KR101650737B1

KR101650737B1 - Apparatus and method for manufacturing complex materials with unidirectional continuous fiber reinforced thermoplasticity resins sheet composite

Info

Publication number: KR101650737B1
Application number: KR1020140153520A
Authority: KR
Inventors: 이재섭; 변의현; 김동욱
Original assignee: 한화첨단소재 주식회사
Priority date: 2014-11-06
Filing date: 2014-11-06
Publication date: 2016-08-25
Also published as: KR20160054660A

Abstract

More particularly, the present invention relates to an apparatus and a method for manufacturing a unidirectional continuous fiber-reinforced thermoplastic composite material having a high mechanical strength and a high degree of freedom in design, and a weak point ) Continuous unidirectional continuous fiber-reinforced thermoplastic composite material.
INDUSTRIAL APPLICABILITY According to the present invention, a unidirectional continuous fiber-reinforced thermoplastic composite material having a high mechanical strength and low cost can be produced.

Description

[0001] APPARATUS AND METHOD FOR MANUFACTURING COMPLEX MATERIALS WITH UNIDIRECTIONAL CONTINUOUS FIBER REINFORCED THERMOPLASTICITY RESINS SHEET COMPOSITE [0002]

More particularly, the present invention relates to an apparatus and a method for manufacturing a unidirectional continuous fiber-reinforced thermoplastic composite material having a high mechanical strength and a high degree of freedom in design, and a weak point ) Continuous unidirectional continuous fiber-reinforced thermoplastic composite material.

Thermoplastic composites are the focus of attention because of the emergence of lightweighting in the automotive sector, especially in the industrial sector as a whole.

In the past, substitution of lightweight metal replacement technology was mainly made up of recycled resin products and thermoplastic resin injection, but it lacks strength and stiffness.

In the following areas, SFT (Short-Fiber Reinforced Thermoplastic), a compound material in which reinforcing materials such as glass fiber and carbon fiber are dispersed in a short fiber form, is mainly made up, but these materials are also difficult to replace metals It is true.

In order to solve this problem, a thermoplastic composite reinforced with long fibers or continuous fibers has been used.

More specifically, it is classified into a thermoplastic composite reinforced with non-continuous fibers and a thermoplastic composite reinforced with continuous fibers.

The thermoplastic composites reinforced with non-continuous fibers are classified into GMT (Glass Mat Thermoplastic), G-LFT (Granule-Long Fiber Reinforced Thermoplastic) and LFT-D (Direct Long Fiber Reinforced Thermoplastic) Compression Flow Molding is divided into GMT and LFT-D, and injection molding is LFT-D.

In addition, CFRTPC (Continuous Fiber Reinforced Thermoplastic) is a typical thermoplastic composite reinforced with continuous fibers.

Thermoplastic resin products are advantageous for product molding because they use injection process with high degree of freedom of design, but they do not satisfy physical properties and when engineered thermoplastic resin is used, it is not economical.

Further, the continuous fiber-reinforced thermoplastic composite material has a high cost compared to the high physical properties, and has only a small amount of use for the purpose of reinforcing the strength because the degree of design freedom is low.

In addition, since the shape of the composite material is manufactured only in the form of a film having a thickness of 0.4 mm or less, a separate cross-laminated layer lamination process is required in order to produce a sheet in a state capable of forming processing, This causes cost increase and lowers competitiveness.

Particularly, as shown in FIG. 1, when a circular rod type CFRTPC 20 is fused and reinforced to a thermoplastic composite material 10 reinforced by non-continuous fibers such as GMT, The weak point 22 is generated and the mechanical properties are deteriorated.

1. Registration No. 1150469 (May 21, 2012) 2. Registration No. 1150470 (May 21, 2012) 3. Published Patent No. 2013-0139100 (2013.12.20) 4. Registration No. 0471561 (Feb. 2, 2005)

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described problems in the prior art, and it is an object of the present invention to provide a continuous fiber-reinforced thermoplastic composite material which is twice as costly as a competitive material, The present invention can solve the problem of difficulty at the same time and greatly improve the production speed so that the high mechanical properties can be maintained without molding lamination without laminating the sheet material, There is provided a device and a method for manufacturing a one-way continuous fiber-reinforced thermoplastic composite material.

The present invention provides a means for achieving the above object, comprising: a krill having a plurality of bobbins wound in a continuous fiber form and wound to unwind the reinforcing fibers; A tension unit for pulling a certain tensile force of the reinforcing fibers unwound from the bobbin of the krill; A spreading unit that uniformly arranges reinforcing fibers that have passed through the tension unit in a width direction and spreads them in a tape form; A filling unit for impregnating the reinforcing fiber passed through the spreading unit with a thermoplastic resin; A resin injection unit for injecting a thermoplastic resin into the filling unit; A roll forming unit that sequentially extrudes the reinforcing fibers impregnated with the thermoplastic resin to form a sheet-like bar; A cooler for cooling the formed sheet bar through the roll forming unit; A pulling-out means for pulling out the cooled sheet bar; And a cutting machine for cutting the drawn sheet bar to a predetermined length. The present invention also provides an apparatus for manufacturing a one-way continuous fiber reinforced thermoplastic composite material on a sheet.

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At this time, the roll forming unit is composed of a plurality of roll forming machines, and the inlet and the outlet of each of the roll forming machines are provided with holes for sequentially extruding the reinforcing fibers on the tape impregnated with the thermoplastic resin, And the width of the outlet shall be the same, and the height shall be maintained at 1.5: 1-3: 1.

In addition, it is preferable that the height ratio of the holes between the respective roll forming machines is made to be gradually smaller within a range of 20% in the direction in which the reinforcing fiber advances.

In addition, each of the roll forming units is divided into an upper roll forming unit and a lower roll forming unit so that the arms and the number of the roll forming units are mutually formed to form the holes.

The present invention also provides a method for producing a one-way continuous fiber-reinforced thermoplastic composite material on a sheet by using the above-described composite material producing apparatus; A step of injecting reinforcing fibers into the molding machine while continuously loosening a plurality of strands of the reinforcing fiber by using the krill; A spreading step of spreading a plurality of reinforcing fibers inserted into the molding machine after the step of inserting the reinforcing fibers to spread uniformly to maintain a uniform density; A resin impregnating step of injecting a polypropylene resin or a nylon resin into the reinforcing fiber after the spreading step; A step of forming a sheet bar on a sheet by lowering the thickness while sequentially advancing the reinforcing fibers on the tape impregnated with the resin while continuously moving the resin impregnated through the plurality of roll forming machines; A sheet bar cooling step of cooling the sheet bar when the sheet bar forming is completed; When the cooling is completed, a drawing step in which the drawing is performed using a drawing machine; And a sheet bar cutting step of cutting the drawn sheet bar to a predetermined length to produce a product.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to realize a uni-directional continuous fiber-reinforced thermoplastic composite material which can be produced at low cost with high mechanical strength and excellent in design freedom.

Figure 1 is an exemplary partial cross-sectional view of a composite according to the prior art.
2 is an exemplary partial cross-sectional view illustrating the use of a one-way continuous fiber reinforced thermoplastic composite material according to the present invention.
3 is a process drawing showing an apparatus for producing a sheet unidirectional continuous fiber-reinforced thermoplastic composite material according to the present invention.
Fig. 4 is an exemplary view showing a roll forming machine constituting Fig. 3. Fig.
5 is a process flow chart showing a method for producing a sheet unidirectional continuous fiber reinforced thermoplastic composite material according to the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Before describing the present invention, the following specific structural or functional descriptions are merely illustrative for the purpose of describing an embodiment according to the concept of the present invention, and embodiments according to the concept of the present invention may be embodied in various forms, And should not be construed as limited to the embodiments described herein.

In addition, since the embodiments according to the concept of the present invention can make various changes and have various forms, specific embodiments are illustrated in the drawings and described in detail herein. However, it should be understood that the embodiments according to the concept of the present invention are not intended to limit the present invention to specific modes of operation, but include all modifications, equivalents and alternatives falling within the spirit and scope of the present invention.

The composite material according to the present invention is compressed and flattened in the form of a sheet bar as in the example of Fig.

Herein, although it is expressed as a sheet bar for convenience of explanation, it may be considered as a block shape having a certain thickness.

Importantly, CFRTPC (Continuous Fiber Reinforced Thermoplastic Composites) on the tape is continuously extruded so that the thickness of the CFRTPC is kept low while maintaining a constant width, so that the internal density is uniform, will be.

At this time, the CFRTPC is configured such that a continuous fiber type reinforcing fiber including glass fiber is dispersed in a state impregnated with a thermoplastic resin such as polypropylene resin (PP Resin).

Moreover, the content (mixing amount) of the reinforcing fiber such as the glass fiber and the thermoplastic resin such as polypropylene resin is in a ratio of 50-70: 30-50 by weight.

Particularly, in the present invention, the reinforcing fibers are oriented and arranged in one direction. Since the reinforcing fibers are processed by using continuous fibers rather than short fibers or long fibers, they are configured to have directionality in the processing direction, .

Moreover, because continuous fiber is used, it is possible to process continuously without interruption, which is advantageous in continuous production.

As the reinforcing fiber, a composite material having the same structure can be formed by using any one of carbon fiber including glass fiber and aramid fiber or by mixing two or more of them. This is because the characteristics of each fiber are different and can be selected and used according to the characteristics.

Further, the reinforcing fiber may be glass fiber, carbon fiber, or aramid fiber alone, but it may be made of a mixture of glass fiber-carbon fiber, glass fiber-aramid fiber, carbon fiber-aramid fiber and glass fiber-carbon fiber-aramid fiber In this case, they may be mixed in the same weight ratios, and only the range of 50 to 70% by weight of the present invention may be added.

In addition, nylon resin may be used in addition to polypropylene resin.

The unidirectional continuous fiber reinforced thermoplastic composite thus produced is fused with GMT, LFT-D, and molded to produce high strength and lightweight products such as stiffeners, bumper beams, and seat backs for automobiles. Can be very useful.

The unidirectional continuous fiber-reinforced thermoplastic composite (R) having such a structure as described above can be used as a non-continuous fiber-reinforced thermoplastic composite material (G) R) are bonded to each other to form a single body. Since the weak points do not occur as in the conventional art, the strength reinforcement can be achieved without deteriorating mechanical properties.

Such sheet unidirectional continuous fiber reinforced thermoplastic composites are made through a manufacturing apparatus as shown in Figs. 3 and 4. Fig.

3 and 4, the unidirectional continuous fiber reinforced thermoplastic composite material producing apparatus according to the present invention includes a creel 100, a molding machine 200, a cooler 300, a drawer 400, And a cutter 500.

At this time, the krill 100 has a plurality of bobbins 110, and the bobbin 110 is wound with reinforcing fibers, preferably glass fibers, in the form of continuous fibers.

The molding machine 200 includes a tension unit 210, a spreading unit 220, a filling unit 230, a resin injection unit 240 and a roll forming unit 250, Is pulled out while maintaining a predetermined tension by the tension unit 210, spreads through the spreading unit 220, spreads uniformly, and is arranged in a plate shape, more precisely on a tape.

It goes without saying that, in order to further reinforce the strength reinforcement, the reinforcing fibers may be unwound and pre-braided before being pulled by the tension unit 210 through the knitting machine.

The reinforcing fibers spread through the spreading unit 220 are introduced into the filling unit 230 and the resin filling unit 240 is connected to the filling unit 230 so that the resin, The nylon resin is impregnated into the spread reinforced fibers, preferably glass fibers, while being injected.

At this time, the mixing ratio of the resin and the reinforcing fiber should be 30-50: 50-70 weight ratio as described above.

In this way, the reinforcing fibers filled with the resin are pressed in the form of being extruded through the roll forming unit 250, and the width is kept constant while the thickness is gradually lowered to have a form of a sheet bar.

Then, the sheet bar, which is made of sheet unidirectional continuous fiber-reinforced thermoplastic composite material, is cooled through the cooler 300, drawn through the drawer 400, and then cut into a predetermined length in the cutting machine 500,

Here, the roll forming unit 250 performs a very important function as a core configuration of the manufacturing apparatus of the present invention.

That is, the roll forming unit 250 is a means for pressing the resin-impregnated reinforcing fiber on the tape to process the sheet bar, which may be defective in the longitudinal direction or the width direction.

4, the height ratio between the inlet and the outlet of each of the plurality of roll forming units 252, 254, and 256 constituting the roll forming unit 250 must maintain a ratio of 1.5: 1-3: 1 do.

If the ratio is out of the above range, a problem of rupture may occur during extrusion, and homogenization may not be performed even after extrusion, so that it is difficult to expect increase in mechanical properties.

In particular, the plurality of roll-forming machines 252, 254, and 256 must be continuously arranged, and each of the roll-forming machines 252, 254, and 256 must be formed into an upper and a lower roll- The height ratio of the through holes between the groups 252, 254, and 256 must be configured to become smaller within a range of 20% toward the processing direction.

This is to improve machinability and to minimize the occurrence of defects while improving machining efficiency.

In addition, when the height ratios of the entrance and exit of the roll forming machines 252, 254, and 256 and the height ratios of the roll forming machines 252, 254, and 256 are out of the ranges described above, This ratio must be maintained as it leads to accidents, resulting in a decrease in productivity due to repair, restart, and a decrease in efficiency.

Furthermore, in the case of the last, or final, roll former 256, it should not be cooled, and the former roll formers 252, 254 must have a cooling structure using a cooling jacket to improve efficiency and formability.

The roll surface temperatures of the respective roll forming machines 252, 254 and 256 gradually start to fall from the vicinity of 200 占 폚 for the first time and must be maintained at about 25-50 占 폚 in the final roll forming machine 256 so that high quality sheet bars, Reinforced thermoplastic composites can be produced.

The production of such a sheet bar is conceptually summarized through a process diagram as shown in FIG.

That is, the reinforcing fiber application step S10 is performed first.

The step S10 of injecting the reinforcing fibers is a step of injecting a plurality of reinforcing fibers, preferably a plurality of glass fibers in the form of a continuous fiber, into the molding machine 200 by continuously unwinding the reinforcing fibers by using the krill 100 described above.

After the reinforcing fiber application step (S10), reinforcing fiber spreading step (S20) is performed.

The reinforcing fiber spreading step S20 is a step of spreading the reinforcing fibers of a plurality of strands inserted into the molding machine 200 widely so as to maintain a uniform density.

Then, a resin impregnation step (S30) is performed.

The resin impregnation step (S30) is a step of impregnating reinforcing fiber by injecting polypropylene resin or nylon resin, and the mixing ratio between resin and reinforcing fiber is as described above.

After the resin impregnation is completed, a sheet bar forming step (S40) for continuously moving the resin-impregnated tape through the plurality of roll forming machines (252, 254, 256) while gradually molding the reinforcing fibers on the tape, Is performed.

Thus, when the sheet bar molding is completed, the heat received at the time of molding through the sheet bar cooling step (S50) is cooled to achieve dimensional stabilization.

When the cooling is completed, the production of the composite material of the present invention is completed by passing through the draw-in step (S60) using the drawer (400) and cutting the drawn sheet bar to a predetermined length and cutting the sheet bar into a product (S70) .

As described above, the present invention is expected to be very useful because it can be commercialized so as to have a sufficient mechanical strength without laminating as in the conventional method.

100: Krill 200: Molding machine
300: cooler 400: phosphorous
500: Cutting machine

Claims

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A krill having a plurality of bobbins wound with reinforcing fibers having a continuous fiber form and rotated to unwind the reinforcing fibers;
A tension unit for pulling a certain tensile force of the reinforcing fibers unwound from the bobbin of the krill;
A spreading unit that uniformly arranges reinforcing fibers that have passed through the tension unit in a width direction and spreads them in a tape form;
A filling unit for impregnating the reinforcing fiber passed through the spreading unit with a thermoplastic resin;
A resin injection unit for injecting a thermoplastic resin into the filling unit;
A roll forming unit that sequentially extrudes the reinforcing fibers impregnated with the thermoplastic resin to form a sheet-like bar;
A cooler for cooling the formed sheet bar through the roll forming unit;
A pulling-out means for pulling out the cooled sheet bar;
And a cutting device for cutting the drawn sheet bar to a predetermined length. &Lt; RTI ID = 0.0 > 21. < / RTI >

The method of claim 5, further comprising:
Wherein the roll forming unit comprises a plurality of roll forming units, and an inlet and an outlet of each of the roll forming units are formed with holes for successively extruding reinforcing fibers on a tape impregnated with a thermoplastic resin, Wherein the width of the continuous fiber reinforced thermoplastic composite material is the same and the height thereof is maintained at 1.5: 1 to 3: 1.

The method of claim 6, further comprising:
Wherein the ratio of the heights of the holes between the respective roll forming machines is set to be gradually decreased within a range of 20% in the direction in which the reinforcing fibers are advanced.

The method of claim 6, further comprising:
Wherein each of the roll forming units is divided into an upper roll forming unit and a lower roll forming unit so that the arms and the water are combined to form a hole.

A method for producing a one-way continuous fiber-reinforced thermoplastic composite material on a sheet using the composite material producing apparatus according to any one of claims 5 to 8, the method comprising:
A step of injecting reinforcing fibers into the molding machine while continuously loosening a plurality of strands of the reinforcing fiber by using the krill;
A spreading step of spreading a plurality of reinforcing fibers inserted into the molding machine after the step of inserting the reinforcing fibers to spread uniformly to maintain a uniform density;
A resin impregnating step of injecting a polypropylene resin or a nylon resin into the reinforcing fiber after the spreading step;
A step of forming a sheet bar on a sheet by lowering the thickness while sequentially advancing the reinforcing fibers on the tape impregnated with the resin while continuously moving the resin impregnated through the plurality of roll forming machines;
A sheet bar cooling step of cooling the sheet bar when the sheet bar forming is completed;
When the cooling is completed, a drawing step in which the drawing is performed using a drawing machine;
And a sheet bar cutting step of cutting the drawn sheet bar to a predetermined length to produce a product.