WO2008056956A1

WO2008056956A1 - Stampable sheet manufacturing device

Info

Publication number: WO2008056956A1
Application number: PCT/KR2007/005645
Authority: WO
Inventors: Duckcheol Seo
Original assignee: Huneco Co., Ltd.
Priority date: 2006-11-09
Filing date: 2007-11-09
Publication date: 2008-05-15
Also published as: KR100818940B1

Abstract

The present invention relates to a stampable sheet manufacturing device.

Description

[DESCRIPTION]

[invention Title]

STAMPABLE SHEET MANUFACTURING DEVICE

[Technical Field]

The present invention relates to a starapable sheet manufacturing device, and more particularly, to a stampable sheet manufacturing device in which a composite mat is prepared by defibrating and mixing different kinds of fibers and the composite mat is heated and pressurized and then cooled and pressurized so as to manufacture a stampable sheet, wherein a heating unit for heating and pressurizing the composite mat and a cooling unit for cooling and pressurizing the composite mat are separately provided so as to increase productivity.

[Background Art]

A composite material, in which two or more kinds of different materials are mixed so as to realize a new function, has been developed for the purpose of maintaining a light weight, a high specific strength and specific modulus, and a strengthened mechanical property, and widely used in various industrial fields such as components of an airplane, a ship and a motor vehicle, precision electrical and electronic components and the like which have required a desired strength, rigidity, durability and the like.

As a representative example of the composite materials, there are FRP (Fiber Reinforced Plastics) in which unsaturated polyester resin is reinforced with glass fiber and FRTP (Fiber Reinforced Thermo-Plastics) using thermoplastic resin.

Since the FRP in which the unsaturated polyester resin is reinforced with the glass fiber has more excellent property than a metallic material, it is widely used in various industrial fields of which products require a desired strength, rigidity, durability and the like.

However, the FRP has some disadvantages that its physical properties such as impact resistance and fracture toughness are not satisfactory, its allowable deformation limit is very small and also its recycling is difficult.

Meanwhile, the FRTP can be used as a substitute which can solve the above-mentioned problems of the FRP, and also it is attracting considerable attention in some fields for substituting metallic materials of motor vehicle parts and the like.

For example, the FRTP is widely applied to structures like a chassis and various exterior materials which require impact resistance and high strength as well as interior materials and non-structural products. Further, since the FRTP can be manufactured by a stamping process which is a metal forming process, it is possible to increase productivity thereof and also have a higher degree of design freedom than a metal material, and thus its use in various industrial fields continues to show an upward tendency.

In order for the FRTP to be applied to the above- mentioned applications, first of all, the FRTP has to be formed into a plate type sheet, which is suitable for forming processes of various products, i.e., a stampable sheet type. To this end, there was proposed a method in which reinforced resin fiber was mixed with powder or pellet type thermoplastic resin and then a heat forming process was performed. However, since the reinforced resin fiber is mixed with the powder or pellet type thermoplastic resin and then heat-formed, it is difficult to uniformly mix the two kinds of materials and also, after the mixing process, there is a tendency that the powder or pellet type thermoplastic resin is easily separated during various treating processes. Further, since the reinforced resin fiber is not dispersed uniformly, it is difficult to manufacture high quality of products .

To solve the above problems, as shown in Figs. 1 to 3, there has been proposed a stampable sheet manufacturing device including a composite mat manufacturing unit 110 which is supplied with different kinds of fibers, as materials for the stampable sheet, such as thermoplastic resin fiber and reinforced resin fiber and the like, and defibrates and mixes uniformly the different kinds of fibers so as to be arranged into layers in any desired pattern and thus to manufacture a composite mat 170, a heating unit 130 which heats and pressurizes the composite mat 170 supplied from the composite mat manufacturing unit 110 so that the thermoplastic resin fiber and reinforced resin fiber are melted appropriately and then compressed toward each other, and a cooling unit 150 for cooling and pressurizing the composite mat 170. However, in the conventional stampable sheet manufacturing device, when the different kinds of fibers are defibrated and mixed so as to manufacture the composite mat, the different kinds of fibers are not mixed uniformly, and thus it is difficult to constantly control a compounding ratio. Further, there is another problem that a large amount of particulates is generated, thereby deteriorating the working environment.

Further, in the heating unit 130 for heating and pressurizing the composite mat, the heat is indirectly transferred through a steel conveyor belt, and thus the heat transfer is not performed smoothly. And according as the heating unit 130 for heating and pressurizing the composite mat 170 and the cooling unit 150 for cooling and pressurizing the composite mat 170 are formed into a single unit, the heating and cooling processes are repeatedly performed, thereby lowering the productivity.

Furthermore, in case that an air-cooling method in which heat exchange is performed by using external air is employed in the cooling unit 150 for cooling and pressurizing the composite mat which is already treated by the heating unit 130, a necessary time for the cooling process is increased and also a large-scaled equipment for the cooling process is required. And in case that a water cooling method in which heat exchange is performed by using cooling water is employed in the cooling unit 150, the necessary time for the cooling process can be reduced. However, since the cooling process is performed within a short time, the pressurizing process is not performed properly, and also since cooling speeds in inner and outer portions of the stampable sheet become different from each other, a gap may be formed between the inner and outer portions of the stampable sheet, or the inner and outer portions of the stampable sheet may be separated from each other.

[Disclosure] [Technical Problem]

An object of the present invention is to provide a stampable sheet manufacturing device which a heating unit for heating and pressurizing a composite mat and a cooling unit for cooling and pressurizing the composite mat are separately provided, thereby reducing heat loss which is generated during a manufacturing process of the stampable sheet and also improving heat efficiency and quality of products.

Another object of the present invention is to provide a stampable sheet manufacturing device in which hot wind is directly supplied to the composite mat in the heating process, thereby improving the heat efficiency and productivity of the products.

Yet another object of the present invention is to provide a stampable sheet manufacturing device in which a first cooling operation using external air and a second cooling operation using cooling water are performed in the cooling process, so that cooling efficiency is improved and also physical properties of the inner and outer portions of the stampable sheet become uniform, thereby improving the quality of products.

And yet another object of the present invention is to provide a stampable sheet manufacturing device in which the large amount of particulates generated during the manufacturing process of the stampable sheet is removed using a particulate remover, thereby improving the working environment . [Technical Solution]

In order to solve the above problem, the present invention provides a stampable sheet manufacturing device comprising a composite mat manufacturing unit comprising a defibrator for defibrating different kinds of fibers, a particulate remover for removing particulates generated in a defibrating process, a feed for interface-treating the fibers defibrated in the defibrator, a measuring hopper for measuring a weight of the fibers supplied through the feed, a mixing tank for mixing the fibers supplied through the measuring hopper, a dispenser for uniformly supplying the fibers mixed in the mixing tank, an arranger for arranging the fibers supplied from the dispenser into layer, and a needle puncher for punching the fiber layer arranged by the arranger; a heating unit for heating and pressurizing a composite mat prepared by the composite mat manufacturing; and a cooling unit for cooling and pressurizing the composite mat heated and pressurized by the heating unit. Preferably, the feed and the measuring hopper are separately disposed at different frames which are spaced apart from each other.

Preferably, the heating unit comprises an upper frame which is disposed at an upper side,- a lower frame which is disposed at a lower side to be spaced apart from each other in a desired distance,- a conveyor which is provided at each of the upper and lower frames; and a hot wind injection nozzle which is provided at each of the upper and lower frames so as to supply hot wind to the conveyor.

Preferably, the conveyor is provided with a conveyor belt which is formed by a plurality of punched plates.

Preferably, the cooling unit comprises an upper frame which is disposed at an upper side; a lower frame which is disposed at a lower side to be spaced apart from each other in a desired distance; a conveyor which is provided at each of the upper and lower frames,- and a cooling water injection nozzle which is provided at each of the upper and lower frames so as to supply cooling water to the conveyor. Preferably, the conveyor is provided with a conveyor belt which is formed of a steel plate.

Preferably, the cooling unit further comprises an air cooling part in which the cooling process is performed using air.

[Advantageous Effects]

According to the stampable sheet manufacturing device of the present invention, the heating unit for heating and pressurizing the composite mat and the cooling unit for cooling and pressurizing the composite mat are separately provided, thereby improving the heating and cooling efficiency and thus reducing a size of the equipment thereof.

Further, the hot wind is directly supplied to the composite mat during the heating process so as to improve the heat efficiency and also uniformize the deep portion of the composite mat as well as the surface thereof, thereby improving the quality of the composite mat.

Further, a first cooling operation using external air and a second cooling operation using cooling water are performed in the cooling process, so that cooling efficiency is improved and also physical properties of the inner and outer portions of the stampable sheet become uniform, thereby improving the quality of the stampable sheet. Furthermore, the large amount of particulates generated in the defibrating process can be removed by the particulate remover, thereby improving the working environment. In addition, the feed for interface-treating the defibrated fibers and the measuring hopper for measuring a weight of the defibrated fibers are separately provided at different frames, thereby exactly measuring the weight of the fibers and thus constantly maintaining the volume and weight of the stampable sheet . [Description of Drawings]

The above and other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:

Fig. 1 is a side view of a conventional stampable sheet manufacturing device .

Fig. 2 is a side view of a composite mat manufacturing unit of the conventional stampable sheet manufacturing device. Fig. 3 is a side view of a heating unit and a cooling unit of the conventional stampable sheet manufacturing device.

Fig. 4 is a side view of a stampable sheet manufacturing device according to the present invention.

Fig. 5 is a side view of a composite mat manufacturing unit of the stampable sheet manufacturing device according to the present invention.

Fig. 6 is a side view of a heating unit of the stampable sheet manufacturing device according to the present invention.

Fig. 7 is a front view of a conveyor belt of the heating unit according to the present invention.

Fig. 8 is a cross-sectional view of the heating unit of the stampable sheet manufacturing device according to the present invention.

Fig. 9 is a side view of a cooling unit of the stampable sheet manufacturing device according to the present invention.

Fig. 10 is a front view of a conveyor belt of the cooling unit according to the present invention.

Fig. 11 is a cross-sectional view of the cooling unit of the stampable sheet manufacturing device according to the present invention.

Fig. 12 is block diagram showing a method of manufacturing the stampable sheet according to the present invention.

[Detailed Description of Main Elements]

10 : composite mat manufacturing unit

11: defibrator 12: feed

13.- particulate remover 14 : measuring hopper

15: mixing tank 16: dispenser

17 : arranger 18 : needle puncher

30: heating unit 31: upper frame

32: lower frame 33: conveyor

34: conveyor belt 35: punched plate

36: hot wind injection nozzle 50: cooling unit

51: air cooling part 52: water cooling part

53: upper frame 54 : lower frame

55: conveyor 56: conveyor belt

57: steel plate 58: air injection nozzle

59: cooling water injection nozzle 60: drum

61: tension regulator 70: composite mat

[Best Mode]

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

Fig. 4 is a side view of a stampable sheet manufacturing device according to the present invention, Fig. 5 is a side view of a composite mat manufacturing unit of the stampable sheet manufacturing device according to the present invention, Fig. 6 is a side view of a heating unit of the stampable sheet manufacturing device according to the present invention, Fig. 7 is a front view of a conveyor belt of the heating unit according to the present invention, Fig. 8 is a cross- sectional view of the heating unit of the stampable sheet manufacturing device according to the present invention, Fig.

9 is a side view of a cooling unit of the stampable sheet manufacturing device according to the present invention, Fig.

10 is a front view of a conveyor belt of the cooling unit according to the present invention, Fig. 11 is a cross- sectional view of the cooling unit of the stampable sheet manufacturing device according to the present invention, and Fig. 12 is block diagram showing a method of manufacturing the stampable sheet according to the present invention.

Referring to Fig. 4, the stampable sheet manufacturing device according to the present invention includes a composite mat manufacturing unit 10 which is supplied with different kinds of fibers, as materials for a stampable sheet, such as thermoplastic resin fiber and reinforced resin fiber and the like, and defibrates and mixes uniformly the different kinds of fibers so as to be arranged into layers in any desired pattern and thus to manufacture a composite mat 70, a heating unit 30 which heats and pressurizes the composite mat 70 supplied from the composite mat manufacturing unit 10 so that the thermoplastic resin fiber and reinforced resin fiber are melted appropriately and then compressed toward each other, and a cooling unit 50 which is supplied with the composite mat 70 passed through the heating unit 30, and cools and pressurizes the composite mat 70 so as to have uniform physical properties and also to be stabilized.

In the present invention, a raw material for the stampable sheet includes thermoplastic resin fiber such as polyethylene, polypropylene, polyvinyl chloride, polyester, polyethylene-polyester copolymer, thermoplastic polyester resin fiber in which isophthalic acid component containing metal sulphonate group is copolymerized, and core-sheath type composite fiber like polyester composite fiber which contains thermoplastic polyethyleneterephthalate resin fiber as a sheath component .

In addition, polyester interlaced textured yarn in which polyester hollow fiber or thermoplastic resin hollow fiber containing polyester-based, polyethylene-based, nylon-based hot-melt fluororesin and highly contractive polyester fiber are interlaced, jute fiber such as kenaf, jute, hemp, fax, abaca, banana, and natural fiber such as coir, wool, cashmere, silk and the like are also used.

Fig. 5 shows a composite mat manufacturing unit. The composite mat manufacturing unit includes a defibrator 11 which receives the different kinds of fibers such as the thermoplastic resin fiber, reinforced resin fiber and the like and then defibrates the fibers, a feed 12 which interface- treats the fibers passed through the defibrator 11, a measuring hopper 14 which is disposed at a lower side of the feed 12 so as to measure a weight of the defibrated fibers, a mixing tank 15 which receives the defibrated fibers from the measuring hopper 14, a dispenser 16 for uniformly supplying the defibrated fibers passed through the mixing tank 15 to an arranger 17, the arranger 17 which receives the fibers from the dispenser 16 and then arranges the fibers into layers, and a needle puncher 18 which receives the fibers arranged into layers by the arranger 17 and then punches the fiber layers so as to have a desired volume.

The defibrator 11 is to is supplied with the different kinds of fibers such as the thermoplastic resin fiber and reinforced resin fiber and the like and then defibrate the fibers. However, since, during the defibrating process of the fibers, the large amount of particulates was generated, there was a problem that the working environment was deteriorated. Therefore, to solve the problem, the defibrator 11 is provided with a particulate remover 13 for removing the particulates generated from the defibrator 11.

According to the present invention, since the defibrator 11 is provided with a particulate remover 13, it is possible to remarkably reduce the particulates and thus improve the working environment.

The fibers defibrated from the defibrator 11 is interlace-treated by the feed 12 and then discharged to the measuring hopper 14 so that the weight thereof is measured. In this process, there is another problem that the measuring operation in the measuring hopper 14 is not performed exactly due vibrations generated from the feed 12. Therefore, it is preferable that a frame for fixing the measuring hopper 14 is separately provided from a frame for fixing the feed 12 so that the vibrations generated from the feed 12 exert an influence on the measuring hopper 14 and thus the measuring operation can be performed exactly regardless of the influence from the outside.

Fig. 6 shows the heating unit 30. The heating unit 30 includes upper and lower frames 31 and 32 which are disposed to be spaced apart from each other at a desired distance, a conveyor 33 which is provided at opposite ends of the upper and lower frames 31 and 32, and a plurality of hot wind injection nozzles 36 which are provided at the upper and lower frames 31 and 32 so as to blow the hot wind to the conveyor 33.

The conveyor 33 which is provided at the ends of the upper and lower frames 31 and 32 is comprised of a plurality of rollers, and a conveyor belt 34 which is rotated along outer surfaces of the rollers, and functions to transfer and pressurize the composite mat 70 supplied from the composite mat manufacturing unit 10.

The composite mat 70 which is transferred into the heating unit 30 by the conveyor 33 is heated by the hot wind supplied from the hot wind injection nozzles 36 so as to be melted and then pressurized by a pressure applied from the conveyor 33.

Fig. 7 shows the conveyor belt 34. The conveyor belt 34 is comprised of a plurality of punched plates 35 through which the hot wind can be directly supplied to the composite mat 70. By using the conveyor belt 34 which is comprised of the plurality of punched plates 35, the hot wind injected from the hot wind injection nozzles 36 can be directly supplied to the composite mat 70 and thus the heat efficiency is improved. Further, since the hot wind can be supplied to a deep portion of the composite mat 70 as well as to a surface thereof, the inner and outer portions of the composite mat 70 can be uniform, thereby improving the quality thereof and also reducing a processing time. Fig. 8 is a cross-sectional view of the heating unit 30. The hot wind injected from the hot wind injection nozzles 36 passes through the conveyor belt 34 comprised of the plurality of punched plates 35 so as to be supplied to the deep portion of the composite mat 70 as well as to a surface thereof. As described above, since the hot wind is directly supplied to the composite mat 70, it is possible to have the excellent heat efficiency and also uniformly heat the inner and outer portions of the composite mat 70.

As shown in drawings, the hot wind injection nozzles 36 may be provided at all of the upper and lower frames 31 and 32, or at only one of the upper and lower frames 31 and 32. Further, the upper and lower frames 31 and 32 may be formed to be crossed each other.

Furthermore, it is natural that the heating unit 30 has a regulator for regulating a volume of the composite mat 70 or a pressure to be applied to the composite mat 70.

Fig. 9 shows the cooling unit 50. The cooling unit 50 includes upper and lower frames 53 and 54, a conveyor 55 which is provided at opposite ends of the upper and lower frames 53 and 54, and a plurality of air injection nozzles 58 and cooling water injection nozzles 59 which are provided at the upper and lower frames 53 and 54 so as to inject air and cooling water to the conveyor 55. The conveyor 55 which is provided at the ends of the upper and lower frames 53 and 54 is comprised of a plurality of rollers, and a conveyor belt 56 which is rotated along outer surfaces of the rollers, and functions to transfer and pressurize the composite mat 70 supplied from the heating unit 30.

The conveyor 55 is driven by a drum 60 which is provided at front and rear end of the cooling unit 50, and the drum 60 has a tension regulator 61 so as to facilely regulate a tension of the conveyor belt 56 driven by the drum 60. Since the tension of the conveyor belt can be regulated facilely, tracking phenomenon is prevented.

The composite mat 70 transferred into the cooling unit 50 by the conveyor 55 is passed through an air cooling part 51 in which the air injection nozzles 58 are provided at the upper and lower frames 53 and 54 and a water cooling part 52 in which the cooling water injection nozzles 59 are provided at the upper and lower frames 53 and 54 so that heat exchange is occurred between the composite mat 70 and air and cooling water, thereby cooling the composite mat 70. Also, the composite mat 70 is pressurized by a pressure applied from the conveyor 55.

Fig. 10 shows the conveyor belt 56. The conveyor 55 provided at the cooling unit 50 has the conveyor belt 56 formed of a steel plate which has high thermal conductivity so that the heat exchange is can be smoothly occurred through the air and cooling water.

Unlike in the heating unit 30 having the conveyor belt 34 formed of the plurality of punched plates 35, the conveyor belt 56 of the cooling unit 50 is a steel plate belt which is integrally formed.

Fig. 11 shows a cross-sectional view of the cooling unit 50. The air and cooling water is injected from the air injection nozzles 58 and the cooling water injection nozzles 59 which are provided at the upper and lower frames 53 and 54 to the conveyor belt 56 formed of the steel plate so that the heat exchange is occurred, thereby indirectly cooling the composite mat 70. Meanwhile, since the cooling process is performed by using the air and the cooling water, it is possible to avoid a problem due to a sharp temperature change and also elastically control the cooling time, thereby facilely manufacturing the stampable sheet.

Alternatively, the heat exchange may be performed through the external air without driving of the air injection nozzles

58, and the whole or a part of the cooling water injection nozzles 59 also may be not driven selectively according to productive conditions.

The air injection nozzles 58 and the cooling water injection nozzles 59 may be provided at the upper and lower frames 53 and 54 together with the hot wind injection nozzles 36, or at only one of the upper and lower frames 53 and 54. Alternatively, the air injection nozzles 58 and the cooling water injection nozzles 59 may be alternately provided at the upper and lower frames 53 and 54 so as not to be opposed with each other.

Like the heating unit 30, the cooling unit 50 has a regulator for regulating a volume of the composite mat 70 or a pressure to be applied to the composite mat 70. Fig. 12 shows a method of manufacturing the stampable sheet according to the present invention. The method of manufacturing the stampable sheet includes the steps of: manufacturing a composite mat including the steps of defibrating different kinds of fibers, mixing the defibrated fibers, arranging the mixed fibers into a layer, and stacking the fiber layer in multiple layers; applying desired heat and pressure to the composite mat; and applying desired pressure to the heated composite mat and then cooling it.

Those skilled in the art will appreciate that the conceptions and specific embodiments disclosed in the foregoing description may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. Those skilled in the art will also appreciate that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims.

[industrial Applicability]

Further, a first cooling operation using external air and a second cooling operation using cooling water are performed in the cooling process, so that cooling efficiency is improved and also physical properties of the inner and outer portions of the stampable sheet become uniform, thereby improving the quality of the stampable sheet.

Furthermore, the large amount of particulates generated in the defibrating process can be removed by the particulate remover, thereby improving the working environment.

In addition, the feed for interface-treating the defibrated fibers and the measuring hopper for measuring a weight of the defibrated fibers are separately provided at different frames, thereby exactly measuring the weight of the fibers and thus constantly maintaining the volume and weight of the stampable sheet.

Claims

[CLAIMS] [Claim l]

A stampable sheet manufacturing device comprising: a composite mat manufacturing unit comprising a defibrator for defibrating different kinds of fibers, a particulate remover for removing particulates generated in a defibrating process, a feed for interface-treating the fibers defibrated in the defibrator, a measuring hopper for measuring a weight of the fibers supplied through the feed, a mixing tank for mixing the fibers supplied through the measuring hopper, a dispenser for uniformly supplying the fibers mixed in the mixing tank, an arranger for arranging the fibers supplied from the dispenser into layer, and a needle puncher for punching the fiber layer arranged by the arranger; a heating unit for heating and pressurizing a composite mat prepared by the composite mat manufacturing; and a cooling unit for cooling and pressurizing the composite mat heated and pressurized by the heating unit.

[Claim 2]

The stampable sheet manufacturing device according to claim 1, wherein the feed and the measuring hopper are separately disposed at different frames which are spaced apart from each other.

[Claim 3]

The stampable sheet manufacturing device according to claim 1, wherein the heating unit comprises: an upper frame which is disposed at an upper side,- a lower frame which is disposed at a lower side to be an upper frame,- a conveyor which is provided at each of the upper and lower frames; and a hot wind injection nozzle which is provided at each of the upper and lower frames so as to supply hot wind to the conveyor .

[Claim 4] The stampable sheet manufacturing device according to claim 3, wherein the conveyor is provided with a conveyor belt which is formed by a plurality of punched plates.

[Claim 5] The stampable sheet manufacturing device according to claim 1, wherein the cooling unit comprises: an upper frame which is disposed at an upper side; a lower frame which is disposed at a lower side to be an upper frame; a conveyor which is provided at each of the upper and lower frames; and a cooling water injection nozzle which is provided at each of the upper and lower frames so as to supply cooling water to the conveyor.

[Claim 6]

The stampable sheet manufacturing device according to claim 5, wherein the conveyor is provided with a conveyor belt which is formed of a steel plate.

[Claim 7]

The stampable sheet manufacturing device according to claim 5, wherein the cooling unit further comprises an air cooling part in which the cooling process is performed using air.