JP2018177624A - Method for molding dry type glass short fiber mat, and manufacturing equipment - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique for manufacturing a glass fiber mat used for FRP molding, capable of bundling a binder with resource saving and energy saving without using water in a conventional manner.SOLUTION: A method for manufacturing a glass fiber mat comprises; spraying glass fiber on one conveyor while using two conveyors on a stainless steel net; spraying a binder for bonding between fibers; superimposing the other conveyor on the one conveyor to sandwich the glass fiber by the conveyors, and heating the conveyors through a plurality of heating rollers to melt the binder by a heating drum; and solidifying the binder by a cooling drum to produce the glass fiber mat. Using the method for manufacturing, the molding method and the equipment reduces a binder amount required for production to half and reduces energy to 1/10. The equipment comprises: a dry molding machine body 3 functionally constituted of a continuous conveyor consisting of a sandwich conveyor and a heating/cooling drum; a cutting machine 4 executing glass fiber high-speed cutting in a previous step and having improvement in reliability; a chamber room allowing uniform dispersion; and a winding equipment 8 having a high-speed winding function.SELECTED DRAWING: Figure 1

Description

    Glass fiber processing, chopped strand mat (CSM) molding

Yoshinori Nishino, Taitaga, Masami Kuwahara, Shinichi Tamura, Development of new mat binders and production equipment for glass fiber, GPI Journal Vol. 1, No. 1, pp. 65-68, 2015.3.6.

   For the production of glass fiber mats, equal weight of water is sprayed to cut glass fibers to make the fibers flexible, for example, at 450 g / m 2, approximately 3.5% of matt binder is sprayed, hot air heating at 200 ° C. 0.3 m / sec. The moisture was dried in about 1 minute, the binder was dissolved between the fibers, and mat cooling was performed by press-cooling bonding. The basis of this technology is how to effectively bond the fiber bundles together. That is, energy saving is required because efficient bonding (resource saving) and use of a large amount of water.

The present invention has a logic configuration that the binder can be drawn to the intersection between the fiber bundles by dispersing the cation ion-treated binder in the logic in which negative ions are concentrated at the intersection between fiber bundles using conventional water. They developed it about 30 years ago, but water spraying is indispensable in the method. The present invention has invented a method for efficiently collecting the binder at the fiber bundle intersection point by eliminating the use of water.

    In order to enable so-called dry molding, water dots are created at glass fiber bundle intersections where negative ions increase, and the same idea as in the logic for adsorbing cation plus ion powder is used to increase the intersection density of fiber bundles to a stainless steel conveyor. Focusing the binder to the fiber bundle intersection point without using water by means of heating and compression with a metal sandwich conveyor so that the glass fiber bundle intersection point becomes the energy where the binder gathers by giving positive ions opposite to the negative ions. To make it possible.

On the other hand, in addition to the electrical characteristics, the binder is likely to be peeled off and separated until it is dissolved. Therefore, the structure of a conveyor for enclosing a binder of about 150 μm in diameter between glass fibers does not apply to a conventional large chain-like structure. Furthermore, since it is necessary to hold | maintain the pinched fiber to heating and cooling consistently, dry molding poses a problem of the heating of a conveyor, and a cooling energy loss.

    The dry mat molding machine shown in FIG. 1 has overcome these problems. BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the dry-mat forming machine whole structure of this invention, and shows the whole from a glass fiber raw material to the product of the end objective, 2 and a CSM mat | matte product. Raw materials are received by being loaded on a pallet from which glass fiber-wound fibers can be pulled out from the inside in 3-4 stacked layers. Shipment products are transported at the same time as product thickness measurement in the width direction with product weighing carriages. 10. Measure the entire product weight with the weighing machine attached to the tip of the weighing crane, print the traceability data with the 10.1 inspection paper printer, paste it on the product, store it in a cardboard box and ship it. In the present invention, 6 glass fibers, 7 by air transporter, 4 by glass fiber feed tubes, 4 by CS cutter equipment, cut and added with a matt binder, 3 by hot pressing by dry mat molding machine main body A mat can be made 5, and is taken up by a product take-up facility. This bird's-eye view shows all the configurations. There are at least three operators shown in the drawing, and two are usually placed in the drawer.

  FIG. 2 is a plan view showing the basic functions of the conveyor for making products. The product mat of the dry mat forming machine is not to spray dry glue on a conventional lower surface mounted conveyor, but to configure a 2.3 heating and cooling drum to apply a 2.3 upper surface conveyor sandwich state press similar to the 2.3 lower surface. It is a production facility with a continuous conveyor by three-dimensional movement. 3.1 CS Cutter Scattering Hot fibers are sprayed from short-cut fibers into the short fibers cut from the 3.2 binder spraying port, heated and joined by joining and cooled, the binder is solidified, and 2 CS products are wound up to a maximum of 2.1 product rolls.

    FIG. 3 is a cross-sectional view showing a functional structure of the dry mat forming machine main body. Raw fiber is 6. 7. by air transporter. Transported by tubing 4. It is carried by CS cutter and cut into 4.1 CS scatter holes and dropped naturally, lower airflow on the lower part of 2.3 lower conveyer, air flow of free fall because there is less vacuum resistance at small points of the number of stacks. Apply a large amount of suction to homogenize the laminated glass fibers. The exhaust duct circulates and is led to the distribution hole, but one side is made of a back filter wall surface and is structured to release the pressure in the distribution hole. The opposite side of the 4.2 matte binder scattering holes is also of a slider structure that sprays and disperses the binder uniformly from the top. 2.3 CSM sandwiched by the upper conveyor is led to a plurality of 3.3 heating drums, given necessary heating and pressing time, cooled with 3.3 cooling drums, cut into product width with 2.2 end-cutting machine, 2.4 glass fibers The scraps that are sucked and opened by the chip suction fan and separated again by the 2.5 cyclone return to the CS cutter scattering hole. The conveyor drive operates the conveyor by contacting the upper drum with a belt or the like, or driving a chain. 2.7 Conveyor tension control rolls keep the necessary tension such as thermal expansion, and through the 2.1CSM product stock chamber, cut the product with the 5.2 size cutter with the 5.3 take-up motor by 5.4 take-up motor and take it out with the 5.4 product take-up transparent cover It is sealed except for the mouth, and 2.4 glass fiber suction fan prevents dust from being discharged from the winding chamber, enabling 5.1 product rolls per ton. And 9. Products are discharged by the product cart.

FIG. 4 is a partial cross-sectional view of the A / B / C / D of FIG. 3. The AA cross section comprises a 3.6 wall frame and a 3.5 horizontal support frame. The 2.3 upper and lower conveyors of the same structure are arranged above and below. There is also a frame of 3.3 heating drum interior in the 3.6 auxiliary frame in the BB cross section. The CC cross section shows that all 3.7 perimeter of the structure is the structure covered by the insulating wall panel. DD section shows that the 2.6 cooling fan is installed inside the 3.3 cooling drum.

FIG. 5 shows the detailed function and structure of the winding machine. 2. The CSM product is fixed by the expansion of the 5.5 internal pressure tube, which is provided on the inner side of the 5.6 fixed inner surface chuck, with a 5.4 paper tube (winding tube) pushed into the 5.1 take-up roll, pivoted 90 degrees, and 5.3 on the take-up drive roll. In the condition that the CSM product falls down and stops, the 5.1 take-up roll is lowered and the adhesive tape is applied to the paper surface or the adhesive is applied. 5.3 The operation of the take-up machine drive shaft takes up the 2.1 CSM product. Furthermore, this winding is applied with a winding auxiliary load, for example by a pneumatic motor, which is in the 5.9 winder frame, It has a structure that attempts to tighten the CSM product. DC motors, AC thermomotors and hydraulic motors are also used instead of pneumatic motors. The purpose is to obtain a tightening effect. Product withdrawal: 5.5 internal pressure tube depressurizing, 5.6 release of fixed internal chuck with spring back, separation of 5.1 take-up roll and 2.1 CSM product, 5.6 take-up roll, 5.6 take-out of 2.1 CSM product, 5.7 weighing machine 9. Move onto the product trolley.
5. Again, take-up the take-up roll by pressing the take-up roll in the direction opposite to the take-up roll pull-out direction of 5.6 take-up roll and turning the take-up frame of 5.9 to set the 5.4 paper tube. The damaged surface of the 5.1 take-up roll has an irregular groove which can be driven to rotate, and in the 5.9 winder frame, a tubular slice metal having a bearing which can be driven is mounted.
5.7 The weighing machine is movable with at least two points, and can be fixed to the carriage. The weight error in the axial direction is measured by weighing both ends of the CSM product to detect the product thickness in the width direction. If one side is reduced, the number of cut CS cutting machines is controlled to equalize. It is also possible to do these automatically. When manufacturing CSM products of 2 divisions and 3 divisions, cut the paper tube into a predetermined length, attach it, adjust the measuring instrument also so that the end can be measured, product width of 2.2 product width cutting roll Production is possible by adjusting the cutting blade. In addition, 10. Measure the final confirmation weight of the shipped product with the weighing machine attached to the measuring crane, attach the inspection sheet of the inspection sheet issuing printer of 10.1 to the product, and also carry out the traceability data input of the product.

FIG. 6 shows the structure of the forming machine drying conveyor. The common structure of the upper and lower 2.3 sandwich conveyors is a net material in which a piano wire made of, for example, 0.4 mm stainless steel, which is a material of the 2.9 conveyor chains and the 2.3 sandwich conveyors, is plain-woven at a pitch of about 2 mm. In order to make it a conveyor, integrate the net end and the chain by 2.8 conveyor and chain connection bolt. At this time, in the case where the end of the net has a double structure by folding back the net or sandwiching a thin reinforcing plate also leads to improvement in durability. In order to make it a conveyor, it is necessary to connect an endless net. The connection of the net is suitable for pinning with a reinforcing plate similar to the connection with the chain by a long hinge.
In order to improve the durability performance and the release of the CSM of the product, two rotary brush cleaning and release oil agent adhesion rolls are respectively attached to the upper and lower conveyors at one end of the conveyor and used.

  FIG. 7 is a detailed structure of the drying drum of the dry mat molding machine. It is a drum for heating and compressing the net conveyor with the desired two upper and lower 2.3 sandwich chains. 3.3 The drying drum is a welded cylinder of stainless steel punching metal wound around a drum frame sprocket. 3.4 Heavy load cam floor metal on each end support by both ends of 3 points, 3.9 only one end face is a sprocket It is structured to be inserted and driven. This drum has an independent frame structure, and is composed of a 3.6 end face frame (drum end face frame) and a 3.5 auxiliary frame. The 3.6 frame (wall frame) and the drum end frame are integrated by bolting. There are eight 3.8 heaters with 2 kw fins attached inside. As a result, the drum is heated from the inside, and the net conveyor to be wound is kept by the sprocket attached to the tension roller or the like for preventing the displacement in the width direction.

  FIG. 8 is a detailed view of the glass fiber cutting machine. A rotary blade fixed to a 4.1-1 drive shaft that communicates 4.19 mm cutters (9 mm cutter blade diameter of 66 mm, 4-divided cutting length 50 mm, 8-divided 25 mm) on two plate-shaped 4.1 frames The 4.3 urethane rubber rollers fixed by the 4.4-1 rubber roller shaft to the 4.3 opening and closing levers that open and close individually are attached so as to be able to open and close by the central axis 4.3-1 pressing roller bearing that they open and close. Glass fibers are pneumatically fed to the rotary blade from a 4.6-1 nozzle φ 8 mm. When rotation is stopped, the glass fiber that is sent contacts the blade and rubber and does not move in the stopped state, but when cutting rotation occurs, the glass fiber can be pulled out with almost no load by the function of the transporter, so the biaxial blade and rubber Local bending and cutting of surfaces can be performed. The cutter is a 4.6 traverser with five 5-piece 4.6-1 nozzles φ8 mm attached to prevent uneven surface wear on the rubber surface at the cutting site by traversing the 4.3-1 axis. The cutter is sealed with a 4.2-1 cutter cover attached to a 4.5 metal cover and a 4.4-2 rubber roll cover attached to a 4.3 open / close lever. To replace the 4.2 rotary blade, release the 4.5-1 M8 bolt, release the metal clamp, and pull out the 4.1-1 drive shaft to disassemble all rotary blades. For replacement of urethane rubber, disassembling can be done by releasing the lever by lifting the 4.3 opening / closing lever. At the same time, it is possible to clean up clogs such as glass fiber.

  FIG. 9 is a maintenance detail of the cutting machine. The necessary maintenance can be done mostly by opening and closing the levers, except replacing the rotary blade. Rubber rollers with a short durability can be particularly easily replaced. By lifting the lever, the cutting function is released, and it is possible to replace glass fiber debris or rubber. Incidentally, the opening / closing lever can be released by the air cylinder in conjunction with the yarn breakage detecting sensor, and the operation of the opening / closing lever for starting the cutting of the set glass fiber can be performed similarly. Furthermore, by stopping the glass fiber feed air, it is possible to interlock the opening / closing control of the feed air which can stop the glass fiber feed.

  FIG. 10 is a detailed structure of the air transporter. The fiber is inserted via a 6.3 thread breakage sensor, 6.7 vibration sensor (vibration detection), a 6.1 conduit, a suction port and an inlet processed by a 6.2 compressed air injection pipe, 1. glass material (roving) 7. tube inside It is a structure that leads to The tube material is fixed to 7.3 traverse with 6.6 hose band and 7.2 rubber packing with metal tube or nylon tube with carbon fiber in which static electricity can be prevented. 6.2 compressed air injection pipe is 7. Within at least 1/3 of the diameter of the tube, it is installed at a central portion at least 1.2 to 2 times the diameter and 5 to 15 times the diameter of the diverging lead-in tube, and can be sprayed toward the central portion. 7. The final end of the transporter jet part is drawn into the inside of the cutting machine, and the structure is such that the sending air becomes the cleaning and cutting fiber discharge of the cutting machine, and the feed air is automatically stopped by yarn breakage detection or sudden stop of the cutting machine. Make it possible to have a mechanism to

The effect of the invention is that the ion energy at which the glass fiber and the mat binder peel off is dispersed using the net conveyor after the glass fiber is dispersed and then the binder is dispersed to form a sandwich on the net conveyor, whereby the binder is released out of the net In order to prevent the problem, the density of the glass fiber bundle was increased by compression, and the number of contacts was increased, and at the same time the bonding area of the binder was enlarged, so that the conventional binder usage amount was halved.
Furthermore, the conventional drying energy that used water at the same weight ratio decreased sharply to 2/10 to 1/10, and the melt adhesion time of the binder could be shortened as well, so the production speed was 80 m with a heating conveyor length of 40 m. It turned out to be possible up to / min. That is, mat production has become possible with 10% energy at 10 times the speed of the prior art. Furthermore, thin mats (50 g / m 2 to 80 g / m 2) which were difficult by the conventional method can also be produced, and the amount of binder conventionally required is reduced by half to obtain the same rigidity and strength at 6%.

The net used for the conveyor is 0.4mm diameter stainless steel wire, and the conveyor with RS40 double pitch chain attached to the 2mm pitch plain weave net conveyor, one type of mat is 80g to 600g / m ² Mats can be produced. Necessary energy is reduced to 1/10 times on average, which is energy saving. Furthermore, when the width is 2.7 m, the production speed is up to 80 m / min with the installed power of about 200 kw. That is, the production of about 30,000 tons or more becomes possible, and the production amount of at least several times that of the conventional one becomes possible with an installation area of 1/5. The durability of the light-weight conveyor was considered to be a problem, but by setting the diameter of the drum to about 1 m and the diameter of the sub roller such as the tension roller to 300 mm, bending fatigue deterioration is eliminated and the durability withstands at least 4 to 6 months or more.

    Similar results were obtained when an emulsion mat binder was used in addition to the powder mat binder. Although the binder contains about 50 to 60% of water, the addition of a high temperature coagulant to the binder improves the binder effect at the glass fiber bundle intersection point compared to the powder binder, and conventionally 3.5% is required. The same effect was produced with the addition of 0.6% for the 450 # mat. This is also the same as the dry molding effect of the powder binder.

    The dry mat molding machine has no exhaust gas as fuel such as heavy oil and gas because all heating energy is electricity. In addition, the recycling of the end face chips was able to raise the material yield to almost 100%.

CSM: Chopped Strand Mat
CS: Chopped Strand
RS40: Standard of chain

Dry mat forming machine whole bird's-eye view: The whole bird's eye view when the dry mat forming machine is installed, showing the equipment necessary for making materials and products. The dry mat molding machine comprises a main body, CS cutter equipment and product winding equipment. Requires 3-4 operators. Stainless sandwich conveyor plan view: A plan view of a two-layer net conveyor, a heating drum, and a cooling drum which are the basis of production. Dry mat forming machine length direction whole front sectional structural drawing: Functional composition and structure details of the dry mat forming machine are shown. It usually consists of heating by eight heating drums and two closing drums. Dry Mat Forming Machine A / B / C / D Partial Cross-Sectional Structural Diagram: All structural members except for the basic frame are made of stainless steel to prevent contamination such as rust. The equipment consists of a structure that can be dismantled, moved and assembled. Dry mat forming machine Product structure of winding equipment: It is a structure provided with the winding start of the product from the set of paper tubes, and the winding and closing function. Quality control is managed by weight measurement. Dry mat forming machine length direction whole front sectional structural drawing: Since the conveyor for the dry mat forming machine is made of a stainless steel net, it is weak to a shearing force. As a countermeasure, attach chains to both ends and maintain homogeneity with sprockets attached to tension rollers. Detailed structure of the drying drum of the dry mat forming machine: The drying drum of the most important member of the dry mat forming machine is a cylindrical body of punching metal structure and is a single steel body connecting both ends by rolling roller bearings at both ends, heater inside Set up. The drum can be pulled out in response to the replacement of the conveyor required for maintenance. Glass fiber cutting detail structure of the dry mat forming machine: Glass fiber cutting machine with feeding function of glass fiber by 2 axes and transporter. Structure that provides maintenance and reliability. Maintenance details of the cutting machine: Maintenance is possible by operating the open / close lever. Detailed structure of glass fiber air transporter of dry mat molding machine: Fiber feeding device of structure that can be used during operation of operation lever that can set glass fiber, detect broken thread, and operate continuously.

Claims (6)

In the mat manufacturing method and equipment made of glass short fibers, after using two conveyors on the net, glass fiber is dispersed on one of the conveyors, then a binder for bonding between the fibers is dispersed and the other conveyor is overlapped. Heat and compress simultaneously through multiple heating rolls, melt the binder continuously while maintaining its state, bond between the fibers, compress and cool through the cooling roll, and fix the binder Manufacturing method and equipment characterized by dry molding a glass fiber mat.
For intra-tube air transport of glass fiber bundles, install a thread break sensor at the inlet of the lead-in tube, and use a metal tube or a plastic tube inside carbon fiber that can prevent static electricity, etc. Air pressure push-in air pipe into the diverging drawing-in port so that the inlet part is at least 1.2 to 2 times the diameter and 5 to 15 times the diameter from the inside of the tube, the air drawing-in pipe can be sprayed in the feed direction to the central part The final end is drawn into the inside of the cutting machine, and the structure that the sending air is the cleaning and cutting fiber discharge of the cutting machine, has a mechanism that automatically stops the feeding air by detecting breakage of thread and sudden stop of the cutting machine. An air transporter characterized in that it is also possible to have.
In a glass fiber bundle cutting machine, it consists of a roller with multiple blades, two rollers made of rubber rollers that press and deform the blades, and fiber feeding from the inside of the tube by air feeding, cutting by feed air It is possible to stop the rest by discharging the fiber and cooling the heat generation of rubber, high-speed pulling resistance of the fiber, stopping the feed air at the time of stopping, fixed drive rotation of the rotary blade and providing the rubber roller open / close shaft at about 45 degrees downward. The cutting pressure of this is a glass fiber cutting machine constructed by the weight of the opening and closing lever, and further, rubber rolls are installed horizontally and in parallel.   In heating and drying equipment using a drying drum and a sandwich conveyor, it has a punching metal material and a drum frame at both ends, a fin heater is embedded in the drum, and the rotating metal of the drum is friction-rolled by a plurality of rollers. A heating and drying conveyor drum characterized in that only the drum is rotated and the drive has a chain sprocket disposed at least on one side. In the glass fiber cutting chamber room equipment, a fiber cutting machine is provided on the conveyor at a height of at least 1 m or more in the upper stage of the sealed chamber room, and the falling stacking time of the conveyor bottom side is at least the conveyor operation speed is 0.5 seconds to 1 The induction suction air volume of the fiber dropped from the lower surface of the net conveyor is at least 6 times or more of the necessary fiber density dropped (6 times the volume of free fall volume air of 0.5 to 1 second). A suction fan is provided, a binder scattering hole is provided on one wall surface, and a ventilation wall of a bag filter is provided on the other wall surface, and a uniform dispersion can be performed in the glass fiber chamber room. .
In the glass fiber mat molding equipment, the mechanical structure is the same width as the outer wall material, the outer surface is panel structure with the heat insulation material and aluminum foil etc. enclosed inside, the structural frame has two side wall materials Has a basic structure frame, an intermediate frame connected by an auxiliary frame, and a conveyor attached heating heating large drum can be formed in another structure that can be put in and out, so that the drum can be dismantled and conveyor maintenance can be performed from the side. Glass fiber mat molding machine.

Images