is configured to adjust the distance.

3. The fiber bundle drawing apparatus according to claim 1, wherein the support portion is a roll configured to be rotatable around an axis parallel to a direction of a rotation axis of the bobbin.

4. The fiber bundle drawing apparatus according to claim 1, wherein the rotation suppression portion includes a bar disposed in a posture in which a longitudinal direction of the bar is parallel to a direction of a rotation axis of the bobbin.

5. The fiber bundle drawing apparatus according to claim 1, wherein the twist prevention mechanism is configured to move in a direction parallel to a direction of a rotation axis of the bobbin by following change in course of the fiber bundle drawn from the bobbin.

6. A method of drawing a fiber bundle from a bobbin around which the fiber bundle is traverse-wound, the method comprising continuously drawing the fiber bundle from the bobbin by using the apparatus according to claim 1.

7. The method of drawing the fiber bundle according to claim 6, wherein the distance is set to less than or equal to 50% of a width of the fiber bundle.

8. A method of manufacturing a fiber composite material containing a fiber bundle and a resin impregnated into the fiber bundle, the method comprising drawing the fiber bundle from a bobbin around which the fiber bundle is traverse-wound, by using the method of drawing the fiber bundle according to claim 6.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 is a schematic view illustrating one embodiment of a fiber bundle drawing apparatus according to a present embodiment.

[0041] FIG. 2 is a schematic view illustrating one embodiment of a twist prevention mechanism according to the present embodiment.

[0042] FIG. 3A is a plan view illustrating another embodiment of the twist prevention mechanism.

[0043] FIG. 3B is a cross-sectional view of the twist prevention mechanism in FIG. 3A taken along line A-A.

[0044] FIG. 4A is a plan view illustrating still another embodiment of the twist prevention mechanism.

[0045] FIG. 4B is a cross-sectional view of the twist prevention mechanism in FIG. 4A taken along line B-B.

[0046] FIG. 5 is a schematic view of a fiber bundle drawing apparatus including the twist prevention mechanism illustrated in FIG. 4A and FIG. 4B.

[0047] FIG. 6 is a flowchart illustrating a method of manufacturing a fiber composite material.

DETAILED DESCRIPTION

[0048] In the following, to facilitate understanding, the present invention is described with reference to drawings as appropriate; however, the present invention is not limited by the drawings. Further, description about a specific embodiment illustrated in the drawings may also be understood as description of the present invention as a superordinate concept.

A. Embodiment

A1. Configuration and Functions of Fiber Bundle Drawing Apparatus:

[0049] FIG. 1 illustrates a fiber bundle drawing apparatus 10 according to a present embodiment. Note that drawings accompanying the present specification do not accurately reflect dimensions of the fiber bundle drawing apparatus and the fiber bundle. The fiber bundle drawing apparatus 10 is an apparatus drawing a fiber bundle 1 from a bobbin 2 around which the fiber bundle 1 is traverse-wound. The fiber bundle 1 has a laterally-elongated cross-sectional shape. In the present specification, the term traverse winding means an aspect of winding in which a fiber bundle is wound while reciprocating winding positions along a center axis of a bobbin. In the traverse winding, when the fiber bundle is wound around the bobbin by one round, a position of the fiber bundle at the end of winding is shifted by a width of the fiber bundle or more from a position of the fiber bundle at the beginning of winding.

[0050] In the present specification, the term width of fiber bundle means a length of the longest line segment among line segments each connecting optional two points positioned on an outer edge of a region occupied by the fiber bundle, in a cross-section perpendicular to a longitudinal direction of the fiber bundle. The term thickness of fiber bundle means a length of the longest line segment among line segments each connecting two points that are positioned on the outer edge of the region occupied by the fiber bundle and positioned along a direction perpendicular to the line segment defining the width of the fiber bundle, in the cross-section perpendicular to the longitudinal direction of the fiber bundle. The width of the fiber bundle and the thickness of the fiber bundle are measured in a state where the fiber bundle is wound around the bobbin.

[0051] The fiber bundle drawing apparatus 10 includes a bobbin holder 3, a twist prevention mechanism 21, a turning roll 4, and a drive device 7 in order along a path of the fiber bundle 1 in the fiber bundle drawing apparatus 10. In the following, in the present specification, the fiber bundle drawing apparatus is simply referred to as drawing apparatus in some cases.

[0052] More specifically, the drawing apparatus 10 includes: the bobbin holder 3 to which the bobbin 2 is attached, wherein the bobbin 2 around which the fiber bundle 1 is traverse-wound; the turning roll 4 that is provided to have a center axis substantially orthogonal to a center axis direction of the bobbin 2, namely, a center axis direction of the bobbin holder 3, and removes a traverse component in the center axis direction of the bobbin holder from the fiber bundle 1 drawn from the bobbin 2; a free roll 5 that is a support portion provided between the bobbin holder 3 and the turning roll 4, namely, in a passage region of the fiber bundle 1 from the bobbin holder 3 to the turning roll 4, and supporting the fiber bundle by coming into contact with the fiber bundle 1 drawn from the bobbin 2; a fixed bar 6 that is a rotation suppression portion provided at a position facing the free roll 5 through the fiber bundle drawn from the bobbin; and the drive device 7 driving the fiber bundle.

[0053] In the present specification, the phrase axis A is substantially orthogonal to axis B means that, when the axis A is projected onto the axis B along a direction perpendicular to the axis B, an angle formed by the two axes is within a range of 90 degrees10 degrees.

[0054] The bobbin holder 3 holds the bobbin 2 in a rotatable state (see lower part in FIG. 1). More specifically, the bobbin holder 3 is a rod-like member holding the bobbin 2 from an inside of a hole provided in the bobbin 2. The bobbin holder 3 is configured so as to rotate the bobbin 2 in a circumferential direction of the bobbin 2. An unillustrated torque application motor is connected to a shaft of the bobbin holder 3 holding the bobbin 2. The torque application motor is configured to generate torque in a direction opposite to rotation of the bobbin 2 and to apply constant tension to the fiber bundle 1 when the fiber bundle 1 is drawn from the bobbin 2. In FIG. 1, a rotation axis when the bobbin holder 3 rotates the bobbin 2 is indicated by AR0. The rotation axis AR0 of rotation of the bobbin 2 is coincident with the center axis of the bobbin 2.

[0055] The twist prevention mechanism 21 prevents the fiber bundle 1 from being twisted. The twist prevention mechanism 21 is provided between the bobbin holder 3 and the turning roll 4 in the path of the fiber bundle 1 in the drawing apparatus 10 (see center part in FIG. 1). The twist prevention mechanism 21 includes the free roll 5 and the fixed bar 6.

[0056] FIG. 2 is a schematic view illustrating a configuration of the twist prevention mechanism 21. The free roll 5 comes into contact with the fiber bundle 1 drawn from the bobbin 2. More specifically, the free roll 5 is a roll configured to be rotatable around an axis substantially parallel to the center axis of the bobbin 2 (see middle right part in FIG. 1). As a result, the free roll 5 is configured to be rotatable around an axis parallel to the direction of the rotation axis AR0 of the bobbin 2. The free roll 5 is rotated with conveyance of the fiber bundle 1 in contact with the free roll 5. Such an aspect makes it possible to reduce a possibility that the fiber bundle 1 is damaged by contact with the free roll 5.

[0057] In the present specification, the phrase axis A is substantially parallel to axis B means that, when the axis A is projected onto the axis B along the direction perpendicular to the axis B, the angle formed by the two axes is 10 degrees or less.

[0058] The fixed bar 6 is disposed to face the free roll 5 with a gap G21 (see lower part in FIG. 2). More specifically, the fixed bar 6 is a columnar bar. The free roll 5 is configured to be rotatable, whereas the bar 6 is not rotatable. Therefore, the bar 6 is referred to as the fixed bar 6. The free roll 5 and the fixed bar 6 are mounted on the same holders 51. Such a configuration reduces the number of parts configuring the twist prevention mechanism 21. Further, adjustment of the gap G21 when the fiber bundle drawing apparatus 10 is installed is unnecessary.

[0059] The fixed bar 6 is installed at a position facing the free roll 5 with the fiber bundle 1 in between so as to be substantially parallel to a center axis of the free roll 5. In other words, the fixed bar 6 is disposed in a posture in which a longitudinal direction is parallel to the direction of the rotation axis AR0 of the bobbin 2 (see middle right part in FIG. 1). Such an aspect makes it possible to simplify the configuration of the fixed bar 6 that has a low possibility of coming into contact with the fiber bundle 1, as compared with the free roll 5.

[0060] A surface of the free roll 5 and a surface of the fixed bar 6 are separated by a distance S21 that is greater than or equal to a thickness T1 of the fiber bundle 1 and less than or equal to a width W1 of the fiber bundle 1. When the fiber bundle 1 passes through the gap G21 between the fixed bar 6 and the free roll 5, the fiber bundle 1 is prevented from being twisted. Further, the twist prevention mechanism 21 is provided at a position where the fiber bundle 1 is peeled from the surface of the bobbin 2 or at a position that is higher than that position and is lower than the turning roll 4 (see middle part in FIG. 1). The fiber bundle 1 drawn from the bobbin 2 passes through the twist prevention mechanism, and then passes through the turning roll 4.

[0061] In the twist prevention mechanism 21, the fixed bar 6 as the rotation suppression portion is adjustably disposed at the position facing the free roll 5 as the support portion through the fiber bundle 1 drawn from the bobbin 2, so as to be separated from the free roll 5 by a distance that is greater than or equal to the thickness T1 of the fiber bundle 1 and is less than or equal to the width W1 (see arrow Aa6 in FIG. 1). More specifically, the twist prevention mechanism 21 includes a screw for adjusting the distance S21 between the fixed bar 6 and the free roll 5. Rotating the screw in a certain direction makes it possible to increase the distance S21 between the fixed bar 6 and the free roll 5. Rotating the screw in an opposite direction makes it possible to reduce the distance S21 between the rotation suppression portion and the support portion.

[0062] Such an aspect makes it possible to draw the fiber bundle 1 having various cross-sectional shapes from the bobbin 2 while maintaining the cross-sectional shape, and to cause the fiber bundle 1 to travel along a fixed course. Note that, in FIG. 1 and FIG. 2, illustration of the screw is omitted for facilitating understanding of the technique.

[0063] The turning roll 4 is a roll rotated around a direction perpendicular to the rotation axis AR0 of the bobbin 2. The turning roll 4 is provided between the twist prevention mechanism 21 and the drive device 7 in the path of the fiber bundle 1 in the drawing apparatus 10 (see center part in FIG. 1). The turning roll 4 receives the fiber bundle 1 drawn from the bobbin 2, turns the fiber bundle 1, and delivers the turned fiber bundle 1. The path of the fiber bundle 1 is bent through the turning roll 4. As a result, change in course of the fiber bundle 1 is reduced.

[0064] The fiber bundle 1 has a laterally-elongated cross-sectional shape (see left part in FIG. 2). The fiber bundle 1 is drawn from the bobbin 2 in a posture in which the longitudinal direction of the cross-section is substantially parallel to the rotation axis AR0 of the bobbin 2, and passes through the twist prevention mechanism 21 while substantially maintaining the posture (see middle part in FIG. 1). Thereafter, the fiber bundle 1 comes into contact with the turning roll 4 as a turning mechanism, is changed in conveyance direction by substantially 90 degrees, and is then delivered from the turning roll 4. As a result, out of the traverse components of the fiber bundle 1 on the bobbin 2, a component At2 in a direction parallel to the rotation axis AR0 of the bobbin 2 is replaced with change in incident angle of the fiber bundle 1 to the turning roll 4, in a plane perpendicular to the center axis of the turning roll 4. The course of the fiber bundle 1 delivered from the turning roll 4 is fixed relative to the turning roll 4 (see middle right part in FIG. 4). When the fiber bundle 1 comes into contact with a surface of the turning roll 4, and is wound around the surface of the turning roll 4 by about 90 degrees, the longitudinal direction of the cross-section of the fiber bundle 1 is changed to the direction substantially perpendicular to the rotation axis AR0 of the bobbin 2.

[0065] The drive device 7 conveys the fiber bundle 1 (see upper right part in FIG. 1). The fiber bundle 1 is drawn from the bobbin 2 by being held and conveyed by the drive device 7. The drive device 7 is provided on a downstream side of the turning roll 4. In other words, the drive device 7 is positioned on an opposite side of the turning roll 4 from the twist prevention mechanism 21 in the path of the fiber bundle 1 in the drawing apparatus 10. The drive device 7 includes a driving roll 8 and a nip roll 9.

[0066] The driving roll 8 has a center axis substantially parallel to the center axis of the turning roll 4. The driving roll 8 is connected to an unillustrated motor adjustable in speed. A rotation speed of the driving roll 8 is settable such that the fiber bundle 1 is drawn from the bobbin 2 at a desired drawing speed and is conveyed.

[0067] The nip roll 9 has a center axis substantially parallel to the center axis of the driving roll 8. The nip roll 9 presses the fiber bundle 1 against the driving roll 8. The drive device 7 is configured to cause the fiber bundle 1 having passed through the turning roll 4 to linearly travel along the fixed course.

[0068] In a case where the fiber bundle 1 is drawn using the drawing apparatus 10 according to the technique of the present disclosure, the following processing is performed. First, in the drive device 7, the driving roll 8 is rotated in a state where the fiber bundle 1 is nipped with the driving roll 8 and the nip roll 9. As a result, the bobbin 2 held by the bobbin holder 3 is rotated, and the fiber bundle 1 traverse-wound around the bobbin 2 is drawn from the bobbin 2. The fiber bundle 1 drawn from the bobbin 2 then reaches the twist prevention mechanism 21, and passes through the gap G21 between the free roll 5 and the fixed bar 6 while coming into contact with and being supported by the surface of the free roll 5 and being traversed along the direction of the rotation axis AR0 of the bobbin 2.

[0069] When passing through the above-described gap G21, the fiber bundle 1 comes into contact with the free roll 5, and travels along the surface of the free roll 5. As a result, irrespective of an outer diameter of the bobbin 2 around which the fiber bundle 1 is wound, a traveling position is fixed to a point where the fiber bundle 1 comes into contact with the free roll 5, in the direction of the center axis of the turning roll 4. Further, the fiber bundle 1 drawn while being traversed along the surface of the free roll 5 passes through the turning roll 4 that intersects with the center axis of the bobbin 2 at 90 degrees. As a result, the traverse component in the center axis direction of the bobbin 2 is removed, and the traveling position in the center axis direction of the bobbin 2 is fixed to a point where the fiber bundle 1 comes into contact with the turning roll 4. In the present specification, the term traverse component means change in course with the lapse of time when the fiber bundle traverse-wound around the bobbin is drawn from the bobbin. Such change in course includes change in a direction parallel to the center axis of the bobbin and change in a direction perpendicular to the center axis of the bobbin. The turning roll 4 reduces the change in course in the direction parallel to the center axis of the bobbin. Note that, generally, the change in course of the fiber bundle drawn from the bobbin may be substantially regarded as the change in the direction parallel to the center axis of the bobbin in most cases in the relatively short run; however, in the relatively long run, the change in course of the fiber bundle drawn from the bobbin may include change in the direction perpendicular to the center axis of the bobbin due to change in winding diameter of the bobbin occurring with drawing of the fiber bundle.

[0070] Since the fixed bar 6 is provided while maintaining the certain gap G21 with the free roll 5, the following effects are achievable. Even in a case where the fiber bundle 1 traveling following free roll 5 is loosened and nearly flutters due to change in tension caused by periodic change in distance from the bobbin 2 to the turning roll 4, the fiber bundle 1 comes into contact with the fixed bar 6, and rotation of the fiber bundle 1 is suppressed. Therefore, the fiber bundle 1 does not flutter, namely, is not rotated in the above-described gap G21. As a result, unstable twist does not occur on the fiber bundle 1 at a position between the free roll 5 and the turning roll 4, and a state of being turned by 90 degrees is stably continued. Therefore, the fiber bundle 1 may maintain the flat rectangular cross-sectional shape on the bobbin 2. In addition, meandering with twist of the fiber bundle does not occur, and the fiber bundle may stably travel in a linear shape on the downstream of the turning roll 4.

[0071] In the fiber bundle drawing apparatus 10 according to the present embodiment, the turning roll 4 may reduce change in course of the fiber bundle 1 mainly in the direction of the rotation axis AR0 of the bobbin 2. Further, on the upstream of the turning roll 4, the free roll 5 may maintain the fixed path of the fiber bundle 1 in the direction in which the free roll 5 and the fixed bar 6 face each other. The fixed bar 6 may prevent the fiber bundle 1 from being twisted. As a result, it is possible to draw the fiber bundle that is traverse-wound around the bobbin 2 and has the laterally-elongated cross-sectional shape while maintaining the cross-sectional shape, and to cause the fiber bundle to travel along the fixed course.

[0072] The above-described change in tension is increased with increase in drawing speed of the fiber bundle 1. Therefore, with increase in drawing speed of the fiber bundle 1, a probability of occurrence of fluttering of the fiber bundle 1 causing twist is increased. However, in the case where the fiber bundle 1 is drawn using the drawing apparatus 10 according to the present embodiment, rotation of the fiber bundle 1 is suppressible irrespective of a speed condition. Therefore, even in a case where the fiber bundle 1 is drawn not only under a low-speed condition that the drawing speed of the fiber bundle 1 is about 10 m/minute, but also under a high-speed condition that the drawing speed of the fiber bundle 1 is 50 m/minute or more, furthermore 100 m/minute or more, it is possible to cause the fiber bundle 1 to stably travel without generating twist. Accordingly, the technique of the present disclosure is particularly suitable for stable traveling under the high-sped condition.

[0073] The turning roll 4 according to the present embodiment is also referred to as turning mechanism. The free roll 5 is also referred to as support portion. The fixed bar 6 is also referred to as rotation suppression portion.

A2. Modifications of Fiber Bundle Drawing Apparatus:

[0074] (1) The separation distance S21 between the free roll 5 and the fixed bar 6 is preferably less than or equal to the width of the fiber bundle 1 at which reverse rotation of the fiber bundle 1 by 90 degrees or more is suppressible in the gap G21. The separation distance between the free roll 5 and the fixed bar 6 is preferably less than or equal to 50% of the width W1 of the fiber bundle 1, and more preferably less than or equal to 25% of the width W1 of the fiber bundle 1. On the other hand, as the gap that enables the fiber bundle 1 to freely move in the center axis direction of the bobbin 2 without restraining the fiber bundle 1 on the free roll 5, the separation distance S21 between the free roll 5 and the fixed bar 6 is preferably greater than or equal to the thickness T1 of the fiber bundle 1. The width of the fiber bundle is generally 3 mm to 30 mm, and the thickness is generally 10 m to 2 mm. Therefore, the separation distance S21 between the free roll 5 and the fixed bar 6 is preferably set to 10 m to 30 mm.

[0075] (2) The angle formed by the center axis of the turning roll 4 and the center axis of the bobbin 2 is not required to be 90 degrees. However, to fix the traveling position of the fiber bundle 1 and to prevent meandering, the angle formed by the center axis of the turning roll 4 and the center axis of the bobbin 2 is preferably an angle close to 90 degrees.

[0076] (3) Each of the free roll 5 and the fixed bar 6 is preferably made of a metal, preferably has a surface subjected to hard chromium plating treatment or ceramic treatment, and preferably has a mat surface with a surface roughness (arithmetic average roughness described in JIS B 0601:1994) Ra of 0.8 to 1.6.

[0077] (5) FIG. 3A is a plan view illustrating another embodiment of the twist prevention mechanism. FIG. 3B is a cross-sectional view of the twist prevention mechanism in FIG. 3A taken along line A-A. In the present embodiment, as illustrated in FIG. 3A, the rotation suppression portion 6 is greater in width than the free roll 5 as the support portion. In other words, in the direction of the rotation axis of the free roll 5, a dimension of the rotation suppression portion 6 is greater than a dimension of the free roll 5. The rotation suppression portion 6 is a member including ends extending to respective sides of the free roll 5. The both ends of the free roll 5 are supported by the respective ends of the rotation suppression portion 6 extending to both sides of the free roll 5. In other words, the rotation suppression portion 6 also functions as a holder supporting the free roll 5. The twist prevention mechanism 21 may have a configuration in which, for example, holes or bearing holders are provided at both ends of the rotation suppression portion 6 and the free roll 5 is attached thereto. As illustrated in the cross-sectional view in FIG. 3B, a ridge line part of the rotation suppression portion 6 coming into contact with the fiber bundle 1, namely, a corner part facing the free roll 5 is preferably chamfered and rounded in order to suppress abrasion with the fiber bundle 1.

[0078] (6) FIG. 4A is a plan view illustrating still another embodiment of the twist prevention mechanism. FIG. 4B is a cross-sectional view of the twist prevention mechanism in FIG. 4A taken along line B-B. In the present embodiment, as illustrated in FIG. 4A, the twist prevention mechanism 21 is an integrated member installed so as to surround the fiber bundle 1 passing through the twist prevention mechanism 21. In other words, the support portion and the rotation suppression portion respectively correspond to one portion 5 and the other portion 6 of the same member. In the present embodiment, to suppress abrasion with the fiber bundle 1, a ridge line part of the twist prevention mechanism 21 facing the fiber bundle 1 is preferably chamfered and rounded as with the cross-sectional shape illustrated in FIG. 4B.

[0079] FIG. 5 illustrates a drawing apparatus 20 including the twist prevention mechanism according to the embodiment illustrated in FIG. 4A and FIG. 4B. As illustrated, in the drawing apparatus 20 according to the present embodiment, the structure of the twist prevention mechanism is simplified. Therefore, the number of members configuring the twist prevention mechanism is reduced. Further, adjustment of the gap G21 when the drawing apparatus 20 is installed is unnecessary.

[0080] In the drawing apparatus 20, the twist prevention mechanism 21 is configured to reciprocate in a direction parallel to the axis direction of the bobbin holder 3, namely, in a direction parallel to the direction of the rotation axis AR0 of the bobbin 2. As a result, the twist prevention mechanism 21 may follow the fiber bundle 1 traversed in the axis direction of the bobbin holder 3. More specifically, the twist prevention mechanism 21 is configured so as to move in a direction parallel to the axis direction of the bobbin holder, and is configured to reciprocate with the fiber bundle 1, in the direction parallel to the axis direction of the bobbin holder by coming into contact with the fiber bundle 1. In such a configuration, the twist prevention mechanism 21 moves in the direction parallel to the direction of the rotation axis AR0 of the bobbin 2 by following change in course of the fiber bundle 1 drawn from the bobbin 2. In FIG. 5, a moving direction of the twist prevention mechanism 21 is indicated by an arrow Af21.

[0081] A swing width of the fiber bundle 1 drawn from the bobbin 2 is varied depending on a width of the bobbin 2. Therefore, in the drawing apparatus in which the twist prevention mechanism 21 is fixed, it is necessary to prepare a plurality of twist prevention mechanisms 21 having various widths, and to exchange the plurality of twist prevention mechanisms 21 based on the width of the bobbin 2 attached to the drawing apparatus. In the above-described aspect, however, a movable distance of the twist prevention mechanism is sufficiently largely provided, which makes it possible to achieve the following effects without preparing the plurality of twist prevention mechanisms 21 corresponding to various widths of the bobbin 2. In other words, it is possible to attach the bobbin 2 having various widths to the fiber bundle drawing apparatus 10, and to draw the fiber bundle 1 traverse-wound around the bobbin 2 while maintaining the cross-sectional shape and to cause the fiber bundle 1 to travel along the fixed course.

[0082] On the other hand, the twist prevention mechanism 21 may include a driving mechanism moving the twist prevention mechanism 21 in the direction parallel to the axis direction of the bobbin holder 3, a video camera, and a control unit. In such an aspect, the control unit may control the driving mechanism based on a position of the fiber bundle 1 imaged by the video camera, and move the twist prevention mechanism 21 in the direction parallel to the axis direction of the bobbin holder 3.

[0083] (7) The drive device 7 is not limited to the above-described configuration, and may not include the nip roll 9, and may wrap the fiber bundle 1 around one or a plurality of driving rolls 8 at a fixed wrap angle. Further, the drive device 7 may be not provided, and the fiber bundle 1 may be directly received by a winding apparatus and directly wound around the bobbin 2.

A3. Method of Manufacturing Fiber Composite Material:

[0084] FIG. 6 is a flowchart illustrating a method of manufacturing a fiber composite material. The fiber composite material is manufactured through steps in the flowchart illustrated in FIG. 6. The manufactured fiber composite material contains the fiber bundle and a resin impregnated into the fiber bundle. In the present embodiment, the resin impregnated into the fiber bundle is a thermosetting resin. As fiber configuring the fiber bundle, carbon fiber, aramid fiber, glass fiber, silicon carbide fiber, alumina fiber, or the like is adoptable.

[0085] In step S100, the fiber bundle 1 is continuously drawn from the bobbin 2 around which the fiber bundle 1 is traverse-wound. In the processing in step S100, the fiber bundle drawing apparatus 10 according to the present disclosure is used (see FIG. 1 and FIG. 2). Performing such processing makes it possible to draw the fiber bundle 1 traverse-wound around the bobbin 2 and having the laterally-elongated cross-sectional shape while maintaining the cross-sectional shape, and to cause the fiber bundle 1 to travel along the fixed course.

[0086] In step S100, the distance S21 between the fixed bar 6 and the free roll 5 is set to 50% or less of the width W1 of the fiber bundle 1, for example, 5% of the width W1 of the fiber bundle 1 (see FIG. 2). When the distance S21 between the fixed bar 6 and the free roll 5 is set to 50% or less of the width W1 of the fiber bundle 1, the fixed bar 6 may effectively prevent the fiber bundle 1 from being twisted.

[0087] In step S200, the fiber bundle 1 is impregnated with the resin. More specifically, the fiber bundle 1 drawn from the bobbin 2 is caused to pass through a tank housing uncured thermosetting resin. As a result, the fiber bundle 1 is impregnated with the resin, and the fiber composite material is completed. Performing the processing in steps S100 and S200 makes it possible to manufacture the fiber composite material having a cross-sectional shape with a designed width and a designed thickness.

[0088] In step S300, the fiber bundle 1 impregnated with the resin is wound around a bobbin different from the bobbin 2 around which the fiber bundle 1 is traverse-wound in step S100.

[0089] As easily understood by those skilled in the art, the present invent is not limited to the embodiments. For example, it should be understood that, for example, appropriate change and application of combinations of the members, the configurations, and the like described in each of the embodiments, and appropriate replacement and application of the members, the configurations, and the like described in each of the embodiments with a well-known technique or members, configurations, and the like easily conceivable by those skilled in the art from a well-known technique are included in aspects of the present invention.

EXAMPLES

Example 1

[0090] Examples of the present disclosure are described in detail with reference to drawings. As the fiber bundle drawing apparatus, the apparatus 10 having the configuration illustrated in FIG. 1 was used. As the fiber bundle 1, a carbon fiber bundle having the number of single filaments of 36000, the width W1 of 10 mm, the thickness T1 of 120 m, tensile strength of 5800 MPa, and an elastic modulus of 295 GPa was used. As each of the support portion 5 and the rotation prevention portion 6 configuring the twist prevention mechanism 21, a free roll that had a diameter of 50 mm and in which a surface roughness Ra of a mat surface subjected to hard chromium plating treatment was 1.6 was used. The distance S21 of the gap G21 between the support portion 5 and the rotation suppression portion 6 was set to 300 m. In other words, in Example 1, the distance S21 of the gap G21 was 3% of the width W1 of the fiber bundle 1 and was 250% of the thickness T1 of the fiber bundle 1. As the turning roll 4, a free roll that had a diameter of 20 mm and in which a surface roughness Ra of a mat surface subjected to hard chromium plating treatment was 1.6 was prepared. The turning roll 4 was installed in a direction orthogonal to the center axis of the bobbin 2 at 90 degrees.

[0091] A camera was installed above the turning roll 4, and the shape of the fiber bundle 1 on the turning roll 4 was imaged. A state where the width W1 of the fiber bundle was contracted to 10% or less of the original width of the fiber bundle was defined as twist, and the number of times of occurrence of twist was measured. As a result of drawing the fiber bundle 1 by 300 m at 10 m/minute by using the drawing apparatus 10, the number of times of occurrence of twist was zero.

Example 2

[0092] The fiber bundle 1 was drawn from the bobbin under the same condition as Example 1 except that the drawing speed of the fiber bundle 1 was set to 300 m at 50 m/minute. As a result, the number of times of occurrence of twist was zero.

Example 3

[0093] The fiber bundle 1 was drawn from the bobbin under the same condition as Example 1 except that the drawing speed of the fiber bundle 1 was set to 300 m at 100 m/minute. As a result, the number of times of occurrence of twist was zero.

Comparative Example 1

[0094] The two free rolls 5 and 6 configuring the twist prevention mechanism 21 were detached from the fiber bundle drawing apparatus 10 used in Example 1, and the fiber bundle 1 was drawn by using the resultant fiber bundle drawing apparatus. The other conditions were the same as in Example 1. As a result, twist occurred five times.

Comparative Example 2

[0095] The fiber bundle 1 was drawn by 300 m at 50 m/minute. The other conditions are same as in Comparative Example 1. As a result, twist occurred 44 times.

Comparative Example 3

[0096] The fiber bundle 1 was drawn by 300 m at 100 m/minute. The other conditions are same as in Comparative Example 1. As a result, twist occurred 72 times.

Comparative Example 4

[0097] In the fiber bundle drawing apparatus 10 used in Example 1, the distance S21 of the gap G21 between the free roll 5 and the fixed bar 6 was set to 100 m. In other words, in Comparative Example 4, the distance S21 of the gap G21 was less than the thickness T1 of the fiber bundle 1. The fiber bundle 1 was drawn from the fiber bundle drawing apparatus 10 set in such a manner, by 300 mm at 50 m/minute. The other conditions were the same as in Example 1. As a result, twist occurred 80 times.

Comparative Example 5

[0098] In the fiber bundle drawing apparatus 10 used in Example 1, the distance S21 of the gap G21 between the free roll 5 and the fixed bar 6 was set to 11 mm. In other words, in Comparative Example 5, the distance S21 of the gap G21 was greater than the width W1 of the fiber bundle 1. The fiber bundle 1 was drawn from the fiber bundle drawing apparatus 10 set in such a manner, by 300 m at 50 m/minute. As a result, twist occurred 42 times.

[0099] It was confirmed from the above-described examples that, even in a case where the fiber bundle is drawn from the bobbin at high speed, using the technique according to the present disclosure makes it possible to draw the fiber bundle while maintaining a stable rectangular cross-sectional shape without generating twist. The apparatus according to the present disclosure is particularly useful for drawing a fiber bundle of reinforced fiber used for a fiber composite material, such as carbon fiber, aramid fiber, glass fiber, silicon carbide fiber, and alumina fiber, in particular, for drawing a carbon fiber bundle.

B. Other Embodiments

B1. Other Embodiment 1

[0100] (1) In the above-described embodiment, the rotation suppression portion is the rod-like fixed bar 6 (see center part in FIG. 1). However, as illustrated in FIG. 3, the rotation suppression portion may include a portion other than a rod-like portion.

[0101] (2) In the above-described embodiment, the twist prevention mechanism 21 is configured such that the distance between the rotation suppression portion and the support portion is adjustable by the screw. However, the twist prevention mechanism may be configured such that the distance between the rotation suppression portion and the support portion is adjustable by, for example, adjusting the number of spacers provided between the rotation suppression portion and the support portion.

[0102] (3) In the above-described embodiment, the turning mechanism is the turning roll 4. However, the turning mechanism is not particularly limited as long as the mechanism may reduce the traverse component of the fiber bundle, and may be an nonrotatable bar or a ring-like member. For example, the turning mechanism includes a yarn contact portion coming into contact with the fiber bundle, and the yarn contact portion may be a curved surface forming at least a part of a cylindrical shape including an axis in a direction different from the rotation axis of the bobbin. The fiber bundle drawn from the bobbin comes into contact with the turning mechanism along a yarn contact surface. As a result, the fiber bundle is turned between the bobbin and the turning mechanism, and the turned fiber bundle is delivered to the downstream. A direction of an axis of the yarn contact surface is preferably substantially orthogonal to the direction of the rotation axis of the bobbin. Further, the turning mechanism does not come into contact with the fiber bundle from one side, but comes into contact with the fiber bundle from the other side, which makes it possible to turn the fiber bundle and to deliver the fiber bundle. Such an aspect makes it possible to reduce risks of disconnection of the fiber bundle and a failure of the fiber bundle drawing apparatus due to catching of the fiber bundle by the turning mechanism.

[0103] (4) In the above-described embodiment, the turning roll 4 is described as a mechanism removing the traverse component from the fiber bundle 1 (see upper left part in FIG. 1). However, the turning mechanism may not completely remove the traverse component at the time of drawing the fiber bundle from the bobbin. In other words, it is sufficient for the turning mechanism to reduce change in course of the fiber bundle in the direction of the rotation axis of the bobbin.

[0104] Further, the turning member may include a plurality of turning members each including a curved surface having a fixed shape in a direction different from the direction of the rotation axis of the bobbin. At this time, the curved surfaces of the turning members are directed to directions different from one another, and gradually change a turning angle of the fiber bundle.

[0105] Further, to suppress change in course of the fiber bundle in the direction of the rotation axis of the bobbin in the steps on the upstream and to reduce influence on the steps on the downstream, the turning mechanism is preferably installed on the upstream close to the bobbin holder. In a passage region of the fiber bundle, a minimum device is preferably installed between the bobbin holder and the turning mechanism.

[0106] Further, to prevent the fiber bundle from being drastically turned and being twisted by the turn when the fiber bundle passes through the turning mechanism, a distance greater than or equal to 30 times the width of the fiber bundle is preferably secured between the turning mechanism and a device installed on the upstream side of the turning mechanism in a passage direction of the fiber bundle.

B2. Other Embodiment 2

[0107] In the above-described embodiment, the twist prevention mechanism 21 includes the screw for adjusting the distance S21 between the fixed bar 6 as the rotation suppression portion and the free roll 5 as the support portion (see middle left part in FIG. 2). However, the twist prevention mechanism may not include a function of adjusting the distance between the rotation suppression portion and the support portion (see FIG. 4A and FIG. 4B). For example, the separation distance between the support portion and the rotation suppression portion may be fixed as long as the apparatus operates based on the premise that the width and the thickness of the fiber bundle are fixed.

B3. Other Embodiment 3

[0108] In the above-described embodiment, the twist prevention mechanism 21 includes, as the support portion, the free roll 5 that is configured to be rotatable around the axis substantially parallel to the center axis of the bobbin 2 (see upper part in FIG. 2). However, the twist prevention mechanism may include, as the support portion, an nonrotatable member, for example, a fixed bar disposed in a posture in which a longitudinal direction is parallel to the direction of the rotation axis AR0. In other words, it is sufficient that the support portion is configured to come into contact with the fiber bundle.

B4. Other Embodiment 4

[0109] In the above-described embodiment, the twist prevention mechanism 21 includes, as the rotation suppression portion, the fixed bar 6 disposed in a posture in which the longitudinal direction is parallel to the direction of the rotation axis AR0 (see lower part in FIG. 2). However, the twist prevention mechanism may include, as the rotation suppression portion, a free roll configured to be rotatable around an axis substantially parallel to the center axis of the bobbin. In other words, one or both of the support portion and the rotation suppression portion may be configured as rotatable rolls, or one or both of the support portion and the rotation suppression portion may be configured as nonrotatable members.

[0110] However, the twist prevention mechanism is preferably configured not to come into contact with the fiber bundle from one side and to come into contact with the fiber bundle from the other side, in a state where the fiber bundle is not rotated as viewed from the conveyance direction. Such an aspect makes it possible to reduce risks of disconnection of the fiber bundle and a failure of the fiber bundle drawing apparatus due to catching of the fiber bundle by the twist prevention mechanism.

B5. Other Embodiment 5

[0111] In the still another embodiment described above, the twist prevention mechanism 21 moves in the direction parallel to the direction of the rotation axis AR0 of the bobbin 2 by following change in course of the fiber bundle 1 drawn from the bobbin 2 (see Af21 in FIG. 5). However, the twist prevention mechanism may be configured so as not to move in the direction of the rotation axis of the bobbin.

B6. Other Embodiment 6

[0112] In step S100 in the method of manufacturing the fiber composite material illustrated in FIG. 6, the case where the fiber bundle 1 is continuously drawn from the bobbin 2 around which the fiber bundle 1 is traverse-wound is described for facilitating understanding of the technique. However, the drawing of the fiber bundle may be stopped one or more times until all of the traverse-wound fiber bundle is drawn from the bobbin.

B7. Other Embodiment 7

[0113] In step S100 in the method of manufacturing the fiber composite material illustrated in FIG. 6, the distance S21 between the fixed bar 6 as the rotation suppression portion and the free roll 5 as the support portion is set to 5% of the width W1 of the fiber bundle 1 (see Aa6 in FIG. 2). However, the distance between the rotation suppression portion and the support portion may be set to the other value such as 2%, 3%, 5%, 10%, 20%, 30%, 50%, and 80% of the width of the fiber bundle. However, the distance between the rotation suppression portion and the support portion is preferably set to 2% to 20% of the width of the fiber bundle, more preferably set to 2% to 10% of the width of the fiber bundle, and further preferably set to 2% to 5% of the width of the fiber bundle.

B8. Other Embodiment 8

[0114] In the method of manufacturing the fiber composite material illustrated in FIG. 6, in step S100, the fiber bundle drawing apparatus 10 is used (see FIG. 1 and FIG. 2). However, when the fiber bundle is drawn from the bobbin around which the fiber bundle is traverse-wound, an optional apparatus and an optional drawing method according to the present disclosure, such as the fiber bundle drawing apparatus 20 may be used (see FIG. 3 to FIG. 5).

[0115] The present disclosure is not limited to the above-described embodiment, and may be realized with various configurations without departing from the gist of the present disclosure. For example, the technical features of the embodiment corresponding to the technical features in the aspects described in Summary may be appropriately replaced or combined in order to solve a part or all of the above-described issues or to achieve a part or all of the above-described effects. The technical features that are not described as essential in the present specification are appropriately deletable.

REFERENCE SIGNS LIST

[0116] 1 Fiber bundle [0117] 2 Bobbin [0118] 3 Bobbin holder [0119] 4 Turning roll (turning mechanism) [0120] 5 Free roll (support portion) [0121] 6 Fixed bar (rotation suppression portion) [0122] 7 Drive device [0123] 8 Driving roll [0124] 9 Nip roll [0125] 10 Fiber bundle drawing apparatus [0126] 20 Fiber bundle drawing apparatus [0127] 21 Twist prevention mechanism [0128] 51 Holder [0129] AR0 Rotation axis of bobbin [0130] Aa6 Arrow indicating adjustment of distance between fixed bar and free roll [0131] Af21 Arrow indicating moving direction of twist prevention mechanism [0132] At2 Arrow indicating component in direction parallel to rotation axis of bobbin, of traverse components of fiber bundle [0133] G21 Gap between fixed bar and free roll [0134] S21 Distance between fixed bar and free roll [0135] T1 Thickness of fiber bundle [0136] W1 Width of fiber bundle