KR102082764B1 - SMC composite continuous molding apparatus using fiber dispersion supply unit and continuous molding method for manufacturing SMC composite - Google Patents

Abstract

The present invention relates to a continuous molding device for a building panel comprising: a transferring unit which transfers an original film; a conveyor unit which forms a coating box to allow a liquefied thermosetting resin to be coated on the original film discharged in the transferring unit; a coating fiber supplying unit which coats a solid fiber on the original film discharged in the conveyor unit; a compressing roller unit which compresses a processing film discharged in the coating fiber supplying unit; and a fiber dispersion supplying unit which supplies the solid fiber on the original film of the conveyor unit through cutting and dispersion in a state of allowing the solid fiber supplied in the coating fiber supplying unit to be entered. The fiber dispersion supplying unit includes: a main body frame which allows the solid fiber supplied in the coating fiber supplying unit to enter; a cutting rotation roll unit arranged in the main body frame to perform a cutting operation for the solid fiber; and a dispersing module which supplies the solid fiber of a cut state to the conveyor unit in a state of being separated on a lower part of the cutting rotation roll unit. The present invention improves directionality and dispersibility of the cut solid fiber towards the original film.

Description

SMC composite continuous molding apparatus using fiber dispersion supply unit and continuous molding method for manufacturing SMC composite}

The present invention relates to an SMC composite continuous molding apparatus and a continuous molding method using a resin supply unit, the original film of the fiber cut in the process of forming a processed film by applying various fibers on the original film supplied for manufacturing the SMC composite It relates to a continuous molding apparatus and a continuous molding method using a resin supply unit to improve the impregnation and dispersibility for.

In general, a synthetic resin panel installed in a house or an office is completed by attaching a synthetic resin decorative plate with a certain pattern to the user's preference on the outer surface with an adhesive.

At this time, as a decorative plate made of a synthetic resin material, a sheet molding sheet (SMC) formed of a sheet-like sheet by compression molding of fiber-reinforced polyester resin having light and excellent durability is widely used.

The SMC sheet is mixed with an unsaturated polyester resin, which is a composite material, and a thickener, an inhibitor, a catalyst, a retarder, a curing agent, etc. are mixed at a certain ratio, and then impregnated with fibers to be drawn out in a sheet form. The SMC sheet thus drawn is applied to a building interior material or an industrial panel by molding in various forms using a heat press or a mold.

These SMC sheets are rolled after they are aged at 3 ° C for 4 to 4 days until the viscosity reaches about 1,000,000 cps by winding the sheets pulled out during manufacturing, and at this time, the release force and shape retention between the sheets are maintained. At this time, an APP (Atactic polypropylene) film is attached for keeping it from sticking to each other.

However, the sheet made with this APP film alone is vulnerable to heat or pressure. Therefore, the conventional SMC sheet cannot be molded by directly applying heat or pressure in the manufacturing process. Accordingly, there is a cumbersome problem that a product must be molded by using a separate heat press process or a mold after drawing out with a sheet.

That is, in the conventional SMC sheet manufacturing process, there is a problem in that the manufacturing process is lengthened until the sheet is taken out, and the manufacturing process is complicated.

In addition, in the process of forming a processed film by applying carbon fibers or glass fibers on the original film supplied during the SMC sheet manufacturing process, fibers are supplied using a rotating roll. In the process, the fibers are cut and scattered. Since there is a limitation in applying onto the film, a problem arises in realizing uniform dispersibility.

The object of the present invention is to improve the impregnation and dispersibility toward the original film of the cut fiber in the process of forming a processed film by applying various fibers on the original film supplied for the production of SMC composite, in order to solve the conventional problems In order to provide a continuous molding apparatus and a continuous molding method using a resin supply unit.

Continuous forming apparatus for a building panel according to an aspect of the present invention for achieving the above object is a conveyor portion formed with a coating box so that a liquid thermosetting resin is applied to the original film drawn out from the transfer unit; A coating fiber supply unit for applying solid fibers to the original film drawn out from the conveyor unit; A resin supply unit functioning to supply additional fibers on the original film supplied with the fibers cut through the coated fiber supply unit; And a crimping roller unit for crimping a processed film drawn out from the coated fiber supply unit, wherein the resin supply unit includes a resin transfer belt, a driving roller disposed at both ends of the resin transfer belt, and an upper portion of the resin transfer belt. It characterized in that it comprises a resin inlet for guiding the resin supplied in a state arranged on the side and a resin separator disposed on one lower end of the resin transfer belt.

The resin applied on the resin transfer belt is transferred to the resin film form having a viscous viscosity in a sticky state through cooling while moving through the resin transfer belt, and the resin film is separated on the resin transfer belt through the resin separator. It is applied on the original film drawn out from the conveyor.

Further comprising; a fiber dispersion supply unit for supplying on the original film of the conveyor through cutting and dispersion in the state of the entry of the solid fiber supplied from the coated fiber supply unit; further comprising, the cutting rotating roll unit of the main frame A structure in which a pair of rotating rollers are arranged in parallel on the inner region, and the cutting rotating roll portion has the cutting rolls formed with cutting edges along the outer circumferential surface and the corresponding rolls arranged parallel to the cutting rolls in the horizontal direction. The solid fiber that entered between the roll and the counter roll is cut.

The dispersion module is disposed on both ends of the dispersion center rod, a plurality of dispersion guide bars radially arranged around the dispersion center rod, and the dispersion center rod and the plurality of dispersion guide bars, which are disposed across the spaced pair of dispersion fiber guides 240. It includes a pair of rotating disks arranged.

Continuous forming method according to another aspect of the present invention for achieving the above object is a first resin coating step of applying a liquid thermosetting resin to the original film; A fiber coating step of applying the solid fiber supplied from the coated fiber supply unit on the original film; A second resin coating step of supplying additional resin through a resin supply unit on the original film supplied with the fibers cut through the coating fiber supply unit; A third resin coating step of adhering an APP film or a deco film to the processed film in a state in which the solid fiber is coated; And it characterized in that it comprises a deco forming step of compression molding the processed film at a high temperature after the third resin coating step.

The original film adopts a deco film having a pattern formed on one side.

According to the present invention, it is possible to achieve all the objects of the present invention described above.

The present inventors continuous molding apparatus and continuous molding method is a process of supplying additional resin on the cut fibers using a resin supply unit in the process of forming a processed film by applying various fibers on the original film supplied for the production of SMC composites Through this, impregnation and dispersibility toward the original film are improved.

1 is a block diagram showing a continuous molding apparatus to which a fiber dispersion supply unit is applied for the production of an SMC composite according to an embodiment of the present invention,
Figure 2 is an exemplary view showing a schematic component of a continuous molding apparatus for producing SMC composite according to an embodiment of the present invention,
Figure 3 is a perspective view showing a specific configuration for a resin supply unit constituting the continuous molding apparatus according to the present invention, and
Figure 4 is a perspective view showing a specific configuration for the fiber dispersion supply unit constituting the continuous molding apparatus according to the present invention, and
5 shows a cutting rotating roll and a dispersion module constituting the fiber dispersion supply unit.
6 is a process chart showing a continuous molding method for producing SMC composite according to an embodiment of the present invention.

Hereinafter, the configuration and operation of the embodiment according to the present invention will be described in detail with reference to the drawings.

1 to 2, the continuous molding apparatus for manufacturing the SMC composite of the present invention includes a transfer section 20, a conveyor section 30, a coated fiber supply section 40, a press roller section 60, and a press roller 60 Fibers cut through the forming roller part 70 and the coated fiber supply part 40 and the fiber dispersion supply unit 200 to be described later, which are disposed on the horizontal line of the drawing and are heat-pressed to the drawn film 100 to a predetermined shape. It is largely composed of a resin supply unit 80 and a fiber dispersion supply unit 200 that functions to supply additional fibers on the supplied original film.

On the other hand, the forming roller portion 70 may work in a removed state on the SMC composite production process.

In the above configuration, the transfer unit 20 may be made of one or more transfer rollers, and functions to transfer the original film 10 in a wound state to the inside of the facility. At this time, the original film 10 may be a resin film or a decorative film is selectively adopted.

The conveyor unit 30 is provided with an application box 32 to apply a liquid unsaturated polyester resin to the original film 10 transferred along the transfer unit 20. In addition, a conveyor belt 33 and an operating roller 31 are installed in the conveyor unit 30 to transfer the original film 10, and the application box 32 is installed to be located on the upper portion of the conveyor belt 33. .

The coated fiber supply unit 40 serves to form the processed film 100 by applying carbon fibers 41 or glass fibers to the original film 10 transferred along the conveyor belt 33.

As a configuration for this, the coated fiber supply unit 40 is provided with a plurality of transfer rollers 42 and 43 so that carbon fibers or glass fibers are inherent in the original film 10 to be moved. In this case, the carbon fiber or glass fiber can be supplied in a cut state to 1 to 70 mm by a separately installed cutting facility.

The compression roll 60 is configured to compress and impregnate the processed film 100 drawn out from the coated fiber supply unit 40. That is, a plurality of films such as carbon fibers 41 or glass fibers are stacked in the processed film 100 that is introduced into the compression roll 60, and while passing through the compression roll 60, these films are subjected to high pressure. It is compressed to each other to achieve adhesion.

Meanwhile, in the above-described configuration, a film supply unit 50 may be installed between the coated fiber supply unit 40 and the compression roller unit 60. The film supply unit 50 serves to provide an APP film 51 or a deco film to the processed film 100 to be transferred.

As a configuration for this, the film supply unit 50 comprises a supply roll 52 in which the supply film is wound, and a plurality of transport rolls 55 for transporting the supplied film. Here, the above-described application box 53 is installed between the transfer rolls 55, and the thermosetting resin may be applied to the original film 10 transferred through the application box 53.

The above thermosetting resin (unsaturated polyester resin) acts as an adhesive medium between the film and the film.

The forming roller portion 70 is installed on the horizontal line of the pressing roller 60 and serves to heat-press the working film 100 drawn from the pressing roller 60 into a predetermined shape. Specifically, a plurality of press rollers are installed to have a pair of press rolls, each up and down. In the heat pressing process, the processed film introduced through a plurality of heating elements arranged on the forming roller portion 70 is heated.

A plurality of pressure rollers are arranged in the direction of the incoming film, and each pressure roller is formed with a deeper curvature of the pattern formed on each outer circumferential surface of the upper and lower pressure rolls as it moves toward the direction of the film, resulting in sudden deformation during molding of the processed film. In order to prevent wrinkles from forming on the flat plate of the processed film, pattern shapes are sequentially formed.

Referring to FIG. 3, a detailed configuration of the resin supply unit 80 constituting the continuous molding apparatus is shown.

The resin supply unit 80 is supplied in a state where the resin transport belt 81, drive rollers 81a and 81b disposed at both ends of the resin transport belt 81, and on the upper side of the resin transport belt 81 are disposed. It includes a resin inlet 82 that functions to guide the resin onto the upper surface of the resin transfer belt 81, and a resin separator 83 disposed on one lower end of the resin transfer belt 81. The resin separator 83 may have a structure in which its end is disposed in close contact with the surface of the resin transfer belt 81.

The resin inlet 82 allows the liquid resin supplied in a state arranged in a transverse direction along the width direction of the resin transport belt 81 to be supplied in a state unfolded in a uniform state on the resin transport belt 81. . On the resin inlet 82, a nozzle-type resin injecting means capable of spraying the supplied resin with a large area may be installed.

The resin supplied through the resin inlet 82 undergoes a process of being cured on the move while being supplied to the resin transfer belt 81. That is, the resin thinly coated on the resin transfer belt 81 is transferred in the form of a resin film 85 having a viscous state in a sticky state through normal temperature cooling while moving through the resin transfer belt 81, and the resin film ( 85) undergoes a process of being separated on the resin transfer belt 81 through the resin separator 83 disposed at the bottom of the front drive roller 81b among the drive rollers 81a and 81b.

That is, the resin film 85 transferred in a cured state on the resin transfer belt 81 is separated from the resin transfer belt 81 through the end of the resin separator 83 and transferred to the conveyor unit 30 ( 10) It is added to the phase.

As described above, the resin input nozzle constituting the resin supply unit 80 in the state in which the fibers cut on the original film is supplied through the application box 32, the application fiber supply unit 40 and the fiber dispersion supply unit 200 The impregnation is performed in a state in which the resin is additionally applied, thereby improving impregnation and dispersibility in the prior art by additionally applying the resin in the middle of the cut fibers. That is, it is possible to realize up to 50-60% by weight of the amount of fibers previously added to 30-40% by weight.

4 to 5, the fiber dispersion supply unit 200 is disposed in the main body frame 210 and the main body frame 210 in which the carbon fibers 41 supplied from the coated fiber supply unit 40 enter. Cutting rotating roll 220 for performing the cutting operation on the carbon fiber 41, the carbon fiber 41 in the cut state in a state spaced apart on the lower portion of the cutting rotating roll 220 conveyor section 30 Dispersion module 230 to be supplied in an unfolded state, distributed fiber guide 240 and dispersion module 230 disposed on both sides of the dispersion module 230 at the same time as being disposed on the lower portion of the cutting rotating roll 220 It includes a power unit 250 for providing a driving force.

The body frame 210 supports the frame body 212 in a downwardly coupled state on the bottom edge of the frame body 212 and the frame body 212 having a hollow fiber inlet 211 formed on the top. It has a frame support (214). The frame body 212 may have a structure in which a plurality of hollow chambers are stepped from the top to the bottom, and in a specific embodiment, the upper chamber is formed with a fiber inlet 211 at the top, and connected to the bottom of the upper chamber, but outwardly It is composed of an intermediate chamber formed stepwise and a lower chamber connected to a lower end of the intermediate chamber and stepped outward. Here, the cutting rotary roll 220 may be a structure disposed on the lower chamber.

The cutting rotating roll part 220 may be a structure in which a pair of rotating rollers are arranged in parallel on the lower side of the fiber inlet 211 on the inner region of the frame body 212.

The cutting rotating roll part 220 has a cutting roll 231 having a cutting edge formed along an outer circumferential surface and a corresponding roll 223 disposed side by side in the horizontal direction with the cutting roll 231. The counter roll 223 allows cutting of the carbon fibers 41 entered between the cutting roll 231 and the counter roll 223 in a state in which the outer peripheral surface has a member having a certain elasticity. That is, under the structural relationship between the cutting roll 231 having a substantially engaged structure and the counter roll 223, when performing the cutting operation by the cutting roll 231, the carbon fiber 41 has a resilient counter roll 223 A smooth cutting operation may be possible through contraction of the outer peripheral surface.

The dispersion module 230 includes a dispersion center rod 231 disposed across a pair of spaced apart dispersion fiber guides 240, a plurality of dispersion guide bars 232 radially disposed around the dispersion center rod 231, and a dispersion center rod 231 and a pair of rotating disks 233 disposed on both ends of the plurality of dispersion guide bars 232. In the space between the dispersion center rod 231 and the plurality of dispersion guide bars 232, while the cut carbon fiber particles are introduced, the dispersion center rod 231 and the dispersion guide bar 232 rotate through driving of the power unit 250 ) Has the effect of being distributed to the surrounding space through the rotating vortex formed through the rotating force of).

The dispersion fiber guide 240 functions to guide the cut carbon fiber 41 so as not to escape the edge of the original film 10 supplied through the conveyor unit 30. Specifically, the dispersion fiber guide 240 has a plate shape having a predetermined thickness, and on the upper and lower portions, refractive portions 241 and 243 each having a predetermined slope are formed. The bends 241 and 243 are formed to have an angle inclined from the outside to the inside.

On the other hand, on the front and rear of the main frame 210, a fiber dispersion barrier film 260 disposed to cross the conveyor unit 30 may be installed. The fiber dispersion barrier film 260 may be made of, for example, an acrylic material having a predetermined strength.

The present inventors continuous molding apparatus and continuous molding method improves the directionality and dispersibility toward the original film of the cut fiber in the process of forming a processed film by applying various fibers on the original film supplied for manufacturing the SMC composite.

The present invention prevents falling only around the fiber inlet 211, which is a place in which roving fibers are introduced during the application process by scattering the cut fibers using a rotating roll and implements uniform dispersibility.

6 is a process flow chart showing a continuous molding method for the production of SMC composite according to the present invention. The continuous molding method for manufacturing the SMC composite is sequentially performed in the first resin coating step (S 10), the fiber coating step (S 20), the second resin coating step (S 30), and the deco forming step (S 40). .

Specifically, the first resin coating step (S 10) is a step of applying a liquid thermosetting resin to the original film. At this time, in the first resin application step (10), the original film may be a decorative film. Deco film is a predetermined pattern is formed on the outer circumferential surface can be mainly applied to the production of building panel exterior materials. In addition, the thermosetting resin may be applied to an unsaturated polyester resin, which serves to bond adjacent films to each other after melting. The fiber coating step (S 20) is a step of applying carbon fibers or glass fibers to the original film. The carbon fiber and the glass fiber are coated on the original film to ensure solidity, and may be subsequently drawn into a press roller to form a predetermined pattern.

Here, the fiber coating step (S 20) may be selectively excluded. That is, in the case of manufacturing a general mining panel rather than a building panel, it is manufactured in a flat shape without the need to form a pattern on the outer circumferential surface. Therefore, in this case, the resin film is applied and compressed without forming a separate pattern so that it can be finally withdrawn.

The second resin coating step (S 30) is a step of supplying additional resin through the resin supply unit on the original film supplied with the fibers cut through the coated fiber supply unit.

That is, through the process of supplying additional resin on the cut fibers using a resin supply unit in the process of forming a processed film by applying various fibers on the original film to improve the impregnation and dispersibility toward the original film.

The third resin coating step (S 40) is a step of providing an APP film or a deco film to the processed film in a state in which the above fibers are coated.

That is, the processed film may be applied with a decorative film on both sides or a decorative film may be applied to only one side. Accordingly, it can be applied to panels of various shapes such as architectural panels or mining panels.

The deco forming step (S 50) is a step of pressure-molding the processed film after the third resin coating step (S 40) at a high temperature. In this step, a high temperature is generated through the heating elements, and the processed film is heated, and then a pattern formed on the press roller is formed on the processed film and then drawn out to naturally cool.

The present invention has been described through the above embodiments, but the present invention is not limited thereto. The above embodiments may be modified or changed without departing from the spirit and scope of the present invention, and those skilled in the art will recognize that such modifications and changes also belong to the present invention.

This patent application is supported by the Korea Industrial Technology Agency with the support of the government (Ministry of Trade, Industry and Energy) in 2019. (Task number: P000 2292, Project name: Advanced carbon panel forming method for 35% weight reduction) Development of applied steelless tailgate module)

10: One film
20: transfer unit
30: conveyor section
40: coated fiber supply unit
50: film supply unit
60: crimping roller unit
80: resin supply unit
100: processed film
200: fiber dispersion supply unit

Claims (6)

A conveyor unit having an application box formed to apply a liquid thermosetting resin onto the original film drawn out from the transfer unit;
A coating fiber supply unit for applying solid fibers to the original film drawn out from the conveyor unit;
A resin supply unit functioning to supply additional fibers on the original film supplied with the fibers cut through the coated fiber supply unit; And
It includes; a crimping roller unit for crimping the processed film drawn out from the coated fiber supply unit;
The resin supply unit includes a resin transport belt, a driving roller disposed at both front and rear ends of the resin transport belt, a resin inlet for guiding resin supplied in a state arranged on an upper side of the resin transport belt, and a lower end of one side of the resin transport belt. It includes a resin separator disposed on,
The resin inlet is to supply the liquid resin supplied in a state arranged in a transverse manner along the width direction of the resin transport belt in a state in which it is spread in a uniform state on the resin transport belt through a nozzle type resin input means. and,
The resin film conveyed in the cured state on the resin conveyance belt is separated from the lower end of the resin conveyance belt through the end of the resin separator and is additionally put on the original film transferred to the conveyor part. Continuous molding device.
According to claim 1,
The resin applied on the resin transport belt is transferred to the resin film form having a viscous viscosity in a sticky state through cooling while moving through the resin transport belt, and the resin film is separated on the resin transport belt through the resin separator. A continuous molding device for architectural panels, which is applied on the original film drawn out from the conveyor.
According to claim 1,
Further comprising; a fiber dispersion supply unit for supplying on the original film of the conveyor unit through cutting and dispersion in the state that the entry of the solid fiber supplied from the coated fiber supply unit is made,
The fiber dispersing supply unit is a body frame in which carbon fibers supplied from the coated fiber supply unit enter, a cutting rotating roll disposed in the body frame and performing a cutting operation on the supplied carbon fiber, a lower phase of the cutting rotating roll Dispersing module for supplying the carbon fibers in the cut state in the state of being spaced apart in the expanded state on the conveyor part, and distributed fiber guides disposed on both sides of the dispersion module at the same time as being disposed on the lower portion of the cutting rotary roll And a fiber dispersion barrier film disposed on the front and rear sides of the body frame to cross the conveyor part.
The dispersion fiber guide guides the cut carbon fibers so as not to deviate from the edge of the original film supplied through the conveyor part by forming refracting parts having angles inclined downwardly on the upper and lower parts, respectively.
The cutting rotating roll is a structure in which a pair of rotating rollers are arranged in parallel on the inner region of the body frame,
The cutting rotary roll cuts the solid fiber entering between the cutting roll and the corresponding roll in a state having a cutting roll having a cutting edge along the outer circumferential surface and a corresponding roll arranged in parallel with the cutting roll,
Continuous forming device for building panels.
According to claim 3,
The dispersion module is on a dispersal center rod disposed across a pair of spaced dispersion fiber guides 240, a plurality of dispersion guide bars radially disposed around the dispersion center rod, and on both ends of the dispersion center rods and the plurality of dispersion guide bars. Comprising a pair of rotating disks arranged,
Continuous forming device for building panels.
A continuous molding method using the continuous molding apparatus for a building panel according to any one of claims 1 to 4,
A first resin coating step of applying a liquid thermosetting resin to the original film;
A fiber coating step of applying the solid fiber supplied from the coated fiber supply unit on the original film;
A second resin coating step of supplying additional resin through a resin supply unit on the original film supplied with the fibers cut through the coating fiber supply unit;
A third resin coating step of adhering an APP film or a deco film to the processed film in a state in which the solid fiber is coated; And
Continuous molding method for a building panel comprising the step of deco forming to compress the processed film at a high temperature after the third resin coating step.
The method of claim 5,
The original film is a continuous molding method for a building panel, characterized in that the decorative film pattern is formed on one side.

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