CN1217778C - 用于制造纤维增强塑性材料的方法和设备 - Google Patents

用于制造纤维增强塑性材料的方法和设备 Download PDF

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CN1217778C
CN1217778C CN011253436A CN01125343A CN1217778C CN 1217778 C CN1217778 C CN 1217778C CN 011253436 A CN011253436 A CN 011253436A CN 01125343 A CN01125343 A CN 01125343A CN 1217778 C CN1217778 C CN 1217778C
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理查德·布吕塞尔
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Maschinenfabrik J Dieffenbacher GmbH and Co
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Abstract

本发明涉及一种用于制造纤维增强塑性材料的方法，该方法使用了一种塑料挤出机，其中，一个连续纤维条料通过一个供料装置和一个预热装置进入到塑料挤出机的供料口中，该连续纤维条料以其宽度平行于挤压轴并且几乎相切于喂料轴进入，而且围绕着挤压轴向前推进并进入到直径加大了的螺杆圆柱体的圆柱孔内，此外，在供料口中，还将液态塑料膜输送到挤压轴/片上，并且将所述纤维条料压入到塑料膜中，接着，将被塑料完全浸透或完全润透的纤维条料的单纤维从喂料和浸渍区段通过一个直径减小了的螺杆圆柱体引导到一个排出和输送区段中，并且作为可以继续加工的纤维增强塑性材料(塑化材料)排出。

Description

用于制造纤维增强塑性材料的方法和设备
本发明涉及一种用于制造纤维增强塑性材料的方法。本发明还涉及一种用于实现所述方法的设备。
从德国专利文献DE 198 36 787 A1中已知一种这样的方法。该方法和其中所述的塑料挤出机在实践中是可用的。但对于特殊的纤维条料和纤维材料来说，还有改进的余地，特别是在用纤维网或纤维絮层和一种液态塑料膜制造纤维增强塑性材料(塑化材料)方面。为了达到与使用DE 198 36 787 A1所述方法相同的效果，迄今使用了下列方法：
-天然纤维被熔化成半成品(粒状物)，例如作为棒状颗粒，或
-通过一种纤维填塞设备将这些纤维放到浸润装置中。以这样的方式得到的是一种很糟糕的浸润物品。
-或者将纤维网混以热塑纤维并且在变形过程中对其进行压制。
在这种已知的方法中和半成品的使用上存在的缺点是，成本高以及在变形过程中有附加的下脚料。
在纤维棒粒的熔化过程中，很小的熔化功率在保护纤维的熔化和用纤维填塞设备工作过程中将会出现严重的纤维损伤或糟糕的纤维浸润。
本发明的任务在于提出一种方法，该方法可以避免上述缺点并且特别是能在塑化材料中提高纤维含量，并且能更好地对其进行限定以及能够在用纤维网和纤维絮层制造塑化材料过程中实现生产能力提高。本发明的目的还在于提出一种用于实现所述方法的具有塑料挤出机的设备，该设备具有一个相匹配的挤出机外壳几何形状和所属的螺杆。
完成上述有关方法的任务的解决方案是提供一种用于制造纤维增强塑性材料的方法，该方法使用了一种塑料挤出机，其中，一个连续纤维条料通过一个供料装置和一个预热装置进入到塑料挤出机的供料口中，该连续纤维条料以其宽度平行于挤压轴并且几乎相切于喂料轴进入，而且围绕着挤压轴向前推进并进入到直径加大了的螺杆圆柱体的圆柱孔内，此外，在供料口中，还将液态塑料膜输送到挤压轴/片上，并且将所述纤维条料压入到塑料膜中，接着，在喂料和浸渍区段内部，还在挤压轴上以全面涂抹或整体涂抹的方式用液态塑料膜对所述纤维条料的单纤维进行湿润或浸润，随后将被塑料完全浸透或完全润透的纤维条料的单纤维从喂料和浸渍区段通过一个直径减小了的螺杆圆柱体引导到一个排出和输送区段中，并且作为可以继续加工的纤维增强塑性材料排出，其中，
带状的、以输入狭缝长度为宽度b制成的连续纤维网或纤维絮层是用天然纤维、化学纤维、玻璃纤维、矿物纤维、碳纤维、撕碎纤维(Reiβfaser)或金属纤维或其可能的组合制造的，它们被提供给具有液态塑料的塑料挤出机的一个狭缝状供料口，并且所述的纤维网或纤维絮层在螺杆圆柱体的扩大区域中通过刮板沿包角被压入到喂料轴的凹槽中和螺杆片上。
另一解决方案是提供一种用于制造纤维增强塑性材料的方法，该方法使用了一种塑料挤出机，其中，一个连续纤维条料通过一个供料装置和一个预热装置进入到塑料挤出机的供料口中，该连续纤维条料以其宽度平行于挤压轴并且几乎相切于喂料轴进入，而且围绕着挤压轴向前推进并进入到直径加大了的螺杆圆柱体的圆柱孔内，此外，在供料口中，还将液态塑料膜输送到挤压轴/片上，并且将所述纤维条料压入到塑料膜中，接着，在喂料和浸渍区段内部，还在挤压轴上以全面涂抹或整体涂抹的方式用液态塑料膜对所述纤维条料的单纤维进行湿润或浸润，随后将被塑料完全浸透或完全润透的纤维条料的单纤维从喂料和浸渍区段通过一个直径减小了的螺杆圆柱体引导到一个排出和输送区段中，并且作为可以继续加工的纤维增强塑性材料排出，其中，带状的、以输入狭缝长度为宽度b制成的连续纤维网或纤维絮层是用天然纤维、化学纤维、玻璃纤维、矿物纤维、碳纤维、撕碎纤维或金属纤维和其可能的组合制造的，它们被提供给具有液态塑料的塑料挤出机的一个狭缝状供料口，并且所述的纤维网或纤维絮层在螺杆圆柱体的扩大区域中通过刮板沿包角被压入到喂料轴和同步轴的凹槽中和螺杆片上。
对于纤维网和/或纤维絮层的喂料来说，有利的方式通常是，将第二螺杆轴区域的外壳的直径也加大。根据纤维的组织结构和浸润性质，在所述喂料区域内的直径加大部分或多或少地伸到下游封闭区域中。特别是在带状的网和/或絮层具有较高的承受拉力的能力情况下，在不用刮板进行作业时，可以改进浸润过程，因为熔融的塑料带/塑料膜在喂料区域被卷入并受纤维带挤压。相反，在网和/或絮层具有较低的抗拉强度情况下，有利的方式是，在喂料轴上使用一个刮板并且在对应于两个螺杆的喂料外壳中设置直径加大部分，其中，在第二轴区域中的直径加大部分可以较小，并且特别可以偏心布置在喂料轴附近。就是说，为了在旋转过程中，在外壳的直径加大部分上，不会不出现材料堆积在喂料轴的螺杆片上的现象，在接收新的熔融塑料带之前，螺杆的外壳内孔减小到螺杆直径。这最好借助一个置入的刮料板来实现。所述刮料板还可以用相对于螺杆片的小间隙来实现。
为了实现上述方法，提供一种制造纤维增强塑性材料的设备，它包括一个塑料熔化挤出机和一个塑料挤出机，在通向塑料挤出机的输料线上设置有对所述连续纤维条料进行加热的加热装置，在塑料挤出机中设置有一个用于输入的纤维条料的浸渍装置，其中，所述塑料挤出机包括一个带有两个孔和两个旋转驱动的挤压轴的外壳，在所述外壳内设置有一个用于将纤维条料输入到所述螺杆孔中的供料口，所述塑料挤出机的长度分成一个喂料和浸渍区段以及一个排出和输送区段，其中，用于喂料和浸渍区段m的壳体具有直径加大的圆柱孔径，所述供料口在其纵向延长线上平行于相切于挤压轴的轴，并且在排出和输送区段中，所述圆柱孔则具有通常的直径，其中，为了将用天然纤维、化学纤维、玻璃纤维、矿物纤维、碳纤维、撕碎纤维或金属纤维制成的带状连续纤维网或纤维絮层输入到塑料挤出机，所述供料口平行于挤压轴并且呈狭缝状布置在喂料轴上方，其中，所述输入狭缝长度大约为纤维网或纤维絮层的宽度b，所述外壳内孔的加大了约2至20mm的最好是偏心布置的直径D沿着包角重新设置为通常的直径d，或沿着包角在同步轴和/或在喂料轴上布置一些刮板。
借助本发明的方法和具有塑料挤出机的设备，还能实现以下的优点或改进：
-在最终产品中可以具有较高和精确限定的纤维含量并且所有纤维都可以具有良好的浸润量，
-在塑化材料的制造过程中可以实现很高的渗透率并且因此很大程度提高生产率，
-不用生产半成品，可以用直接的方法直接用原料球通过制网机进行浸润并制造塑化材料，其中，对所述纤维网没有很高有关输送稳定性的要求，并且
-借助本发明的塑化技术还可以实现挤压，借此可以将一些筋条和榫舌成形在压制件中。
作为有利的方式还在于，在进入到挤出机之前，对所述纤维网/絮层和/或配纱(Gelege)的单位面积重量或每米重量进行连续称重，并且通过一种向后和/或向前定向的级联调节策略，将一定百分比的纤维加重率保持在塑化材料中并且将塑化材料的重量保持在很窄的误差范围内。有利的方式还在于，可以将成筒/卷提供的带状纤维网和/或纤维絮层供给到挤出机，在此，它们将通过人工或自动更换筒/卷形成连续的纤维网或纤维絮层，以供给挤出机，或者通过撒布纤维的方式将所述纤维网直接成形在一个输送带上，并且提供给所述挤出机。也可以在所述纤维网和/或纤维絮层进入到所述挤出机中以前，直接在生产线内对其进行干燥。另外，在进入到所述挤出机中以前，最后还包括对纤维网进行干燥的可能性，并且所述纤维网幅面或纤维絮层幅面还可以作为输送幅面用于撒布的短纤维、长纤维颗粒、颗粒、回收片料或填充料。
本发明主题的其他优选措施和结构进一步见说明书及其附图。
其中：
图1是实现本发明所述方法的设备沿图2中B-B剖面的侧视图，
图2是本发明设备沿图1中的A-A剖面的视图，
图3是本发明设备的第二实施例，
图4是本发明设备的第三实施例，并且
图5是本发明设备的第三实施例，但具有进料口颚板。
图1是实现本发明所述方法的设备，它包括塑料挤出机1和塑料熔化挤出机30。在图2至5中所描述的本发明所述塑料挤出机1是具有长度L的双轴挤出机。如图1所示，塑料挤出机1的长度分成两个功能区域并且为此相应设计成一个喂料和浸渍区段m以及一个排出和输送区段n。在端部安装了一个出口喷嘴8用于最终产品24(纤维增强塑性材料)的成形排出。图2是沿图1中的A-A剖面的视图，显示了所述纤维网或纤维絮片14喂入到供料口18中的情况和布置在供料口18左侧的排出喷嘴13。所述塑料挤出机1还包括在喂料和浸渍区段m上的具有外壳内孔2和3以及用于喂料轴5和同步轴4的挤压轴6和7的外壳25、具有用于排出和输送区段n的挤压轴4′和5′的内孔2′和3′的螺杆外壳26。根据图1，用于对塑料进行加工的塑料熔化挤出机30包括用于塑料颗粒供给的料斗19和塑料输送装置29。此外该塑料输送装置29还通过塑料输入装置28将加工好的塑料膜11输送到排出喷嘴13中。所述驱动装置20用于驱动挤压轴4/5和4′/5′。在生产过程中，所述的纤维网14在输送运动中被输送到喂料通道27中并从此处借助所述塑料挤出机1的螺杆通过最好被倒圆的螺杆片9和被倒圆的螺杆底22朝产品排出方向运送。此外所述纤维网14还在外径和内径间的螺杆片9上做时上时下的运动并且在同向旋转的双螺杆挤出机1中总是在从喂料轴5到同步轴4的方向上和相反的方向上进行移送。这就是说，所述纤维网14以旋转方式，根据纤维幅面的宽度b，或多或少有所重叠地向出口喷嘴8的方向上输送。在这种滑动输送运动过程中，夹带有所述纤维网14的液态塑料膜11摩擦进入到具有单纤维的纤维网14中。
如图1和2所示进一步可以见到的那样，根据第一实施例，所述纤维网14以其宽度b进入到塑料挤出机1的供料口18的入口中，该宽度b平行于挤压轴6和7并且大致相切于喂料轴5，而且向前推进着且重叠地以包角围绕在同步轴4上，并且所述纤维网从直径D加大了约2至20mm的、必要时偏心布置的外壳内孔2和3喂入。与此同时在供料口18中，液态塑料膜11直接被涂布到纤维网14的一个平面上，并且这种涂布是通过将纤维网带挤压到从左边的排出喷嘴13落到喂料轴5上的液态塑料膜11里实现的。此外在喂料和浸渍区段m内部，还以涂抹两个平面的方式在挤压轴4和5上用液态塑料膜11对所述纤维网14进行湿润或浸润。接下来，将被塑料膜11完全浸透或完全润透的纤维网14的单纤维从喂料和浸渍区段m借助螺杆片23引导到外壳内孔2′和3′的直径减小为d的排出和输送区段n中，在容易浸润的纤维条料塑料熔融体相适应的组成情况下，根据第二和第三实施例，所述纤维网14只以简单围绕着具有外壳内孔2和3的直径加大为D的喂料轴5和同步轴4的形式输入即可，其中在第二实施例中，借助一个刮板10将所述纤维网14压入到凹槽中以及压到喂料轴5的螺杆片23上，而在第三实施例中，则借助一个刮板15将所述纤维网14压入到凹槽中以及压到喂料和同步轴5和4的螺杆片23上。
适当的方式是，在供料口18中，通过一个倒圆的进料口侧壁12可以将所述纤维网14引导到喂料轴5上。根据图5，一种有关纤维网14无障碍进入到供料口18中的改进和一种对这一区域进行清洁的可能性在于，设置一个可移入和移出或者可进入和抽出的进料口颚板16来取代所述的进料口侧壁12。该进料口颚板16相对于所述螺杆外壳25是绝热的，并且借助一个孔17可以进行加热或冷却，而且可以设定到一个大约在纤维网14的粘合温度以下的温度上。此外，有利的方案是，所述进料口颚板16装备有一个振动式驱动装置，并且所述刮板10和15被制成可更换的刮板21并且
在采用由纤维碎片制成的纤维网14时，在供料口18后的下游区域，缩小的直径d呈旋转方向上的螺旋状结束。
标号一览表
1.塑料挤出机
2.外壳内孔(浸渍部分)
3.外壳内孔(浸渍部分)
4.同步轴(浸渍部分)
5.喂料轴(浸渍部分)
6.挤压轴
7.挤压轴
8.出口喷嘴
9.倒圆的螺杆片
10.刮板
11.液态塑料膜
12.倒圆的进料口侧壁
13.排出喷嘴
14.纤维网
15.刮板
16.进料口颚板
17.进料口颚板16上的孔
18.供料口
19.料斗
20.挤压轴4、5的驱动装置
21.刮板
22.螺杆底
23.螺杆片
24.产品，塑化材料
25.m段螺杆外壳
26.n段螺杆外壳
27.喂料通道
28.通向排出喷嘴13的塑料输入装置
29.通向塑料挤出机的塑料输送装置
30.塑料熔化挤出机
b纤维幅面的宽度
D缠绕孔径
d切割孔径
m喂料和浸渍区段
n排出和输送区段
L塑料挤出机的长度

Claims (17)

1.一种用于制造纤维增强塑性材料的方法，该方法使用了一种塑料挤出机，其中，一个连续纤维条料通过一个供料装置和一个预热装置进入到塑料挤出机的供料口中，该连续纤维条料以其宽度平行于挤压轴并且几乎相切于喂料轴进入，而且围绕着挤压轴向前推进并进入到直径加大了的螺杆圆柱体的圆柱孔内，此外，在供料口中，还将液态塑料膜输送到挤压轴/片上，并且将所述纤维条料压入到塑料膜中，接着，在喂料和浸渍区段内部，还在挤压轴上以全面涂抹或整体涂抹的方式用液态塑料膜对所述纤维条料的单纤维进行湿润或浸润，随后将被塑料完全浸透或完全润透的纤维条料的单纤维从喂料和浸渍区段通过一个直径减小了的螺杆圆柱体引导到一个排出和输送区段中，并且作为可以继续加工的纤维增强塑性材料排出，其特征在于：带状的、以输入狭缝长度为宽度b制成的连续纤维网或纤维絮层是用天然纤维、化学纤维、玻璃纤维、矿物纤维、碳纤维、撕碎纤维或金属纤维或其可能的组合制造的，它们被提供给具有液态塑料的塑料挤出机的一个狭缝状供料口，并且所述的纤维网或纤维絮层在螺杆圆柱体的扩大区域中通过刮板沿包角被压入到喂料轴的凹槽中和螺杆片上。
2.一种用于制造纤维增强塑性材料的方法，该方法使用了一种塑料挤出机，其中，一个连续纤维条料通过一个供料装置和一个预热装置进入到塑料挤出机的供料口中，该连续纤维条料以其宽度平行于挤压轴并且几乎相切于喂料轴进入，而且围绕着挤压轴向前推进并进入到直径加大了的螺杆圆柱体的圆柱孔内，此外，在供料口中，还将液态塑料膜输送到挤压轴/片上，并且将所述纤维条料压入到塑料膜中，接着，在喂料和浸渍区段内部，还在挤压轴上以全面涂抹或整体涂抹的方式用液态塑料膜对所述纤维条料的单纤维进行湿润或浸润，随后将被塑料完全浸透或完全润透的纤维条料的单纤维从喂料和浸渍区段通过一个直径减小了的螺杆圆柱体引导到一个排出和输送区段中，并且作为可以继续加工的纤维增强塑性材料排出，其特征在于：带状的、以输入狭缝长度为宽度b制成的连续纤维网或纤维絮层是用天然纤维、化学纤维、玻璃纤维、矿物纤维、碳纤维、撕碎纤维或金属纤维或其可能的组合制造的，它们被提供给具有液态塑料的塑料挤出机的一个狭缝状供料口，并且所述的纤维网或纤维絮层在螺杆圆柱体的扩大区域中通过刮板沿包角被压入到喂料轴和同步轴的凹槽中和螺杆片上。
3.根据权利要求1或2的方法，其特征在于：在进入到挤出机之前，对所述纤维网和/或配纱的单位面积重量或每米重量进行连续称重并且通过一种向后和/或向前定向的级联调节策略将一定百分比的纤维加重率保持在纤维增强塑性材料中并且将纤维增强塑性材料的重量保持在很窄的误差范围内。
4.根据权利要求1或2的方法，其特征在于：所述连续纤维网用纤维原料球在制网机中制成并且直接供应给塑料挤出机。
5.根据权利要求1或2的方法，其特征在于：通过人工或自动更换筒/卷，所述纤维网或纤维絮层的端部形成连续的纤维网或纤维絮层，用于供给挤出机。
6.根据权利要求1或2的方法，其特征在于：通过撒布纤维的方式将所述纤维网直接成形在一个输送带上并且提供给所述挤出机。
7.根据权利要求1或2的方法，其特征在于：所述纤维网和/或纤维絮层在进入到所述挤出机中以前，直接在生产线内进行干燥。
8.根据权利要求1或2的方法，其特征在于：所述纤维网和/或纤维絮层在进入到所述挤出机中以前，在生产线内进行预热。
9.根据前述权利要求之一的方法，其特征在于：所述纤维网幅面或纤维絮层幅面还作为输送幅面用于撒布的短纤维、长纤维颗粒、颗粒、回收片料或填充料。
10.一种制造纤维增强塑性材料的设备，它包括一个塑料熔化挤出机和一个塑料挤出机，在通向塑料挤出机的输料线上设置有对所述连续纤维条料进行加热的加热装置，在塑料挤出机中设置有一个用于输入的纤维条料的浸渍装置，其中，所述塑料挤出机包括一个带有两个孔和两个旋转驱动的挤压轴的外壳，在所述外壳内设置有一个用于将纤维条料输入到所述螺杆孔中的供料口，所述塑料挤出机的长度分成一个喂料和浸渍区段以及一个排出和输送区段，其中，用于喂料和浸渍区段m的壳体具有直径加大的圆柱孔径，所述供料口在其纵向延长线上平行于相切于挤压轴的轴，并且在排出和输送区段中，所述圆柱孔则具有通常的直径，所述设备用于实现权利要求1至10所述的方法，其特征在于：为了将用天然纤维、化学纤维、玻璃纤维、矿物纤维、碳纤维、撕碎纤维或金属纤维制成的带状连续纤维网或纤维絮层(14)输入到塑料挤出机(1)中，所述供料口(18)平行于挤压轴(6，7)且狭缝状布置在喂料轴(5)的上方，其中，所述输入狭缝长度为纤维网或纤维絮层(14)的宽度(b)，所述外壳内孔(2，3)的加大了2至20mm的是偏心布置的直径(D)沿着包角重新设置为通常的直径(d)，沿着包角在同步轴和/或在喂料轴(4，5)上布置一些刮板(10/15)。
11.根据权利要求10的设备，其特征在于：通过输入狭缝的一个倒圆的进料口侧壁(12)将所述连续纤维网或连续纤维絮层(14)引导到供料口(18)中。
12.根据权利要求10的设备，其特征在于：在采用由纤维碎片制成的纤维网(14)时，在供料口(18)后的下游区域，缩小的直径(d)呈旋转方向上的螺旋状结束。
13.根据权利要求10的设备，其特征在于：在所述供料口(18)喂料侧设置一个装备有一个振动式驱动装置的可移动的进料口颚板16。
14.根据权利要求10的设备，其特征在于：所述进料口颚板(16)相对于所述螺杆外壳(25)是绝热布置的。
15.根据权利要求10的设备，其特征在于：所述进料口颚板(16)的温度设定在所述纤维网(14)的粘合温度以下。
16.根据权利要求10的设备，其特征在于：在供料口(18)中必要时设置一些可替换的刮板(21)。
17.根据权利要求10至16之一的设备，其特征在于：所述刮板(10，15和21)相对于螺杆片(23)具有间隙，该间隙小于在加大的外壳内孔(2，3)处的间隙。
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