KR101924505B1 - The manufacturing method for thermoforming PET bellows air duct - Google Patents

Abstract

The present invention relates to a method for manufacturing a PET bellows air duct by inserting nonwoven having a waterproof film for blocking the inflow of water, between a center disk and an auxiliary disk which are in close contact with each other and applying heat and pressure. The method for manufacturing a thermoformed PET bellows air duct according to the present invention includes a nonwoven manufacturing step of placing a waterproof film made of polyethylene and polypropylene as a material between a pair of nonwoven fabrics made of a polyester fiber as a material and manufacturing the nonwoven by a needle punching method; a nonwoven fabric cutting step of cutting the thickness and width of the nonwoven, a bellows manufacturing step of thermally molding the nonwoven to produce a bellows, and a bellows cutting step of cutting the bellows having an increased length every predetermined length.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a thermoformed PET bellows air duct,

The present invention relates to a method for manufacturing an air duct for PET corrugated tubes by applying heat and pressure to a nonwoven fabric. More particularly, the present invention relates to a method for manufacturing a PET corrugated pipe air duct by applying heat and pressure to a nonwoven fabric, And then applying heat and pressure to the PET tube to manufacture a PET bell pipe air duct.

Generally, the corrugator air duct is used to protect the wiring by preventing the wiring from being exposed to the outside, or to be used as a passage through which fluid or gas passes. In general, the corrugated pipe It has various advantages such as superior durability because it is more elastic than tube.

However, when a corrugated pipe such as an air duct for a vehicle is used as a passage through which a gas passes, a fabric such as a nonwoven fabric may be used because of cost reduction and weight reduction. Therefore, It is important to choose the material for the purpose for which it is used,

The present invention discloses a method for manufacturing a thermoformed PET corrugated pipe air duct.

An invention relating to the production of such a corrugated pipe air duct is disclosed in Korean Patent Laid-Open Publication No. 1997-0028025 entitled " Corrugated pipe having a surface coating layer and its manufacturing method " and Korean Patent Laid-Open Publication No. 2003-0010093 entitled " "Manufacturing Apparatus and Manufacturing Method of Flexible Tube" of Patent Publication No. 10-0658829 and Korean Patent Laid-Open No. 10-2010-0121168 "Corrugated Pipe and Manufacturing Method Thereof" have been proposed and disclosed.

Korean Patent Laid-Open Publication No. 1997-0028025 discloses a corrugated pipe having a surface coating layer and a method for producing the same. The rolled aluminum foil is heat treated to soften its physical properties, and then the heat-treated aluminum foil is surface-treated with an abrasive, The present invention relates to a method for obtaining a high-quality coated corrugated tube through a series of steps of coating and heat-treating the substrate by coating and heat-treating the coated corrugated tube at a thickness of 1 to 5 mm and a method of manufacturing the corrugated tube described in Korean Patent Publication No. 2003-0010093 "Is a structure in which a band-shaped soft synthetic resin is joined to form an inner side, and a reinforcing core composed of a hard synthetic resin is coupled to the upper side thereof. This structure ensures that a constant inner diameter can be secured without changing the inner diameter even when bent at an arbitrary angle, Invention relating to a method for manufacturing a corrugated tube capable of ensuring flow It proposed.

In addition, the above-mentioned Korean Patent Registration No. 10-0658829 entitled " Apparatus and Method for Manufacturing Flexible Tube " discloses a method for manufacturing a flexible tube having a large diameter, which is mainly used for a duct for heating / cooling air- , An invention relating to an apparatus and a method capable of rapidly and mass-producing a wrinkle part by repeating the joining and separating of outer molds and solving the problem of repeatedly forming the wrinkles on the workpiece has been proposed, and in Japanese Patent Application Laid-Open No. 10-2010-0121168 &Quot; Corrugated tube and its manufacturing method " includes steps of forming a tube body having a corrugated shape at predetermined intervals on the outer periphery by processing a carbon steel material, and a step of heating the tube body to a temperature at which the internal structure of the carbon steel is transformed, Heat-treating the tube body by performing a tempering heat treatment, forming a coating on the outer surface of the heat-treated tube body, And a step of forming a coating on the outer surface of the tube body to complete the corrugated pipe, thereby producing a corrugated tube having improved strength, hardness and elasticity.

However, since the above-mentioned prior arts have a problem that productivity of a product is lowered because a cylindrical workpiece is first formed at the time of manufacturing a corrugated tube and wrinkles are formed on the surface thereof, So that the elasticity of the product is lowered, the weight is increased, and the production cost of the product is increased.

Therefore, the productivity of the product can be improved by forming the cylindrical workpiece and the wrinkle on the surface, and it is possible to prevent the increase of the weight and the production cost of the product The present invention provides a manufacturing method of a corrugated pipe capable of preventing the inflow of moisture into the inside of the corrugated pipe.

Korean Unexamined Patent Publication No. 1997-0028025 (June 24, 1997) Korean Patent Publication No. 2003-0010093 (Feb. Korean Registered Patent No. 10-0658829 (December 11, 2006) Korean Patent Publication No. 10-2010-0121168 (Nov. 17, 2010)

The method for manufacturing a thermoformed PET corrugated pipe according to the present invention is a technique proposed to solve the problems of the related art as described above,

There has been a need to improve the productivity of the product by simplifying the manufacturing process of the product,

The necessity of ensuring the elasticity of the product and lightening the weight of the product has been raised,

Since the necessity of reducing the production cost of the product has been raised, it is aimed to provide a solution to this.

The method for manufacturing a thermoformed PET corrugated pipe according to the present invention,

A nonwoven fabric manufacturing step of placing a waterproof film made of polyethylene and polypropylene as a material between a pair of nonwoven fabric fabrics made of a polyester fiber as a material and forming a nonwoven fabric by a needle punching method; A nonwoven fabric cutting step of cutting the thickness and width of the nonwoven fabric; Forming a corrugated pipe by thermoforming the nonwoven fabric; A corrugated pipe cutting step of cutting the corrugated pipe having an increased length every predetermined length; The present invention also provides a method of manufacturing a thermoformed PET corrugated pipe air duct.

In the method for manufacturing a thermoformed PET corrugated pipe according to the present invention,

A cylindrical workpiece is formed and a wrinkle is formed on the surface, so that the productivity of the product is improved due to the simplification of the manufacturing process,

Since the metal material such as aluminum or stainless steel is not used, the elasticity of the product is guaranteed, the weight of the product is increased and the production cost is prevented from being increased,

The waterproof film was inserted into the nonwoven fabric constituting the corrugated pipe, thereby preventing the inflow of water into the corrugated pipe.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flow chart of a method for manufacturing a thermoformed PET corrugated air duct according to the present invention; FIG.
FIG. 2 is a perspective view of a corrugated pipe manufacturing apparatus of a method for manufacturing a thermoformed PET corrugated pipe according to the present invention. FIG.
3 (a) to 3 (b) are views showing a state in which a corrugated pipe is manufactured using the corrugated pipe manufacturing apparatus of the method for manufacturing a thermoformed PET corrugated pipe according to the present invention.
The present invention relates to a method for manufacturing a thermoformed PET corrugated air duct, and more particularly,

An internal combustion engine for a vehicle is required to receive air from outside for combustion of fuel, and a passage through which air is supplied is referred to as an air duct.

The present invention relates to a method for producing an air duct of a PET corrugated tube by applying heat and pressure to a nonwoven fabric, wherein a waterproof film made of polyethylene and polypropylene as a material between a pair of nonwoven fabric fabrics made of polyester fiber A nonwoven fabric manufacturing step of forming a nonwoven fabric by a needle punching method; A nonwoven fabric cutting step of cutting the thickness and width of the nonwoven fabric; Forming a corrugated pipe by thermoforming the nonwoven fabric; A corrugated pipe cutting step of cutting the corrugated pipe having an increased length every predetermined length; The present invention relates to a method for manufacturing a thermoformed PET corrugated pipe.

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

First, as shown in Fig. 1, the method for manufacturing a thermoformed PET corrugated pipe air duct according to the present invention is a method for manufacturing a thermoformed PET corrugated pipe air duct, which comprises a pair of nonwoven fabric fabrics made of polyester fiber, And a nonwoven fabric manufacturing step of positioning the film and producing a nonwoven fabric by a needle punching method.

The nonwoven fabric manufacturing step is a step of producing a nonwoven fabric having a waterproof film as a main material of an air duct for a duct, comprising 20 to 60 wt% of PET (polyethylene terephthalate) material, a low melting fiber (LMF) And a waterproof film made of polyethylene and polypropylene are bonded to each other by a needle punching method. Since the needle punching method is a known method A detailed description thereof will be omitted.

However, the connection between the nonwoven fabric fabric and the waterproof film is not necessarily achieved by a known needle punching method. In the method of manufacturing a thermoformed PET pearl tube air duct according to the present invention, instead of the needle punching method, And a thermosetting adhesive is applied to the surface of the waterproof film and then adhered to the surface of the waterproof film.

Also, as shown in FIG. 1, the method for manufacturing a corrugated pipe for an air duct according to the present invention includes a nonwoven fabric cutting step of cutting the thickness and width of the nonwoven fabric.

The nonwoven fabric cutting step is a step of uniformly cutting the thickness and the width of the nonwoven fabric manufactured through the nonwoven fabric manufacturing step to produce a corrugated tube having the same standard. The thickness of the nonwoven fabric is 1 to 5 cm and the width is 3 to 10 cm Preferably, the nonwoven fabric is cut so that the cut nonwoven fabric is advantageous for storage and transportation, and wound in a roll form so that it can be easily used at a later stage.

Also, as shown in FIG. 1, the method for manufacturing a thermoformed PET corrugated pipe according to the present invention includes a corrugated pipe manufacturing step for manufacturing a corrugated pipe by thermoforming the nonwoven fabric.

The step of fabricating the corrugated tube is a step of producing a corrugated tube having a cylindrical shape with corrugations formed on the entire side surface by applying heat and pressure to the flat type nonwoven fabric cut to have a certain thickness and width, It is necessary to provide a corrugated pipe manufacturing apparatus configured to apply heat and pressure to the nonwoven fabric.

2, the corrugated pipe manufacturing apparatus used in the method for manufacturing the thermoformed PET corrugated pipe air duct according to the present invention is characterized in that spiral protrusions and protrusion grooves are formed on the entire side surface, And a control unit.

The center disk 100 is a component used as a frame for forming a corrugated tube. The nonwoven fabric is flat on both sides and has a thickness of 1 to 5 cm and a width of 3 to 10 cm. The nonwoven fabric has spiral- And has a cylindrical or cylindrical shape having a spiral protrusion formed on the entire side surface so as to be transformed into a cylindrical shape, and a rotary shaft is formed at one end.

The rotating shaft is a component that fixes the center disc 100 to one side of the corrugator manufacturing apparatus and becomes a shaft on which the center disc 100 is rotated. The method of rotating the rotating shaft may be a manual driving method or a machine Or an automatic driving method by an apparatus, and may be configured to be applicable to both of the above-described methods.

2, the corrugated pipe manufacturing apparatus used in the method for manufacturing the thermoformed PET corrugated pipe air duct according to the present invention is characterized in that spiral protrusions and protrusion grooves are formed on the entire side surface, And a pair of auxiliary disks (110) which are in close contact with each other and are rotatable about their axes.

The pair of auxiliary disks 110 are automatically rotated by the rotation of the center disk 100 without separate driving means and the nonwoven fabric sandwiched between the center disk 100 and the auxiliary disk 110 is processed in the form of a corrugated tube The spiral protrusion formed on the entire side surface is formed in the same shape as the spiral protrusion formed on the entire side surface of the center disc 100. The spiral protrusion formed on the side surface of the center disc 100 is formed in the auxiliary disc 110 The helical protrusions formed on the side surface of the auxiliary disk 110 are configured to engage with the protrusions formed on the side surface of the center disk 100 and are formed on the entire side surface of the corrugated tube So that the wrinkles are formed in the same shape.

That is, the helical protrusions formed on the entire side surface of the center disc 100 apply pressure to one side of the nonwoven fabric, one side of which becomes the inner side of the corrugated tube, and the helical protrusions formed on the entire side surface of the auxiliary disc 110 And the other side of the spiral protrusion is an outer surface of the corrugated pipe.

In an embodiment of the present invention, the center disk 100 may be rotated in a clockwise direction or in a counterclockwise direction by a manual driving system or an automatic driving system, and may be rotated on both sides of the center disk 100 A pair of auxiliary disks 110 positioned in close contact with each other are axially rotated by the center disk 100 in a direction opposite to the center disk 100.

In this case, the nonwoven fabric, which is a material of the corrugated tube, is disposed between the center disc 100 and the auxiliary disc 110, and the center disc 100 is rotated along the inclined direction of the spiral protrusion formed on the entire side surface. The position to be fitted may be easily judged by looking at the rotation direction of each of the center disk 100 and the pair of auxiliary disks 110. [

In addition, the apparatus for manufacturing a corrugated pipe used in the method for manufacturing a thermoformed PET corrugated pipe according to the present invention comprises a heating unit for heating the auxiliary disk 110.

In order to manufacture a corrugated pipe having a spiral protrusion formed on the entire side surface by molding a nonwoven fabric made of polyester fiber, the nonwoven fabric must be heated while being pressed simultaneously by the center disc 100 and the auxiliary disc 110 The heating unit heats any one or more of the pair of auxiliary disks 110 to apply heat and pressure to the nonwoven fabric at the same time.

Therefore, the auxiliary disk 110 is made of a metal material so that it can be heated easily, and the temperature of the auxiliary disk 110 is 200 ° C or more. Any method may be used for heating, It is preferable that the rising range is limited.

That is, the apparatus for manufacturing a corrugated pipe used in the method for manufacturing a thermoformed PET corrugated pipe according to the present invention may include a control unit for controlling the heating unit, and a temperature measuring device for measuring the temperature of the auxiliary disk 110 may be provided The controller controls the heating unit when the temperature measured by the temperature measuring device reaches a preset temperature, thereby restricting the temperature of the auxiliary disk 110 from rising indefinitely.

The apparatus for manufacturing a corrugated pipe used in the method for manufacturing a thermoformed PET corrugated pipe according to the present invention is characterized in that the length of the center disk 100 is longer than the length of each of the pair of auxiliary disks 110 .

Since the corrugated pipe manufactured by the corrugated pipe manufacturing apparatus forms a shape by simultaneously applying heat and pressure to the central disc 100 and the pair of auxiliary discs 110 in which at least one of the auxiliary discs 110 is heated, 100 and the pair of auxiliary disks 110 are disposed in parallel with each other in close contact with each other. However, since the corrugated pipe immediately after being manufactured must undergo the cooling process while maintaining its shape, the length of the center disk 100 is The length of each of the pair of auxiliary disks 110 is preferably longer than the length of each of the pair of auxiliary disks 110.

That is, since the pair of auxiliary disks 110 are configured to manufacture the corrugated tube only by the interaction with the center disk 100, the length of the pair of auxiliary disks 110 is longer than the length of the center disk 100 The center disc 100 and the pair of auxiliary discs 110 are formed to have the same length but the center disc 100 and the pair of auxiliary discs 110 have the same length The corrugated tube may be formed longer than the length of the center disk 100 and may be deformed during the cooling process. Therefore, the length of the center disk 100 is longer than the length of each of the pair of auxiliary disks 110 It is preferable that the corrugated tube is configured so as to be able to maintain its shape during cooling.

As described above, the corrugated pipe manufacturing step is a necessary step for the corrugated pipe manufacturing apparatus. Hereinafter, the corrugated pipe manufacturing step using the corrugated pipe manufacturing apparatus will be described in detail.

As shown in FIG. 4, the corrugated pipe manufacturing step includes a heating step of heating the temperature of the auxiliary disk 110 to 200 ° C. or higher.

As described above, in order to manufacture a corrugated pipe having a spiral protrusion formed on the entire side surface thereof by molding a nonwoven fabric made of a polyester fiber, the nonwoven fabric is pressed simultaneously with the center disc 100 and the auxiliary disc 110 It is preferable that the heating is performed so that the temperature of any one or more of the pair of auxiliary disks 110 is heated to 200 ° C or more through the heating unit so that the temperature difference between the center disk 100 and the auxiliary disk 110 So that heat and pressure are simultaneously applied to the nonwoven fabric.

At this time, it is preferable that the heating step during the corrugated pipe manufacturing step precedes other steps, but is not limited thereto.

4, the corrugated pipe manufacturing step includes a nonwoven fabric mounting step in which one end of the nonwoven fabric is sandwiched between the center disk 100 and the auxiliary disk 110. As shown in FIG.

As described above, the center disk 100 can be rotated in a clockwise direction or in a counterclockwise direction by a manual driving system or an automatic driving system, so that the nonwoven fabric, which is a material of the corrugated tube, 100 and the auxiliary disk 110 must be changed by the axial rotation direction of the center disk 100. [

That is, it is preferable that the nonwoven fabric be sandwiched between the auxiliary disk 110 located in the direction in which the center disk 100 rotates, so that the position where the nonwoven fabric is inserted according to the rotation direction of the center disk 100 is changed to be.

Also, as shown in FIG. 4, the corrugated pipe manufacturing step includes a rotating step of rotating the center disc 100 about its axis.

The rotating step is a step of increasing the length of the corrugated tube formed by continuously pulling the nonwoven fabric having the distal end portion sandwiched between the center disk 100 and the pair of auxiliary disks 110, The nonwoven fabric is sandwiched between the center disc 100 and one side of the pair of auxiliary discs 110. The auxiliary disc 100 is wound around the center disc 100, The auxiliary disk 110 is rotated while being rotated with the rotation of the center disk 100 to form a corrugated tube having corrugations formed on the nonwoven fabric and the center disk 100 And the pair of auxiliary disks 110 are rotated to form a corrugated tube of a desired length.

Also, as shown in FIG. 1, the method for manufacturing a thermoformed PET corrugated pipe air duct according to the present invention includes a corrugated pipe cutting step for cutting the corrugated pipe having a longer length by a predetermined length.

As described above, since the heating unit heats only the auxiliary disk 110, the corrugated pipe formed by the continuously supplied nonwoven fabric is naturally cooled with an increase in length. The corrugated pipe to be cooled is advantageous for storage and transportation, It is preferable to cut every constant length so that it can be used in manufacturing.

Therefore, the corrugated pipe manufacturing apparatus may include a sensing sensor for sensing the length of the corrugated pipe and a cutting member for cutting one end of the corrugated pipe, and the control of the cutting member may be performed by the control unit.

The embodiments described above are provided by way of example for the purpose of enabling a person skilled in the art to sufficiently transfer the technical idea of the present invention to a person skilled in the art, But may be embodied in other forms without limitation.

In order to clearly explain the present invention, parts not related to the description are omitted from the drawings, and in the drawings, the width, length, thickness, etc. of the components may be exaggerated or reduced for convenience.

Further, like reference numerals designate like elements throughout the specification.

S100: Nonwoven fabric manufacturing step S110: Nonwoven fabric cutting step
S120: Corrugated pipe manufacturing step S121: Heating step
S122: nonwoven fabric mounting step S123: rotation step
S130: Corrugator cutting step
100: center disk 110: auxiliary disk
A: nonwoven fabric B: corrugated tube

Claims (6)

A nonwoven fabric manufacturing step of placing a waterproof film made of polyethylene and polypropylene as a material between a pair of nonwoven fabric fabrics made of polyester fiber as a material and making a nonwoven fabric by a needle punching method;
A nonwoven fabric cutting step of cutting the thickness and width of the nonwoven fabric;
Forming a corrugated pipe by thermoforming the nonwoven fabric;
A corrugated pipe cutting step of cutting the corrugated pipe having an increased length every predetermined length; , ≪ / RTI &
In the corrugated pipe manufacturing step,
A center disk 100 on which spiral protrusions and protruding grooves are formed on the entire side surface and is rotatable about an axis;
A pair of auxiliary disks 110 having spiral protrusions and protruding grooves formed on the entire side surface thereof and being rotatable on both sides of the center disc 100 and being rotatable about their axes;
And a heating unit for heating the auxiliary disk 110,
A heating step of heating the temperature of the auxiliary disk 110 to 200 ° C or more;
A nonwoven fabric mounting step of sandwiching one end of the nonwoven fabric between the center disk 100 and the auxiliary disk 110;
And rotating the center disk (100) about the axis of rotation of the center disk (100).
The method according to claim 1,
The non-
20 to 60% by weight of the PET material, and 40 to 80% by weight of the LMF material.
The method according to claim 1,
The nonwoven fabric manufacturing step comprises:
Wherein the nonwoven fabric is manufactured by a bonding method in which a thermosetting adhesive is applied and adhered to the surface of the pair of nonwoven fabrics and the surface of the waterproof film in place of the needle punching method.
The method according to claim 1,
Wherein the thickness of the nonwoven fabric cut at the nonwoven fabric cutting step is 1 to 5 cm and the width is 3 to 10 cm.
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