KR20000010382A - Complex material having reinforced performance manufacturing method and manufacturing device thereof - Google Patents

Abstract

PURPOSE: A device is provided to manufacture a complex material that has a reinforced performance by layering the reinforced fiber in the same direction as a sheet. CONSTITUTION: A complex mat manufacturing device(200) comprises: transferring unit(210) transferring a heat-plastic fiber resolved; a pair of feed rollers(220) regularly supporting and catching the heat-plastic fiber that is transferred by the transferring unit; a first fiber dispersion cylinder(230) closely installed in the first feed roller and dispersing fiber that is provided from the first feed roller in the revolving state by high speed; and an inhaler(290) inducing fiber falling.

Description

Composite material manufacturing method with enhanced performance and manufacturing device

The present invention relates to a manufacturing apparatus and a manufacturing apparatus of a reinforced composite material, and more particularly, to produce a composite mat using the thermoplastic resin fibers and reinforcing fibers of the matrix resin, and to the upper and lower sides of the manufactured composite mat The present invention relates to a reinforced composite material manufacturing method and a manufacturing apparatus having a reinforced performance of a composite material by laminating reinforcing fibers in one direction through a stampable sheet manufacturing apparatus.

BACKGROUND ART In the fields of automobile parts, electric parts, electronic parts, and other industrial parts, fiber reinforced composite materials are frequently used for applications requiring strength, rigidity, and durability of products. The purpose of the composite material, which combines different materials to express new performance, is to have light weight, high specific strength, high inelasticity, and enhanced mechanical properties. Fiber-reinforced thermosetting resin composite material (FRP), which is made of glass fiber reinforced unsaturated polyester resin, which is a thermosetting resin, has been used as a component of aircraft, ships, and precision equipment electronic devices. FRP has the advantage of starting to use as a highly elastic material because the elastic modulus becomes very high when molded in one direction. However, fiber-reinforced composite materials using thermosetting resins as matrix resins have problems in terms of physical properties such as impact resistance and fracture toughness, and have disadvantages such as small allowable deformation and difficult recycling in deformation of materials. Recently, in order to solve such problems, fiber-reinforced thermoplastic resin composite materials (FRP) using thermoplastic resins have been developed, and application fields are rapidly expanding to replace metals based on automobile parts. FRTP has better molding processability than FRP and has a greater recycling ability, which has recently emerged as a serious social problem. FRTP has been used mainly for interior parts and non-structural parts as automotive parts. However, in recent years, FRTP has been applied to structural parts such as equipments and bodies that require impact resistance and high strength. In addition, unlike the conventional FRP, FRTP has a high productivity because the stamping forming method can be applied like a metal forming method, and the freedom of design is superior to that of metal, thereby increasing the adoption in various industrial fields. Among the industrial applications, automotive parts require more than a certain level of strength when used as interior parts, such as headlining and door trim, and non-structural parts such as battery trays and engine covers, but bumperback beams, front ends, fenders, seat frames, etc. Efforts to develop special performance enhancement methods have been underway because the performance of ordinary FRTP cannot be satisfied to apply to structural parts. In order to manufacture molded articles such as automobile parts using FRTP as a stamping molding method, first, FRTP must be manufactured into a sheet shape to be suitable for molding processing of molded articles, and this sheet is specifically called a stampable sheet.

On the other hand, although not shown in the drawings, a method of heating and mixing a thermoplastic resin in a powder or pellet form with a reinforcing fiber for the purpose of manufacturing a conventional FRTP stampable sheet has been proposed, but a thermoplastic resin in a powder or pellet state as a matrix resin Is not only difficult to uniformly mix the two types of materials, but also it is easy to separate powder or pellets in various processes after mixing, and uniformly disperse the reinforcing fibers in the matrix resin. It was difficult to obtain high quality products.

On the other hand, Japanese Patent Application Laid-Open No. 5-285947 discloses a thermoplastic resin particle, a reinforcing long fiber (length: 3-5 mm), and a glass ballun (hollow particle). Three raw material supply hoppers each containing a; a dispersion container for dispersing / spreading the raw materials supplied from these raw material supply hoppers in a liquid; a head box for removing water from the dispersion / suspension; and moving in the head box. Disclosed is a stampable sheet manufacturing apparatus comprising a web which forms a web on a mesh paper, a hot air dryer for drying the web, and a continuous press. This device is difficult to handle because the raw material is particulate or short fiber, cannot handle continuous fiber or long fiber, and there is a possibility of dust generation, which can contaminate the working environment and also supply each raw material separately to disperse / suspend In addition to this, a dehydration device was required, and there was a risk of water pollution.

Japanese Patent Laid-Open No. 6-47737 discloses a resin extruder for compressing / supplying a molten polypropylene resin between a polypropylene sheet in which glass short fibers are dispersed and a continuous glass fiber sheet; A conveying pressure transfer part belt for pressurizing and laminating the polypropylene sheet, the molten polypropylene resin, and the continuous glass fiber sheet together at the same time while being pressed up and down, and heating the laminated sheet to impregnate and laminate the molten polypropylene into the continuous glass fiber sheet. Disclosed is a stemler sheet manufacturing apparatus comprising a heating furnace for integrating and a cooling furnace for cooling the heated sheet.

In the above prior art, the molten polypropylene must be extruded between the sheets, so a melt extrusion means of the resin is required, and it is difficult to distribute the molten resin uniformly over the entire width of the continuous sheet. In addition, it is difficult to adjust the thickness of the sheet by the conveying pressure conveyor belt, and it is also difficult to secure the dense connective structure and the uniform surface smoothness of the product. In addition, since the heating furnace and the cooling furnace are simple chamber-type, there is no means such as a roller that can make the thickness of the product uniform again in the heating step and the cooling step.

Further, Japanese Patent Laid-Open No. 5-16137 discloses a fluidized bed device having a top, a middle, and a bottom separately for producing a fiber bundle with resin, a rotary cutter at the top and a bottom for cutting the fiber bundle, and a fluidized bed device of the middle. Disclosed is an apparatus for producing a fiber composite sheet composed of an endless for attaching and transporting a resin-attached fiber adherend cut into a continuous post-attached fiber bundle from the top and bottom edges, and heating and cooling means.

In the above apparatus, the heating means is a heat transfer type or a hot air circulation type, and although a plurality of heating rollers of a direct heating type can be used in the heating means, the axis between the rollers is fixed so that the heat history factor of the molten thermoplastic resin is melted. Since the flow direction cannot be changed, uniform penetration of the molten resin is impossible, and the sheet tension cannot be adjusted properly, resulting in uneven thickness and surface smoothness, and the cooling means is simple due to air blowing or cooling of the fixed guide roller. There was a drawback that it was difficult to adjust the finish thickness of the heated sheet after cooling the sheet.

The prior arts described above are in the form of application or impregnation of molten resin in sheet production and simple hot air heating type in heating, or simply fixing the roller even if a roller is used, so that the melt flow direction of the heat history factor of the molten resin Can not be variably controlled to ensure a uniform thickness and uniform surface smoothness.

Recently, a matrix mat and a reinforcing fiber are manufactured using a centrifugal force to produce a composite mat in which the main kinds of fibers are randomly oriented, and the composite mat is melt-pressed in a sheet manufacturing apparatus consisting of a plurality of heating rollers and a plurality of cooling rollers. By varying the angle between the roller axes, the molten matrix resin can be uniformly distributed and impregnated with the reinforcing fibers, thereby improving the interfacial adhesion between the matrix and the reinforcing fibers, thereby improving the physical properties, the uniform thickness, and the smooth surface. A method of continuously manufacturing a stampable sheet of a composite material has been disclosed. However, the random orientation reinforcing fiber alone has insufficient rigidity, and various methods have been sought to improve the impact resistance characteristics of the stampable sheet. The method includes one-way reinforcing method, 2D weaving reinforcement rice method, and 3D weaving. To strengthen it. While 2D and 3D weaves are difficult to process with thermoplastic resins, multi-layered reinforcement methods have been studied using reinforcing fibers laminated in one direction, and methods of impregnating molten resins are made of matrix fibers and composite fibers randomly oriented as reinforcement fibers. Was used. In order to improve impact resistance or modulus of elasticity, such a technique needs to improve the strength in one direction, and when the fiber is aligned in one direction, the strength in one direction is good when the fiber is aligned in one direction. Lose. However, there is a disadvantage that the strength is weak in the vertical direction of the one direction in which the reinforcing fibers are oriented.

The present invention is to solve the above problems, to produce a composite mat using the thermoplastic resin fibers and reinforcing fibers of the matrix resin, the sheet and one side of the sheet through the stampable sheet manufacturing apparatus on the upper and lower sides of the manufactured composite mat It is an object of the present invention to provide a manufacturing method and apparatus for manufacturing a composite material having enhanced performance by laminating reinforcing fibers.

The present invention is configured as follows to achieve the above object. That is, the method of manufacturing a composite material having increased strength, comprising: a sea fiber raw material supplying process for spinning and supplying fibers; Processing the sea fiber raw material to produce a composite mat; And a method of manufacturing a stampable sheet by sequentially laminating a sheet and reinforcing fibers in one direction on upper and lower surfaces of the composite mat.

Another feature of the present invention is an apparatus for producing a composite material of increased strength, comprising: sea fiber raw material supply means for supplying the fibers to be spun; Means for processing the sea fiber raw material to produce a composite mat; And a composite mat manufacturing apparatus with enhanced performance consisting of a means for producing a sheet and a sheet on the upper side and the lower side of the composite mat, the reinforcing fiber in one direction sequentially to produce a tamperable sheet.

In the above-described configuration, the sea fiber raw material supply means, the transfer unit for transferring the fiber to a predetermined position; A seam cylinder for isolating the fiber conveyed by said transfer part; A drive motor for rotating the island cylinder; An inhaler that sucks the fibers deemed by the island cylinder into a duct; A disperser for uniformly dropping the sea fibers sucked into the duct; A vibration damper installed below the disperser to vibrate to increase density of the sea fiber and to reduce porosity; And it consists of a sensor for sensing the supply amount of sea fiber supplied to the supply roller installed at the end of the duct.

In the above-described configuration, the composite mat manufacturing means, the transfer unit for transporting the resolved thermoplastic fibers; A pair of first feed rollers serving to constantly supply or hold the thermoplastic fibers conveyed by the conveying unit; A first splitting cylinder installed close to the first feed roller and splitting the fiber provided from the first feed roller while rotating at a high speed; A collecting port for collecting the fibers provided from the first divided cylinder; A suction drum having a filter net for sucking the fibers collected in the collecting port; A second feed roller for transferring the fiber passed through the filter net to a predetermined position; A second splitting cylinder rotated at high speed to redistribute the fibers provided from the second feed roller; A guide tool having a boiling passage for guiding fibers falling from the second divided cylinder; An inhaler positioned below the guide tool to induce a drop of the fiber provided from the second divided cylinder; And a compression roller for pressing the dropped fibers (web) in a predetermined state.

In the above configuration, the stampable sheet manufacturing means, the fiber pressing roller for pressing the composite mat; A lower transfer part having a drive cylinder installed to transfer the composite mat compressed by the fiber pressing roller to a predetermined position; An upper transfer part positioned at a predetermined distance above the lower transfer part and having a driving cylinder; A seating / one direction reinforcing fiber roll which is wound around the driving cylinder so as to be sequentially stacked on the upper and lower side surfaces of the composite mat and the sheet and one direction reinforcing fiber are pressed by the driving cylinder; A heater for heating the composite mat; A heating pressing roller for heating / compressing the composite mat so as to maintain a state in which sheets and reinforcing fibers in one direction are sequentially stacked on upper and lower sides of the composite mat; And a cooling / high foaming machine for cooling / high foaming the composite mat again through the heating compression roller.

In the above-described configuration, the reinforcing fiber manufacturing means in one direction, the selection pin to select the composite fiber to each strand; A pair of feed rollers which are installed to face the selected composite fiber so as to be supplied; Molten resin impregnation / binding means for impregnating and binding the molten resin onto the composite fiber provided from the feed roller; A heating roller for heating and compressing the impregnated / bonded composite fiber to a predetermined thickness; A cooling roller for cooling / compressing the molten resin to a predetermined thickness while passing through the heating roller; And it is composed of a play adjuster for adjusting the distance of the roller.

1 is a block diagram showing a fiber supply apparatus of the present invention,

Figure 2 is a block diagram showing a composite mat manufacturing apparatus of the present invention,

3 is a block diagram showing an apparatus for manufacturing a sheet of the present invention,

Figure 4 is a block diagram showing a reinforcing fiber manufacturing apparatus of one side of the present invention,

5 to 7 are each a side view / plan view / front view showing a composite mat of the present invention,

8 is a flow chart showing a manufacturing process of a composite material with enhanced performance.

** Description of symbols for the main parts of the drawing **

50: composite mat 52: sheet

54: unidirectional reinforcing fiber 100: fiber feed device

110: transfer part 120: sea cylinder

130: drive motor 140: duct

150: inhaler 160: disperser

170: vibration damper 180: feed roller

200: composite mat manufacturing apparatus 210: transfer unit

220: 1st feed roller 230: 1st minute cylinder

240: collecting port 250: suction drum

252: net 260: second feed roller

270: 2nd minute cylinder 280: guide port

290: suction 295: compression roller

300: stampable sheet manufacturing apparatus 310: fiber pressing roller

320: lower transfer unit 322: drive cylinder

330: upper transfer part 332: drive cylinder

340: Citrol 350: Reinforcing fiber in one direction

360: heater 370: compression roller

380: cooling / high foaming machine 400: unidirectional reinforcing fiber manufacturing apparatus

410: selection pin 420: feed roller

430: impregnation / binding means 440, 450: heating roller

460: cooling roller 470: play adjuster

Hereinafter, with reference to the accompanying drawings will be described a preferred embodiment of the present invention;

Figure 1 is a block diagram showing a fiber supply apparatus of the present invention, Figure 2 is a block diagram showing a composite mat manufacturing apparatus of the present invention, Figure 3 is a block diagram showing a moldable sheet manufacturing apparatus of the present invention. 4 is a configuration diagram showing a reinforcing fiber manufacturing apparatus in one direction of the present invention, Figures 5 to 7 is a side view / plan view / front view respectively showing the composite mat of the present invention, Figure 8 is enhanced performance It is a flow chart showing the manufacturing process of the composite material.

First, as shown in Figure 1, the fiber supply apparatus 100 includes a conveying unit 110 for transferring the fiber to a predetermined position; A seam cylinder (120) for islanding the fiber transferred by the transfer unit (110); A drive motor 130 for rotating the island cylinder 120; An inhaler 150 that sucks the fibers desealed by the seam cylinder 120 into the duct 140; Disperser 160 to uniformly drop the sea fibers sucked into the duct 140; A vibration damper 170 installed below the disperser 160 to vibrate to increase the density of the sea fiber and reduce porosity; And a sensor 190 for detecting a supply amount of sea fiber supplied to a supply roller 180 installed at an end of the duct 140. Here, the above-described fiber supply apparatus 100 is also designed to cut the continuous fiber to a certain length, but in order to reduce the efficiency and raw material production cost in the raw material supply side, the fiber supply apparatus 100 has a predetermined content of the cut fiber It is configured to be supplied in rain.

And, as shown in Figure 2, the composite mat manufacturing apparatus 200 includes a conveying unit 210 for conveying the resolved thermoplastic fiber; A pair of first feed rollers 220 serving to constantly supply or hold the thermoplastic fibers conveyed by the conveying unit 210; A first splitting cylinder (230) installed close to the first feed roller (220) and splitting fibers provided from the first feed roller (220) while rotating at high speed; A collecting port 240 for collecting the fibers provided from the first divided cylinder 230; A suction drum 250 having a net 252 for sucking the fibers collected in the collecting port 240; A second feed roller 260 which transfers the fiber having passed through the web 252 to a predetermined position; A second splitting cylinder 270 for redistributing the fiber provided from the second feed roller 260; A guide tool 280 having a boiling passage 282 for guiding fibers falling from the second splitting cylinder 270; An inhaler 290 positioned below the guide port 280 to induce a drop of the fiber provided from the second divided cylinder 270; And a pressing roller 295 for pressing the dropped fibers in a predetermined state.

In the above-described composite mat manufacturing apparatus 200, the fiber provided from the fiber supply device 100 is provided to the conveying unit 210 through the supply roller 296. The sea fiber provided in the transport unit 210 is supplied to the first feed roller 220 by the transport unit 210, where the first feed roller 220 serves to hold or support the sea fiber. The first branching cylinder 230 rotates at a high speed to cut and mix the reinforcing fibers and the matrix resin fibers, and supplies the reinforcing fibers and the thermoplastic resin fibers into the collecting holes 240. That is, the first divided cylinder 230 has a needle (포 布) (not shown) in which the needles are arranged on the circumference, the fiber supplied to the first divided island cylinder 230 is rotated at high speed (diameter 20) Mm, the number of revolutions 2000 to 5000rpm) is cut and mixed, and collected into the collecting port 240. The fibers collected in the collecting port 240 are sucked into the net 252 of the suction drum 250 and are deposited into a web in which the reinforcing fibers and the thermoplastic resin fibers are almost uniformly mixed by centrifugal rotation of the suction drum 250. . Thereafter, the fiber (web) is supplied to the second feed roller 260 while being compressed by the pressing roller 254. The second feed roller 260 again supplies and feeds the web to the second splitting cylinder 270, where the web supplied to the second splitting cylinder 270 is subjected to the suction action of the inhaler 290, as described above. It is cut and mixed in the form, and is divided in a state close to one strand to be released into the non-passage path 282, where different fibers are uniformly mixed. Thus, a flat mixing mat is collected on the fiber collecting portion next to the exit of the non-passage path 282 constituted by the inhaler 290, that is, on the collecting belt traveling toward the non-passage path 282. When the outlet side of the non-passage path 282 is a slit having a width smaller than the length of the supplied fiber, and collected on the collecting belt through this slit, each fiber forming the mixed mat can be oriented in the length direction of the slit. have. In forming the fiber reinforcing material, when the fiber collecting part is formed into a product shape by a ventilation material such as a gold mesh, it can be collected as a product shape mat in which non-coated fibers are uniformly mixed on the shape. The mixed mat can be heat-molded to produce a fiber-reinforced composite material of a desired shape, but since the reinforcing fibers and the thermoplastic resin fibers are deposited in the mixed mat and both are fibrous, they have excellent shape retention characteristics. Also, the separation of the reinforcing fibers and the thermoplastic resin is difficult to occur, so the handling is easy.

The composite mat manufacturing apparatus 200 as shown in FIG. 2 is supplied with carbon fiber as nylon 6 (hereinafter referred to as PA 6) fiber and reinforcing fiber, which is a thermoplastic resin, to produce a composite mat. It can be manufactured into flat fiber-reinforced thermoplastic composite material by 1mm in thickness and suitable amount in a mold of 15cm long x 15cm wide, then heating and compressing (heating temperature 240 ℃, compressive strength 50㎏ / ㎠) for about 4 minutes. have. In addition, the plate-shaped fiber-reinforced composite material may be placed in a mold having a thickness of 5 mm, reheated (about 4 minutes at a heating temperature of 240 ° C.) to melt and expand the resin, and then cooled to prepare a foamed composite material. As for the composite mat used for molding, it is preferable to use a CF volume fraction having a large repulsive force of reinforcing fibers of 20% and 30%.

Figure 3 is a block diagram showing an apparatus for manufacturing a tamperable sheet of the present invention.

As shown in Figure 3, the stampable sheet manufacturing apparatus 300 is a fiber pressing roller 310 for pressing the composite mat; A lower conveying unit 320 having a driving cylinder 322 installed to convey the composite mat compressed by the fiber pressing roller 310 to a predetermined position; An upper transfer part 330 positioned above the lower transfer part 320 and having a driving cylinder 332; Sitrol / unidirectional reinforcement fibers are wound adjacent to the drive cylinders (322,332) so as to be laminated by the drive cylinders (322,332) to sequentially stack the sheet and one side reinforcement fibers on the upper and lower sides of the composite mat Rolls 340 and 350; A heater 360 for heating the composite mat; A heating pressing roller 370 for heating / pressing the composite mat so as to maintain a state in which the sheet and the reinforcing fibers in one direction are sequentially stacked on the upper and lower sides of the composite mat; And a cooling / high foaming machine 380 for cooling / highly foaming the composite mat which has passed through the heating compression roller 360.

In the stampable sheet manufacturing apparatus 300 of the composite material of FIG. 4, the transfer units 320 and 330 are operated by the driving force of the driving motor 334, and thus the respective driving cylinders 322 and 332 are rotated. The composite mat manufactured through the composite mat manufacturing apparatus 200 is transferred to a predetermined position along the transfer units 320 and 330.

In the process of moving the composite mat to a predetermined position, the pressing roller 310 installed at the inlet side of the conveying unit (320,330) is to compress the composite mat. At this time, since the ends of the sheet and the unidirectional reinforcing fibers are connected to the driving cylinders 322 and 332, the sheets and the unidirectional reinforcing fibers are sequentially stacked on the lower side of the composite mat. Here, the heater 360 maintains the lamination state by applying heat to the composite mat, and then compresses the driving cylinders 322 and 332 while laminating the sheet and one side reinforcing fibers on the upper side of the composite mat and heating them.

In the process of conveying the composite mat along the conveying part (320,330), the composite mat is pressed by 1/4 or more of the original thickness by the pressing roller 310, and then compressed by the driving cylinder (322,332) and the sheet and the upper and lower sides , Unidirectional reinforcing fibers are laminated.

In other words, the composite mat is compressed by the pressing roller 310, and then transferred to the heater 360, first by the hot air of 80 to 250 ℃, preferably 100 to 200 ℃ supplied from the heater 360 Moisture in the composite mat is dehydrated to make the moisture content 0.01 to 0.2% or less, and preheating treatment is performed on the thermoplastic fibers. On the other hand, the water removed from the composite mat is recovered to the waste heat recovery apparatus through a hot air discharge duct (not shown) and then reused. The dehydrated and preheated composite mat of thermoplastic fibers passes through the respective heating and cooling and / or preheating process steps sequentially while passing through the up and down conveying parts 320 and 330.

In the stampable sheet manufacturing apparatus 300 of the composite material of the present invention as described above can be produced by selecting the thickness of the composite sheet within the range of 0.5 to 10 mm arbitrarily, produced at a speed of 0.3 to 10 m per minute In addition, a foamed sheet can also be manufactured. In the apparatus of the present invention, thermoplastic resins used in the production of the composite stampable sheet include polyethylene, polypropylene, polystyrene, polyvinyl chloride, nylon 6, nylon 66, nylon 10, polyamide, vinylon, polyester, and the like. Various thermoplastic resins can be used alone or in combination of two or more kinds thereof, and generally used plasticizers, heat stabilizers, light stabilizers, fillers, colorants, pigments, impact modifiers, lubricants and the like can be used.

As the reinforcing fibers used in the manufacture of the sheetable sheet of the present invention, inorganic fibers such as glass fibers, carbon fibers, and boron fibers, and organic fibers such as nylon 6, nylon 66, nylon 10, vinylon, aramid, and polyester are used alone. If necessary, two or more kinds of these fibers may be mixed.

On the other hand, the stampable sheet manufacturing apparatus 300 of the present invention is characterized in that the angle of the axis between the roller and the roller can be arbitrarily adjusted in the range of 0 to 45 °, the molten when the angle of the axis between the rollers is maintained at a constant angle By changing the thermal history factor of the thermoplastic resin in the melt flow direction, a remarkable effect of the penetration of the molten thermoplastic resin deep into the composite mat is exerted. Therefore, the molten thermoplastic resin is sufficiently wetted and impregnated on the surface of the reinforcing fiber, so that a high strength composite material can be produced.

It is also possible to manufacture foamed composite materials using the restoring force of the reinforcing fibers. In other words, the reinforcing fibers reinforced in the thermoplastic matrix fibers in three-dimensional orientations in the x, y, and z directions are compressed by a roller. When this pressure is removed, a foamed composite sheet similar to a chemically foamed material is obtained. Are manufactured. The foamed composite material can be produced with a thickness of 3 to 20 mm, and the specific gravity of the sheet can be produced with 0.3 to 0.8 g / cm 3. That is, when the composite mat is transported to the melt-compression part, the molten resin phase of the thermoplastic fiber melted at the set temperature of the heating roller 370 acts on the upper roller to improve fluidity so as to penetrate deeply into the unreinforced reinforcing fiber phase. The direction of the force and the direction of the force acting on the lower roller are different from each other to change the flow direction of the resin. Therefore, it is possible to improve the melting of the fibers of the thermoplastic resin therein as well as to efficiently penetrate between the thermoplastic reinforcing fibers or inorganic reinforcing fibers having a high melting temperature of the molten resin.

As described above, although the stampable sheet manufacturing apparatus 300 of the composite material according to the present invention is not shown in the drawings, the angle formed by the axes between the rollers may be varied in the range of 0 to 45 °, thereby greatly improving physical properties. Improved composite materials can be produced. Furthermore, since the foamable composite stampable sheet can be manufactured without using a chemical foaming agent, process efficiency and economic efficiency can be expected in this industrial field.

2 and 3, in the present invention, the reinforcing fibers and the thermoplastic resin fibers are supplied to the composite mat manufacturing apparatus 200, and the heterogeneous fibers are uniformly formed by the high speed rotation of the cylinder 230 in which the needles are arranged. The composite mat is divided, mixed and collected to form a composite mat, and the composite mat thus formed is compression molded while being heated above the softening point or melting point of the thermoplastic resin fiber to produce a flat fiber reinforced thermoplastic composite material. At this time, when supplying to the stampable sheet manufacturing apparatus 300 in order to sheet the composite mat according to the application, the characteristics of the composite sheet is further enhanced by laminating the fibers or woven fabric in one direction on the top and bottom of the composite mat It is possible to manufacture reinforced composites. As the reinforcing fiber that can be used in the present invention, various fibers such as glass fiber, carbon fiber, vinylon fiber, polyester fiber, aramid fiber can be used, but the needle of the composite mat manufacturing apparatus 200 such as glass fiber or carbon fiber The arrayed cylinder 230 can be rotated at high speed to be cut as continuous fibers, and fibers that cannot be cut in the cylinder 230 of the composite mat manufacturing apparatus 200 as aramid fibers are supplied as discontinuous fibers cut in advance. do. The thermoplastic matrix fibers are generally general-purpose polyolefin fibers such as polypropylene fibers or polyethylene fibers, but are used in combination with high performance resin fibers that emphasize functionality such as heat resistance, for example polyamide fibers, polyester fibers, and the like. Doing. In this case as well, the cuttable cylinder 230 of the composite mat manufacturing apparatus 200 is supplied as continuous fibers, and the fibers difficult to cut are supplied as discontinuous fibers.

The reinforcing fibers in the composite mat manufactured by the composite material manufacturing apparatus 200 have three-dimensional orientations in x, y, and z directions. When the composite mat is laminated in an appropriate amount and heated and compressed, a fiber-reinforced thermoplastic composite material of a compressed state can be obtained by coiling the reinforcing fibers well in a random orientation.

The composite mat manufacturing apparatus 200 of the present invention receives a raw material cut into a continuous fiber by a reel method and supplies a predetermined amount thereof, and manufactures a composite mat supplying fiber 100 which may premix. When installed in front of the device, efficiency can be improved and work division can be applied.

Figure 4 is a block diagram showing a reinforcing fiber manufacturing apparatus 400 in one direction.

As shown in Figure 4, the reinforcing fiber manufacturing apparatus 400 in one direction includes a selection pin 410 for selecting the composite fiber to each strand; A pair of feed rollers 420 opposed to each other so as to supply the selected composite fiber; Molten resin impregnation / binding means (430) for impregnating and binding the molten resin onto the composite fiber provided from the feed roller (420); Heating rollers (430, 440) for heating and compressing the impregnated / bonded composite fiber to a predetermined thickness; Cooling roller 450 for cooling / compressing the molten resin to a predetermined thickness while passing through the heating rollers (430, 440); And a clearance controller 460 for adjusting the interval of the rollers 430, 440, 450.

In the one-way reinforcing fiber manufacturing apparatus 400, the continuous fibers are wound around the bobbin and the product is placed at regular intervals by walking the selection pins 410, and the continuous fibers pass through the selection pins 410 to reduce their spacing after the first selection. For the second choice, the fiber spacing is almost close enough. The selected fiber arrangement is compressed to be fixed to the upper and lower feed rollers 420 in order to prevent the disorder. When the fiber selected in the above is bound to the same resin as the resin used in the composite mat, the impregnating properties can be excellent and high strength properties can be exhibited, and the compatibility between the resin can be improved even when the composite mat and the laminate are laminated. Therefore, the impregnation degree of resin can be raised by performing reverse L type type calendaring. Extruder 432 is supplied from above to extrude the molten resin for binding of UD fiber (reinforced fiber in one direction), and the direction can be extruded by installing from the vertical or horizontal side and heating compression roller (434,436). The drawing die should be parallel to the upper heating extrusion roller 434 to supply a certain amount to the surface. The molten resin adhered to the surface of the roller 434 was able to supply a predetermined amount by the blade 438 and at the same time to remove the remaining molten resin, and the resin discharged through the blade 438 was impregnated into the fibers selected in advance. It was. The lower heating compression roller 436 is to impregnate the impregnated resin evenly between the fibers and to maintain a constant thickness in the heat compression rollers (430, 440) and to cool in the final roll, that is, the cooling compression roller (450) The orientation is complete. Completed one-way reinforcing fiber is installed in the winding means of the above-described stampable sheet manufacturing apparatus 400 in the form of a roll.

5 to 7 is a side / front / plan view showing a composite material molded through the stampable sheet manufacturing apparatus 300. The sheet 52 and the unidirectional reinforcing fibers 54 are sequentially stacked on the upper and lower sides of the composite mat 50.

On the other hand, when the fiber is used as a reinforcing material in the conventional composite material, short fibers of less than several millimeters and long fiber lengths have used short fibers of less than 25 millimeters, but shorter reinforcing fibers do not effectively carry out stress transfer under a certain stress, so the reinforcing effect is good. Will not. Therefore, in order to improve the reinforcing effect, it is better to use long fibers as reinforcing materials rather than short fibers. If the length of the long fiber is more than 30mm, the reinforcing effect may be good, but more than 50mm is effective, and the appropriate fiber length is selected according to the type of composite material or its use. Depending on the length of the fiber, there are changes in physical properties such as stiffness, dimensional stability, heat resistance, etc. of the composite material, and these properties are also affected by the filling amount of the fiber, the fiber length after molding, the fiber dispersion state, and the arrangement state. In general composite materials in which reinforcing fibers are randomly distributed, the distribution of reinforcing fibers is randomly distributed only in the xy direction, and thus the impact strength is less than the required value. However, as in the present invention, random orientation is performed using a composite mat manufacturing apparatus using centrifugal force Reinforcing fibers are strongly coiled to produce effects such as triaxial weaving. That is, the composite material manufacturing method reinforced by fiber weaving is to develop a technology that can produce the effect of weaving as a technique similar to weaving because of low productivity. That is, in general, when the reinforcing fibers are randomly oriented in the matrix resin, the fibers are formed in the xy direction and have little orientation force in the z direction. However, the strength is limited, but the technique of the present invention provides both the matrix and the reinforcing fibers in fibrous form. Because of strong mixing with centrifugal force, 10-20% as well as the xy direction are coiled in the z direction, and the mechanical strength is similar to that of the 3D weaving method. However, in order to further reinforce the strength characteristics of the composite material, the UD fiber or woven fiber should be reinforced. In the present invention, the length of the reinforcing fiber is 50-200 mm, optimally 80-130 mm, and the diameter of various fibers is It is good in it being 2 micrometers-30 micrometers, and 5 micrometers-25 micrometers optimally. In the present invention, the content of the reinforcing fiber of the composite mat is 10 to 70% by weight, preferably 15 to 50% by weight. The physical properties of the composites are greatly influenced by the properties of the matrix and the reinforcing material as well as the bonding force between the matrix and the reinforcing fibers, i.e., interfacial properties. In addition, the interface property of the composite material is more important because the impact energy applied from the outside plays a role in transferring stress, deformation, etc. from the matrix to the fiber.

On the other hand, Figure 8 shows a flow chart of the present invention, briefly look at the overall flow of the present invention, in the step (S500) to transfer the fiber to the island islet cylinder 120 through the transfer unit in the process of isolating the fiber islet cylinder ( The fibers are decoded by 120, and the decoded fibers are introduced into the duct 140 by the suction force of the inhaler 150 (shown in FIG. 1). The sea fibers introduced into the duct 140 are uniformly dropped by the disperser 160 and are accumulated on the supply roller 180 in a state where the density is increased by the vibration of the vibration damper 170. Is to sense / control the supply amount of sea fiber (shown in Figure 1).

In step S510, the fibers are spun at high speed to the splitting cylinder 230 for splitting, and then centrifugally rotated through the suction drum 250 to form a composite mat. When the composite mat is molded, the process proceeds to step S520 (FIG. City on 2). In step S520, it is determined whether the composite mat manufactured by the composite mat manufacturing apparatus 200 has a predetermined thickness. If the composite mat does not have a predetermined thickness, the process proceeds to step S510. If the composite mat has a predetermined thickness, the process proceeds to step S530 and step S540.

In step S530, the composite mat is pressed and moved by the pressing roller 310, after laminating the sheet and the reinforcing fibers in one direction on the upper and lower sides of the composite mat, the heater 360 and the pressing roller for heating (370) The final sheet is manufactured through S) (S540).

As described above, the present invention does not use powdery or pelletized thermoplastic resin as a matrix, but prevents the separation of the reinforcing fibers and the matrix using thermoplastic fibers, and then stores or transports them as a mat. It is advantageous to be able to mold at any time. In addition, the composite material obtained by molding the uniformly dispersed fiber-fiber dispersion mat is uniformly bonded at the interface between the reinforcing fibers and the matrix resin and the degree of adhesion is improved, resulting in good interfacial adhesion. have.

In the present invention, when the fiber is used as the reinforcing material, when the matrix is fibrous, the fiber becomes a support for each other when the reinforcing fibers are mixed with the matrix fibers by high-speed rotation of the composite mat manufacturing apparatus, thereby enabling three-dimensional orientation. Impact resistance can be strengthened. Also, no dust generation or dehydration device is required.

In addition, in the case of the present invention, when the composite material is manufactured by using the fibrous form as a matrix and simultaneously using the fiber as the reinforcing material, not only the dispersion state of the fibrous matrix is good but also the fiber is maintained in the first dispersed state as it is easy to handle. For this reason, the fibers have three-dimensional orientations of x, y, and z phases, and the fine reinforcing fibers are melted and evenly bonded to the reinforcing fibers, so that the interfacial adhesion is improved. Therefore, a composite mat is manufactured using the thermoplastic resin fibers and the reinforcing fibers, which are matrix resins, and the sheet and one side reinforcing fibers are laminated on the upper and lower sides of the manufactured composite mat by using a sheetable sheet manufacturing apparatus. You can get the material. In the present invention, the penetration of the molten resin is enabled, the planar smoothness of the sheet is made uniform, and the application or impregnation of the molten resin is performed uniformly, so that the strength is excellent and heat resistance and toughness are improved.

Claims (7)

In the method of manufacturing a composite with enhanced strength, Sea fiber raw material supply step of feeding the fiber to the island; Processing the sea fiber raw material to produce a composite mat; And The composite material manufacturing method of claim 1, wherein the sheet and the reinforcing fibers in one direction are sequentially stacked on the upper side of the composite mat to manufacture a stampable sheet. In the apparatus for producing a composite with enhanced strength, Sea fiber raw material supply means for supplying the fiber that has been spun; Means for processing the sea fiber raw material to produce a composite mat; And The composite material manufacturing apparatus with enhanced performance, characterized in that consisting of a means for producing a sheet and a sheet and the reinforcing fibers in one direction in the upper and lower side of the composite mat sequentially. The method of claim 2, wherein the sea fiber raw material supply means A transfer unit for transferring the fiber to a predetermined position; A seam cylinder for isolating the fiber conveyed by said transfer part; A drive motor for rotating the island cylinder; An inhaler that sucks the fibers deemed by the island cylinder into a duct; A disperser for uniformly dropping the sea fibers sucked into the duct; A vibration damper installed below the disperser to vibrate to increase density of the sea fiber and to reduce porosity; And Performance-enhanced composite material production apparatus comprising a sensor for sensing the amount of sea fiber supplied to the supply roller installed at the end of the duct. According to claim 2, wherein the composite mat manufacturing means A conveying part for conveying the resolved thermoplastic fibers; A pair of first feed rollers serving to constantly supply or hold the thermoplastic fibers conveyed by the conveying unit; A first splitting cylinder installed in proximity to the first feed roller and splitting the fiber provided from the first feed roller while rotating at a high speed; A collecting port for collecting the fibers provided from the first divided cylinder; A suction drum having a filter net for sucking the fibers collected in the collecting port; A second feed roller for transferring the fiber passed through the filter net to a predetermined position; A second dividing cylinder for redistributing fibers provided from the second feed roller; A guide tool having a boiling passage for guiding fibers falling from the second divided cylinder; An inhaler positioned below the guide tool to induce a drop of the fiber provided from the second divided cylinder; And The reinforced composite material manufacturing apparatus, characterized in that composed of a pressing roller for pressing the dropped fibers (web) in a predetermined state. The method of claim 2, wherein the stampable sheet manufacturing means A fiber pressing roller for pressing the composite mat; A lower transfer part having a drive cylinder installed to transfer the composite mat compressed by the fiber pressing roller to a predetermined position; An upper conveying part positioned above the lower conveying part and spaced apart from each other, the upper conveying part having a driving cylinder; A seating / one direction reinforcing fiber roll which is wound around the driving cylinder so as to be sequentially stacked on the upper and lower side surfaces of the composite mat and the sheet and one direction reinforcing fiber are pressed by the driving cylinder; A heater for heating the composite mat; A heating pressing roller for heating / compressing the composite mat so as to maintain a state in which sheets and reinforcing fibers in one direction are sequentially stacked on upper and lower sides of the composite mat; And Performance-enhanced composite material manufacturing apparatus comprising a cooling / high foaming to cool / high foaming the composite mat again through the heating pressing roller. According to claim 2, wherein the reinforcing fiber manufacturing means in one direction, A selection pin for selecting the composite fiber into each strand; A pair of feed rollers which are installed to face the selected composite fiber so as to be supplied; Molten resin impregnation / binding means for impregnating and binding the molten resin onto the composite fiber provided from the feed roller; A heating roller for heating and compressing the impregnated / bonded composite fiber to a predetermined thickness; A cooling roller for cooling / compressing the molten resin to a predetermined thickness while passing through the heating roller; And Performance-enhanced composite material production apparatus, characterized in that consisting of a play adjuster for adjusting the interval of the roller. The method of claim 6, wherein the molten resin impregnation / binding means Up and down heating rollers installed at predetermined intervals to allow the composite fiber to pass therethrough; An extruder for ejecting molten resin to one side of the upper heating roller so as to impregnate / bond the composite fiber; And The composite material manufacturing apparatus with enhanced performance, characterized in that consisting of a blade for removing the remaining molten resin attached to the other side of the upper heating roller.