KR20180092594A - Method for manufacturing container using carbon fiber structural material - Google Patents

Abstract

The present invention relates to a method for producing a container using a carbon fiber structural material, comprising the following steps: preparing a carbon fiber plate by laminating and extruding carbon fiber; preparing a rectangular structural material having an empty interior by using the carbon fiber plate and inserting at least one carbon fiber rod therein; filling the inside of the carbon fiber structural material with a thermosetting resin and a curing agent; and fabricating the container by assembling the prepared carbon fiber plate and the structural material. According to the present invention, the container using the carbon fiber structural material can be lightweight to load large quantity of items onto vessels, thereby increasing profits by reducing transportation costs.

Description

TECHNICAL FIELD [0001] The present invention relates to a method for manufacturing a container using a carbon fiber structural material,

Containers are classified according to ownership type, material, use and size, and there are various kinds, for example, general use, liquid use, automobile use, refrigeration use,

Containers can be divided into 20feet (TEU), 40feet (FEU), and 45feet (Jumbo) depending on the standard. Ownership can be divided into pre-owned, leased, and shippers.

Firstly, the dry container is used for cargo that does not require temperature control. It is suitable for general goods transportation. Reefer Container is used for refrigerated cargo, fruit, vegetables, etc. Containers for transporting the required cargo can be adjusted between -25 ° C and 25 ° C. The bulk container is used for transporting powdered or powdered cargo such as malt, flour, etc. It is easy to clean because it has a hole in the ceiling and the inside is made of FRP. The effect of external temperature change is less than that of the dry container. Open Top Container is used in machinery, steel products, As a container suitable for heavy cargo accumulation, the ceiling is made of canvas with high watertightness and can be removed. The Flat Rack Container can be attached to both side walls by removing the ceiling and sidewalls of the dry container so that it can be attached to the bottom and the bottom of the container, Steel, wood and other heavy cargo can be unloaded from the front, rear, left or right side by forklift. Lastly, Tank Container is a container which prepared tank to transport fluid cargo such as oil, For dangerous cargoes, for high-pressure gas, etc., and may have high-pressure, low-pressure, thermal insulation or heating facilities.

On the other hand, most containers are made of steel (steel), aluminum, and flywood / fiber reinforced plastic (FRP).

The steel container is made of steel frame and panel, and the entire container is made by electric welding. Most of the containers (more than 90%) are made of iron. Iron containers are cheap, but they are heavy, rusty and costly to dispose of, causing many problems.

Aluminum containers are high in price due to the price of materials, but they are light and non-rusting, and are mainly used in refrigeration / reefer containers. Used as a material. Aluminum containers are divided into two types according to their production methods: i) the frame is made entirely of steel and only the panel is made of aluminum alloy; and ii) the frame is made of both ends of steel and the rest is made of aluminum alloy. The steel part is machined by welding and the aluminum part is assembled by rivet.

Fiber Reinforced Plastics (FRP) containers are made of steel, framed FRP panels on both sides of the plywood or laminated FRP panels. The frame is welded and the panel is finished by assembling with special rivets or bolts. The current market share is small and is rarely used.

As shown above, the container uses various shapes and materials depending on the purpose of use and the purpose of use. However, the most commonly used steel container is very light in weight and has a problem such as corrosion, so it is a lightweight material, There is a demand for development of a material free from the problem of

Carbon fiber is generally defined as a fiber having a carbon content of 90% or more obtained by heating an organic fiber precursor. In the high strength / high elasticity aspect, it is 10 times / 3 times that of iron. And it is getting popular as a dream material to lead future growth in machinery and automobile industry. In addition, carbon fiber is superior in thermal dimensional stability to iron and aluminum, has excellent chemical resistance, and has low thermal conductivity, which is considered to be an optimal material for automobile parts.

In recent years, studies on fiber reinforced composite materials (GF, CF) which are excellent in strength and chemical resistance and can reduce weight have been actively carried out. Carbon fiber-reinforced plastics have been attracting attention as a representative high-strength lightweight material with a nasal strength of 6 times and a specific gravity of 1/4 based on the properties of steel materials.

Meanwhile, demand for new and renewable energy (23%) and automobiles (6%), including wind power and photovoltaic applications, including new products such as tennis and golf equipment (16%) and aerospace .

On the other hand, carbon fiber composite materials have been difficult to realize molds and molding processes for mass production, and have been limited to simple shapes of aircraft structures, building auxiliary materials, sporting goods and the like. However, due to mechanical performance, The development of automotive parts that are applicable to manufacturers and material companies is accelerating.

TORAY (Sun) has already been vertically sequenced from precursors to products. In addition, CYTEC is developing carbon fiber composite and synthetic resin composite materials, and BMW (Germany) And has great strengths.

Currently, carbon fiber reinforced plastic parts and products are manufactured in the shape required by the molding process such as Autoclave, Resin Transfer Molding (RTM), etc., but these processes require several tens of minutes to several hours of process time There is a drawback that it requires.

When the reinforced plastic material is produced by the RTM process, the glass fiber reinforced plastic has a disadvantage that the production of parts and products through injection molding becomes very difficult when the content of fibers is increased. That is, since the short fiber or long fiber type glass fiber is added to the matrix resin, the injection molding difficulty is greatly changed according to the fiber content, and the mechanical characteristics are changed depending on the fiber orientation caused by various factors between the injection molding .

On the other hand, when developing fiber-reinforced plastic materials for automobile light-weighting, high-quality (maintenance of design performance) and mass production (within minutes) process technology different from existing molding processes are required.

It is essential to develop process technologies such as compression molding and insert injection molding in order to produce high strength and lightweight materials by applying fiber reinforced plastic materials based on metal plate molding and injection molding process.

Meanwhile, the present invention relates to a process for manufacturing a container using a carbon fiber material plate and a structural material, and has proposed a method for achieving a light weight of a container and improving the performance of a container material.

Although steel, aluminum, plywood and fiber reinforced plastic (FRP) are used as the material of the container, the production of container using carbon fiber has been successfully tried due to various reasons such as the price of carbon fiber, none.

Carbon fiber is a structural material, which is formed into a matrix of epoxy resin or the like and then used as a composite material. This composite material has high strength, high modulus, good fatigue resistance, chemical stability, and x-ray transmission. Particularly, since the specific gravity is low, the nodal strength and the nonelasticity ratio per unit weight are much higher than those of the other materials, and thus they are evaluated as advanced composite materials.

In the case of the high strength carbon fiber, the non-elasticity is 20Mcm and the non-elasticity is 1,300Mcm. In case of the high-elasticity carbon fiber, the non-elasticity is 12Mcm and the non-elasticity is 2,100Mcm.

When a carbon fiber is stretched into a bundle and then hardened by a resin, it is called an unidirectional reinforcing plate and has an anisotropic property. Lightweight structures such as airplanes and shafts are mostly used by stacking a plurality of unidirectional reinforcing plates. The characteristics of the laminated plates are determined by the characteristics of the unidirectional reinforcing plate and the lamination structure (orientation direction of the fibers). Therefore, it is necessary to design an appropriate laminated structure in accordance with the required characteristics of the composite material.

Conventionally, a hand lay up method which is hand-operated to manufacture such a carbon fiber-reinforced plastic has been widely used. The dry lay strand mat (Dry Chopped Strand Mat) is placed on a mold half of the outer shape of the product A resin is impregnated into the strand mat by using a roller, and the resin is hardened and molded. The molding is mainly performed by hand. Such a hand layup process is a manual process, which involves quality problems such as durability and surface defects of the product, and causes a problem of increasing the cost of parts due to difficulty in mass production.

Further, since the quality of the product depends on the skill level of the operator, it is difficult to obtain uniform quality and there is a limit in the production amount. In order to solve these problems, Resin Transfer Molding (RTM) method is widely used to produce carbon fiber reinforced plastic in recent years. In the resin transfer molding method, the space between the molds After placing the preformed article made of the reinforcing fiber made of the fiber fabric made of the laminated base material of the fiber fabric, etc., the upper and lower molds are closed and the inside of the mold is depressurized, then the liquid resin is injected by using a resin injector or the like, A method for manufacturing a fiber-reinforced plastic.

However, the carbon fiber-reinforced plastic product manufactured by the resin transfer molding method has a problem in that it is difficult to produce a high-quality product because bubbles are generated in the manufacturing process as well as the strength is lowered due to a high resin content.

The present invention relates to a method of manufacturing a container by making a plate with a carbon fiber laminate to manufacture a square pipe, inserting a carbon fiber rod (shaft) into the pipe, reinforcing the strength thereof, will be.

Conventionally, all the structural members of the container are made of steel, but they are very heavy and have a problem of corrosion of such steel due to marine climate and environmental conditions. In order to solve these problems, the inventor of the present invention has devised a method of manufacturing a container using a carbon fiber material.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method of manufacturing a container using a structural member made of carbon fibers.

Another problem to be solved by the present invention is to provide a method for improving the strength of a carbon fiber structural member by forming a rectangular plate by using a plate made of carbon fiber, inserting at least one carbon fiber rod into the rectangular pipe, .

A method of manufacturing a structural member using a carbon fiber material and a container using the structural material includes the steps of: laminating and extruding carbon fiber to produce a carbon fiber sheet;

Preparing a rectangular structural member having an interior hollow by using the carbon fiber plate and inserting at least one carbon fiber rod therein; Filling the inside of the carbon fiber structural member with a thermosetting resin and a curing agent; And assembling the manufactured carbon fiber plate and structural material to manufacture a container.

The proportion of such carbon fiber structural members is preferably such that the volume ratio of the plurality of carbon fiber rods within the carbon fiber rectangular structural member is 75 to 95%. If the volume percentage of the carbon fiber rod in the rectangular structural member is less than 75%, it is difficult to maintain a sufficient strength, and it is not preferable that the carbon fiber rod is maintained at 95% or more because it is difficult to assemble and is inefficient.

  On the other hand, it is preferable that the ratio of the carbon fiber plate material and the carbon fiber structural material to the total container components is 50 to 95%. Although it is possible to make all of the container components as carbon fibers, it is desirable to maintain the ratio of the carbon fiber materials within an appropriate range in consideration of processing technology and material cost.

In addition, a variety of thermosetting resins may be used, but they are preferably fiber-reinforced plastics.

It is preferable that the diameter of the carbon fiber rod to be contained in the carbon fiber structural member is 30 to 70 mm. If the diameter of the carbon fiber rod is less than 30 mm, it is difficult to sufficiently exhibit the strength as a reinforcing material. If it exceeds 70 mm, the carbon fiber rod becomes too bulky and inconvenient in assembling.

On the other hand, in the step of laminating the carbon fibers, it is preferable that the carbon fiber lamination is repeated 5 times or more and 10 times or less. It is preferable that the carbon fiber lamination is performed repeatedly enough to produce a sheet sufficiently as a carbon material. Less than 5 times is insufficient, and if stacking 10 times or more, the process time and cost are increased, but the efficiency is increased in terms of the lamination effect Which is undesirable.

Carbon fiber rods have ten times stronger strength and high durability than ordinary steel. Therefore, when such carbon fiber rods are used as structural materials, they can be manufactured to withstand the loads required for large-sized containers. When the container is made of carbon fiber structural material, it is possible to lighten the container, and thus it is possible to place a large amount of water on the vessel, and as a result, it is possible to increase the profit by reducing the transportation cost.

In addition, there are no problems such as corrosion of containers due to weather conditions at sea. Therefore, if the production cost can be greatly reduced, the demand for containers using carbon fiber structural materials is expected to increase.

Fig. 1 is a process flow chart briefly showing the present process.
2 is a view schematically showing a carbon fiber rod (carbon fiber shaft) inserted into a square pipe made of carbon fiber.
FIG. 3 is a schematic view simply showing a container inner frame made using a carbon fiber structural material. FIG.

1. Manufacture of carbon fiber sheet

First, the carbon fiber was cut into a length of 1.8 m and a length of 3 m, and the cut carbon fiber was laminated eight times using a gel coat and a reinforcing agent. The amount of carbon fiber used was about 20 kg. The carbon fiber sheet prepared by laminating the carbon fibers was heated to a temperature capable of being formed using a 200T extruder prepared to produce a carbon fiber sheet.

2. Carbon fiber square pipe construction

Heat was applied to the extruded plate manufactured as described above to make a rectangular pipe shape. Then, three carbon fiber rods were inserted inside the square pipe, and the inside of the rectangular pipe was filled with FRP resin and hardener.

Carbon fiber rods have ten times stronger strength and high durability than ordinary steel. Therefore, when such carbon fiber rods are used as structural materials, they can be manufactured to withstand the loads required for large-sized containers.

3. Container assembly

The X-bend T-bend of the container was made of steel using castings. Based on the X-bend and T-bend, a square pipe frame made of carbon fiber and a plate were assembled to produce a container. However, plywood finishing agent was used for the interior of the container as in the prior art.

1. Carbon fiber rods (carbon shaft)
2. Pipes made of carbon fiber sheet

Claims (6)

Laminating and extruding carbon fibers to produce a carbon fiber sheet;
Preparing a rectangular structural member having an interior hollow by using the carbon fiber plate and inserting at least one carbon fiber rod therein;
Filling the inside of the carbon fiber structural member with a thermosetting resin and a curing agent;
A method of manufacturing a container using a carbon fiber structural material including a step of assembling the manufactured carbon fiber plate and structural material to form a container The method according to claim 1,
Wherein the volume ratio of the one or more carbon fiber rods in the carbon fiber rectangular structural material is 75 to 95% The method according to claim 1,
Wherein the ratio of the carbon fiber plate material and the carbon fiber structure material in the total container configuration is 50 to 95% The method of claim 1, wherein
Wherein the thermosetting resin is a fiber-reinforced plastic; and a method of manufacturing a container using the carbon fiber structural material The method of claim 1, wherein
Wherein the carbon fiber rod has a diameter of 30 to 70 mm; and a method of manufacturing a container using the carbon fiber structural material The method of claim 1, wherein
A method for manufacturing a container using a carbon fiber structural material, characterized in that, in the step of laminating the carbon fibers, the carbon fiber lamination is repeated 5 times or more and 10 times or less

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