WO2009045190A1 - Filière d'imprégnation pour fabriquer un matériau de moulage en résine thermoplastique renforcée par de longues fibres - Google Patents

Filière d'imprégnation pour fabriquer un matériau de moulage en résine thermoplastique renforcée par de longues fibres Download PDF

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Publication number
WO2009045190A1
WO2009045190A1 PCT/US2007/021204 US2007021204W WO2009045190A1 WO 2009045190 A1 WO2009045190 A1 WO 2009045190A1 US 2007021204 W US2007021204 W US 2007021204W WO 2009045190 A1 WO2009045190 A1 WO 2009045190A1
Authority
WO
WIPO (PCT)
Prior art keywords
impregnation die
tapered section
section
thermoplastic resin
straight section
Prior art date
Application number
PCT/US2007/021204
Other languages
English (en)
Inventor
Masahiko Tominaga
Original Assignee
Owens-Corning Fiberglas Technology Ii, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Owens-Corning Fiberglas Technology Ii, Llc filed Critical Owens-Corning Fiberglas Technology Ii, Llc
Priority to KR1020107007311A priority Critical patent/KR101472618B1/ko
Priority to CN200780101624A priority patent/CN101868334A/zh
Priority to PCT/US2007/021204 priority patent/WO2009045190A1/fr
Priority to JP2010527919A priority patent/JP5027929B2/ja
Publication of WO2009045190A1 publication Critical patent/WO2009045190A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/525—Component parts, details or accessories; Auxiliary operations
    • B29C70/526—Pultrusion dies, e.g. dies with moving or rotating parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex

Definitions

  • the present invention relates generally to the manufacture of long fiber reinforced thermoplastic resin molding material and more particularly to a method for this purpose.
  • JP-A- 10-309756, JP-A-10-315341 and JP-A- 2003-305779 are documents exemplary of state of the art methods and apparatus for this purpose.
  • the prior art methods disclosed in these documents may be generally described as comprising a series of continuous steps including (a) the feeding of a continuous fiber material into an impregnation die filled with molten thermoplastic resin, (b) the pultruding of the continuous fiber material impregnated with thermoplastic resin from a pultrusion hole of the impregnation die and (c) the cutting of the resulting rod shaped product into pellets of desired length after cooling.
  • a nozzle is attached to the pultrusion hole of the impregnation die.
  • the shape of the nozzle and the size of the hole or aperture in the nozzle are selected to perform several functions including the removal of excessive molten thermoplastic resin so that the desired amount of resin is impregnated into the pultruded rod shaped product and the formation of the pultruded rod shaped product so that its cross section becomes the desired shape.
  • the design of the nozzle largely determines the efficiency and extent of molten thermoplastic resin impregnated into the continuous fiber material during processing.
  • JP-A-11-042639 discloses a method of preventing molten thermoplastic resin from trickling from a rod shaped pultruded product. This is done by setting a processing value calculated using a certain formula relating to the length and cross-sectional area of the hole in a nozzle.
  • JP-A-2001-088223 discloses a nozzle having a cone portion and a linear portion of a particular size and shape designed to prevent cut filaments from accumulating near the nozzle as fuzz-balls that could potentially interfere with the efficient manufacture of the pelleted product.
  • JP-A-05-050432 discloses the concept of providing a removable nozzle on an impregnation die.
  • JP-A-08-090659 discloses a nozzle including a thinned down tip portion designed to improve the impregnation level of molten thermoplastic resin in the continuous fiber material.
  • a method for making long fiber reinforced thermoplastic resin pellets in an impregnation die including a processing chamber.
  • the method comprises the steps of (a) filling the processing chamber with molten thermoplastic resin, (b) feeding at least one continuous fiber strand through the processing chamber, (c) pultruding the at least one continuous fiber strand impregnated with the molten thermoplastic resin and (d) cutting the at least one pultruded continuous fiber strand impregnated with the molten thermoplastic resin into pellets.
  • A a processing value ⁇ 5.0
  • Q total quantity in mm /sec of molten thermoplastic resin applied to said at least one continuous fiber strand and removed from said processing chamber during pultruding
  • L length in mm of said processing chamber in a continuous fiber strand feeding direction
  • N total number of continuous fiber strands impregnated with molten thermoplastic resin pultruded from said impregnation die
  • processing value A is between 0.5 and
  • the method may further include fully partitioning the impregnation die in order to provide completely separate multiple processing chambers in a single impregnation die.
  • the method includes partially partitioning the impregnation die in order to provide multiple processing chambers in a single impregnation die wherein the multiple processing chambers are in communication with one another.
  • the method includes filling each of the multiple processing chambers with molten thermoplastic resin, feeding a continuous fiber strand through each of the chambers, pultruding the continuous fiber strands impregnated with molten thermoplastic resin and cutting the continuous fiber strands impregnated with the molten thermoplastic resin into pellets.
  • the method may further include the using of glass fiber strand as the continuous fiber strand.
  • the method may include the using of carbon fiber strand as the continuous fiber strand.
  • the method may include using polyolefin resin as the molten thermoplastic resin.
  • the method may include polyamide resin as the molten thermoplastic resin.
  • the method may include spreading multiple filaments of the continuous fiber strand in order to aid in the impregnation of the strand with molten thermoplastic resin.
  • Fig. 1 is a perspective view of an impregnation die of the present invention
  • Fig. 2 is a perspective view similar to Fig. 1 but of an alternative embodiment incorporating partitions so that the impregnation die includes multiple processing chambers;
  • Fig. 3 is a partially schematical and cross- sectional view illustrating the impregnation die of Fig. 1;
  • Fig. 4 is a detailed, longitudinal cross-sectional view of the nozzle of the impregnation die of preferred embodiment of the present invention.
  • Fig. 5 is a similar view of a prior art nozzle.
  • the impregnation die 10 includes a body or housing 12 constructed from an appropriate high strength material.
  • the housing 12 includes an internal processing chamber 14. As illustrated in
  • the impregnation die 10 includes a single processing chamber 14.
  • the housing 12 includes a supply aperture 18 to allow the introduction of molten thermoplastic resin into the processing chamber 14. Additionally, the housing 12 includes an introduction aperture 20 for feeding continuous fiber strand 50 into the processing chamber 14. Further, the housing 12 includes a pultrusion aperture 22 opposite the introduction aperture 20.
  • an impregnation die 10 is illustrated in Fig. 2.
  • the impregnation die 10 includes a series of partitions 16 forming multiple processing chambers 14.
  • the partitions 16 may each extend across the full length and width of the internal cavity of the housing 12 so that the processing chambers 14 are each completely separate.
  • the partitions 16 may extend partially across the length and/or width of the internal cavity of the housing 12 so that the processing chambers 14 are in communication with one another.
  • each of the multiple chambers 14 includes a supply aperture 18, an introduction aperture 20 and a pultrusion aperture 22.
  • a nozzle 24 is carried on the housing 12 (see Fig. 3).
  • the nozzle 24 may be made from any appropriate material including, for example, brass or special steel.
  • the nozzle 24 overlies the pultrusion aperture 22 and communicates with the processing chamber 14 through the pultrusion aperture.
  • the base end 26 of the nozzle 24 is received in a counter bore 28 formed in the housing 12 concentrically around the pultrusion aperture 22.
  • a collar 30 engages the shoulder of the base end 26.
  • the collar 30 may be fixed by screws or other fastening means (not shown) to the housing 12 in order to secure the nozzle 24 in position.
  • the nozzle 24 includes an opening 32 having an inlet end 34, an outlet end 36 and a central axis A.
  • the inlet end 34 is in direct communication with the processing chamber 14 by means of the pultrusion aperture 22.
  • the opening 32 when described in detail is characterized by including a first tapered section 40 adjacent the inlet end 34, a first straight section 42 directly downstream from the first tapered section 40, a second tapered section 44 directly downstream from the first straight section 42 and a second straight section 46 directly downstream from the second tapered section 44 and adjacent to the outlet end 36.
  • the first tapered section 40 incorporates a curved taper (note the arcuate sidewall of the opening) while the second tapered section 44 incorporates a linear taper (note the straight sidewall of the opening).
  • the first tapered section 40 may incorporate a linear taper and the second tapered section 44 may incorporate a curved taper if desired.
  • both the first and second tapered sections 40, 44 incorporate linear tapers.
  • both the first and second tapered sections 40, 44 incorporate curved tapers.
  • the first tapered section 40 may incorporate a linear taper while the second tapered section 44 may incorporate a curved taper.
  • the first tapered section 40 converges toward the first straight section 42.
  • the second tapered section 44 converges toward the second straight section 46.
  • both the first straight section 42 and the second straight section 46 are symmetrically aligned and extend longitudinally along the central axis A of the opening 32.
  • the tip of the nozzle 24 typically extends outwardly from the mounting collar 30 by a length of from 5 to 20 mm. This distance helps to ensure that the product pultruded from the nozzle 24 becomes stable, thereby reducing cracking of the product and any fuzz created by fibers falling when the pultruded product is cut into pellets of a certain desired length.
  • the first tapered section 40 of the opening 32 has a length Ll.
  • the first straight section 42 of the opening 32 has a length L2 and a diameter D2.
  • the second tapered section of the opening 32 has a length L3.
  • the second straight section of the opening 32 has a length L4 and a diameter D4.
  • the length Ll of the first tapered section 40 and the length L3 of the second tapered section 44 are between 0.5 and 5 mm respectively.
  • the length L2 of the first straight section 42 is longer than the length L4 of the second straight section 46.
  • the diameter D2 of the first straight section 42 is greater than the diameter D4 of the second straight section 46.
  • the method includes the step of continuously filling the processing chamber 14 with a molten thermoplastic resin through the supply aperture 18. At least one supply aperture 18 is provided for each processing chamber 14 provided in the impregnation die 10. Any thermoplastic resin known to be useful in the production of long fiber reinforced thermoplastic resin pellets may be utilized including but not limited to polyolefin resins, polyamide resins and combinations thereof.
  • the method also includes the feeding of at least one continuous fiber strand 50 through the processing chamber 14. More specifically, the continuous fiber strand 50 is fed from a supply spool (not shown) across a guide member 48 and through the introduction aperture 20 into the processing chamber 14. The continuous fiber strand 50 is contacted with the molten thermoplastic resin in the processing chamber 14 before being pultruded and fully impregnated with the resin by passing through the pultrusion aperture
  • the continuous fiber strand 50 may be made from any appropriate material including reinforcing material such as glass fiber strand and/or carbon fiber strand.
  • Optional spreaders 54 of a type known in the art may be provided at spaced locations in the processing chamber 14 to spread the individual filaments of the continuous fiber strand 50 and aid in the impregnation process.
  • the pultruded rod shaped product 56 comprising the continuous fiber strand 50 impregnated with the molten thermoplastic resin 51, is extruded through the nozzle 24 and then cut by a cutting device 52 into pellets 60 of a desired length.
  • L length in mm of said processing chamber in a continuous fiber strand feeding direction
  • N total number of continuous fiber strands impregnated with molten thermoplastic resin pultruded from said impregnation die
  • the processing value A is provided between 0.5 and 3.5.
  • pellets produced from continuous strand 50 passing through each of those individual chambers 14 are processed in accordance with the processing value A.
  • the total value of the corresponding cross-sectional areas Sl, S2, S3, S4 of each of the chambers 14 is used as the cross-sectional area S of the impregnation die 10 when calculating the value A in the aforementioned formula.
  • Long fiber reinforced thermoplastic resin molding material in pellet form was obtained using an impregnation die in a shape shown in Fig. 2 with a length L and the cross-section area S (total value of the cross-section area of each processing chambers) as described in the table 1 , and setting the total number N of rod shaped product pultruded from the impregnation die to 4, and setting the speed of pultrusion of rod shaped product so that the total quantity Q of molten thermoplastic resin removed from the impregnation die becomes as described in the table 1.
  • glass fibers bundling 4,080 glass filaments of 16 ⁇ m in diameter were used.
  • Polypropylene resin with 151 melt flow rate (MFR) as measured by the procedure set forth in ISO-1133 was used as thermoplastic resin.
  • MFR melt flow rate
  • the rate of content of glass fiber of the obtained long fiber reinforced thermoplastic resin molding material was 50% by weight.
  • the pellets of the examples 1 to 5 which are long fiber reinforced thermoplastic resin molding material of the invention have a good level of impregnation of resin.
  • Long fiber reinforced thermoplastic resin molding material was manufactured using an impregnation die 10 as illustrated in Fig. 3 to which several nozzles in a shape shown in Fig. 4 were attached.
  • the fiber a glass fiber strand that draws together 17 pieces of a glass fiber, which was obtained by bundling 600 glass filaments with 13.5 ⁇ m in diameter was used. Also, polypropylene resin was used as the thermoplastic resin.
  • the number of breakage of rod-shaped product was counted using a nozzle in a shape shown in Fig. 5 (prior art) under the same conditions and in the same method as above.
  • the nozzle 60 has a shoulder 68, it has almost a cylindrical shape with the hole 65 whose cross-section is circular penetrating it.
  • the hole 65 has a tapered part 66 and a parallel or straight part 67.
  • the breakage frequency in rod shaped product in this prior art was 0.77 times per nozzle per day.
  • the breakage frequency of rod-shaped product of the present invention is much smaller than the one in the prior art. Therefore, productivity of long fiber reinforced thermoplastic resin molding material is higher in an impregnation die of this invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention porte sur une filière d'imprégnation, comprenant : un boîtier avec chambre de traitement interne et ouverture de pultrusion; et buse supportée sur ledit boîtier.. Ladite buse comprend une ouverture comportant une extrémité d'entrée, une extrémité de sortie et un axe central, ladite extrémité d'entrée étant en communication avec ladite chambre de traitement au moyen de ladite ouverture de pultrusion. La filière d'imprégnation est caractérisée en ce que ladite ouverture comprend une première section tronconique à l'extrémité d'entrée, une première section droite en aval de ladite première section tronconique, une deuxième section tronconique en aval de ladite première section droite et une deuxième section droite en aval de la deuxième section tronconique adjacente à l'extrémité de sortie.
PCT/US2007/021204 2007-10-02 2007-10-02 Filière d'imprégnation pour fabriquer un matériau de moulage en résine thermoplastique renforcée par de longues fibres WO2009045190A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
KR1020107007311A KR101472618B1 (ko) 2007-10-02 2007-10-02 장섬유 강화 열가소성 수지 성형 재료를 제조하기 위한 함침 다이
CN200780101624A CN101868334A (zh) 2007-10-02 2007-10-02 用于制造长纤维增强热塑树脂模塑材料的浸渍模
PCT/US2007/021204 WO2009045190A1 (fr) 2007-10-02 2007-10-02 Filière d'imprégnation pour fabriquer un matériau de moulage en résine thermoplastique renforcée par de longues fibres
JP2010527919A JP5027929B2 (ja) 2007-10-02 2007-10-02 長繊維強化熱可塑性樹脂成形材料の製造用含浸ダイ

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2007/021204 WO2009045190A1 (fr) 2007-10-02 2007-10-02 Filière d'imprégnation pour fabriquer un matériau de moulage en résine thermoplastique renforcée par de longues fibres

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WO2009045190A1 true WO2009045190A1 (fr) 2009-04-09

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JP (1) JP5027929B2 (fr)
KR (1) KR101472618B1 (fr)
CN (1) CN101868334A (fr)
WO (1) WO2009045190A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012131980A1 (fr) * 2011-03-31 2012-10-04 ポリプラスチックス株式会社 Procédé pour la production de pastille de composition de résine thermoplastique, extrudeuse, et plaque de filière
RU2591988C1 (ru) * 2015-04-24 2016-07-20 Федеральное казенное предприятие "Алексинский химический комбинат" (ФКП АХК) Способ изготовления гранул армированного полимерного пресс-материала и установка для его осуществления
RU167566U1 (ru) * 2015-10-16 2017-01-10 Общество с ограниченной ответственностью "Рекстром-М" Камера пропитки непрерывного волокна связующим
EP3470196A1 (fr) * 2017-10-16 2019-04-17 Feddem GmbH & Co. KG Dispositif et procédé d'imprégnation de faisceaux de fibres au moyen d'un polymère fondu
EP3763775A1 (fr) * 2019-07-09 2021-01-13 Arkema France Procede de preparation d'un materiau fibreux impregne par pultrusion reactive

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101814055B1 (ko) 2015-10-16 2018-01-03 지에스칼텍스 주식회사 장섬유 강화 열가소성 수지 제조장치
CN112793042B (zh) * 2021-04-08 2021-08-10 江苏国富氢能技术装备股份有限公司 用于纤维湿法缠绕工艺的纤维无损浸胶方法

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US4728387A (en) * 1986-12-15 1988-03-01 General Electric Company Resin impregnation of fiber structures
JPH06254852A (ja) * 1993-03-02 1994-09-13 Kobe Steel Ltd 長繊維強化合成樹脂ストランドの製造方法
JPH1142639A (ja) * 1997-07-29 1999-02-16 Kawasaki Steel Corp 熱可塑性樹脂含浸用装置およびこれを用いた長繊維強化熱可塑性樹脂ペレットの製造方法
JP2001088223A (ja) * 1999-09-21 2001-04-03 Chisso Corp 長繊維で強化された熱可塑性樹脂長尺体の製造装置
EP1790448A1 (fr) * 2005-11-24 2007-05-30 LATI Industria Termoplastici S.p.A. Appareil de fabrication de composés polymères à fibres longues
WO2007074908A1 (fr) * 2005-12-28 2007-07-05 Ocv Intellectual Capital, Llc Filière d’imprégnation pour matériau de moulage de résine thermoplastique renforcée de longue fibre et procédé de fabrication utilisant celle-ci

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JP3337171B2 (ja) * 1993-12-27 2002-10-21 株式会社秩父富士 樹脂練りバーの成形機
JP3908504B2 (ja) * 2001-11-01 2007-04-25 ポリプラスチックス株式会社 樹脂押出機ダイ装置及び押出成形方法
CH696347A5 (de) * 2003-05-23 2007-05-15 Sia Abrasives Ind Ag Verfahren zum Kalibrieren und/oder Verzwirnen von mit Kunststoff beschichteten Fasern.

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3993726A (en) * 1974-01-16 1976-11-23 Hercules Incorporated Methods of making continuous length reinforced plastic articles
US4728387A (en) * 1986-12-15 1988-03-01 General Electric Company Resin impregnation of fiber structures
JPH06254852A (ja) * 1993-03-02 1994-09-13 Kobe Steel Ltd 長繊維強化合成樹脂ストランドの製造方法
JPH1142639A (ja) * 1997-07-29 1999-02-16 Kawasaki Steel Corp 熱可塑性樹脂含浸用装置およびこれを用いた長繊維強化熱可塑性樹脂ペレットの製造方法
JP2001088223A (ja) * 1999-09-21 2001-04-03 Chisso Corp 長繊維で強化された熱可塑性樹脂長尺体の製造装置
EP1790448A1 (fr) * 2005-11-24 2007-05-30 LATI Industria Termoplastici S.p.A. Appareil de fabrication de composés polymères à fibres longues
WO2007074908A1 (fr) * 2005-12-28 2007-07-05 Ocv Intellectual Capital, Llc Filière d’imprégnation pour matériau de moulage de résine thermoplastique renforcée de longue fibre et procédé de fabrication utilisant celle-ci

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012131980A1 (fr) * 2011-03-31 2012-10-04 ポリプラスチックス株式会社 Procédé pour la production de pastille de composition de résine thermoplastique, extrudeuse, et plaque de filière
JP5728077B2 (ja) * 2011-03-31 2015-06-03 ポリプラスチックス株式会社 熱可塑性樹脂組成物ペレットの製造方法、押出機及びダイプレート
RU2591988C1 (ru) * 2015-04-24 2016-07-20 Федеральное казенное предприятие "Алексинский химический комбинат" (ФКП АХК) Способ изготовления гранул армированного полимерного пресс-материала и установка для его осуществления
RU167566U1 (ru) * 2015-10-16 2017-01-10 Общество с ограниченной ответственностью "Рекстром-М" Камера пропитки непрерывного волокна связующим
EP3470196A1 (fr) * 2017-10-16 2019-04-17 Feddem GmbH & Co. KG Dispositif et procédé d'imprégnation de faisceaux de fibres au moyen d'un polymère fondu
WO2019076653A1 (fr) * 2017-10-16 2019-04-25 FEDDEM GmbH & Co. KG Dispositif et procédé servant à imprégner des faisceaux de fibres d'une matière fondue de polymère
EP3763775A1 (fr) * 2019-07-09 2021-01-13 Arkema France Procede de preparation d'un materiau fibreux impregne par pultrusion reactive
WO2021005302A1 (fr) * 2019-07-09 2021-01-14 Arkema France Procede de preparation d'un materiau fibreux impregne par pultrusion reactive
FR3098517A1 (fr) * 2019-07-09 2021-01-15 Arkema France Procede de preparation d’un materiau fibreux impregne par pultrusion reactive

Also Published As

Publication number Publication date
JP2010540296A (ja) 2010-12-24
JP5027929B2 (ja) 2012-09-19
KR20100071053A (ko) 2010-06-28
KR101472618B1 (ko) 2014-12-15
CN101868334A (zh) 2010-10-20

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