Multi-layer sheet manufacturing device with a mixture of fabric layers and long fiber layers

Abstract

The present invention is characterized by the ability to manufacture a multilayer sheet in which a fabric layer and a long fiber layer are mixed in a single process, thereby reducing material processing costs and labor costs resulting from conventional dual manufacturing processes and improving product quality.

Description

Technology Field

[0001] The present invention is characterized by the ability to manufacture a multilayer sheet in which a fabric layer and a long fiber layer are mixed in a single process, thereby reducing material processing costs and labor costs resulting from conventional dual manufacturing processes and improving product quality. Background Technology

[0002] The bottom cover protecting the lower part of an electric vehicle battery pack must safeguard the cooling channels from external impacts. Therefore, the recent trend is to manufacture bottom covers using fiber-reinforced plastic sheets.

[0003] In addition, to reinforce physical properties, a sheet formed by a fabric layer is manufactured by impregnating a reinforcing fiber woven body (see Korean Patent Publication No. 10-2016-0071199, etc.), or the fabric layer is formed into a multilayer structure to reinforce physical properties. Glass fibers, carbon fibers, etc., are utilized as reinforcing fibers.

[0004] In addition, a mixed multilayer sheet has recently been developed. As shown in FIG. 1, the mixed multilayer sheet is a hybrid type sheet that combines the advantages of each layer, in which a fabric layer (2) and a long fiber layer (1) are laminated. As with the woven fabric, it is common for reinforcing fibers to be selected for the long fibers as well, and glass fibers, carbon fibers, etc. are utilized.

[0005] The general manufacturing process for these mixed multilayer sheets involves producing a fabric layer and a long fiber layer separately and then laminating them. The fabric layer is manufactured by supplying a woven material and impregnating it with resin, and the long fiber layer is also manufactured by supplying long fibers and impregnating them with resin; the two are then manufactured by inserting them into a mold and laminating them.

[0006] Therefore, since different types of materials were manufactured at different facilities and production sites, there was a problem of increased material processing costs, and the dualization of quality control led to a decline in quality.

[0007] In addition, when inserting the manufactured fabric layer and long fiber layer into the mold, the fabric layer and long fiber layer must be cut separately to fit the mold size. This process had the problem of requiring a significant amount of cutting time, and the process of placing the cut fabric layer and long fiber layer into the mold was performed manually, which frequently resulted in quality degradation due to the stacked fabric layer and long fiber layer becoming twisted. Prior art literature

[0008] Republic of Korea Published Patent Application No. 10-2016-0071199 The problem to be solved

[0009] The present invention is characterized by the ability to manufacture a multilayer sheet in which a fabric layer and a long fiber layer are mixed in a single process, thereby reducing material processing costs and labor costs resulting from conventional dual manufacturing processes and improving product quality. means of solving the problem

[0010] To achieve the objective of the present invention, a multilayer sheet manufacturing apparatus according to the present invention, comprising a first compound supply unit for supplying a compound for a fabric layer; a second compound supply unit for supplying a compound for a long fiber layer; a woven body supply unit for supplying a woven body; and a long fiber supply unit for supplying a long fiber; wherein the woven body is impregnated into the compound for a fabric layer supplied from the first compound supply unit to form a fabric layer, and simultaneously, the long fiber is impregnated into the compound for a long fiber layer supplied from the second compound supply unit to form a long fiber layer, so that the fabric layer and the long fiber layer are simultaneously transported and pass through a roller unit to form a multilayer sheet.

[0011] In addition, the first compound supply unit of the multilayer sheet manufacturing apparatus having a fabric layer and a long fiber layer mixed according to the present invention comprises: a first roll on which a first carrier film is wound; a first guide roll that guides the first carrier film supplied from the first roll toward the roller unit; and a first bath that supplies a compound for the fabric layer to the first carrier film being transported.

[0012] In addition, the second compound supply unit of the multilayer sheet manufacturing apparatus having a fabric layer and a long fiber layer mixed according to the present invention comprises: a second roll on which a second carrier film is wound; a second guide roll that guides the second carrier film supplied from the second roll toward the roller unit; and a second bath that supplies the compound for the long fiber layer to the second carrier film being transported.

[0013] In addition, the woven material supply unit of the multilayer sheet manufacturing apparatus having a mixed fabric layer and a long fiber layer according to the present invention comprises a third roll on which the woven material is wound; and the woven material is supplied from the third roll so as to be placed on top of the first carrier film on which the compound for the fabric layer is applied.

[0014] In addition, the third roll of the multilayer sheet manufacturing device having a mixed fabric layer and a long fiber layer according to the present invention is positioned in the longitudinal direction forward of the first bath, and the woven body is supplied during the longitudinal rearward to forward transfer of the first carrier film and the compound for the fabric layer.

[0015] In addition, the long fiber supply unit of the multilayer sheet manufacturing device having a fabric layer and a long fiber layer mixed according to the present invention comprises: a first cutting roller rotating in one direction; and a second cutting roller rotating in the opposite direction to the first cutting roller and having a blade formed thereon; and when a long fiber body passes between the first cutting roller and the second cutting roller, the long fiber body is cut by the second cutting roller and the long fiber falls.

[0016] In addition, the long fibers cut in the multilayer sheet manufacturing apparatus according to the present invention, in which the fabric layer and the long fiber layer are mixed, fall onto the upper part of the woven body being transported while placed on the first carrier film coated with the compound for the fabric layer, and are transported together toward the roller section.

[0017] In addition, the long fiber supply unit of the multilayer sheet manufacturing device having a fabric layer and a long fiber layer mixed according to the present invention is positioned in the longitudinal direction forward of the third roll, and the long fiber is supplied during the transfer from the rear to the front in the longitudinal direction of the first carrier film, the compound for the fabric layer, and the woven body.

[0018] In addition, the second carrier film of the multilayer sheet manufacturing apparatus, in which a fabric layer and a long fiber layer are mixed according to the present invention, is transported from the front to the rear direction in the longitudinal direction, and the transport direction is reversed by the second guide roll so that the compound for the long fiber layer applied to the upper part of the second carrier film meets the upper part of the woven body being transported, and moves from the rear to the front in the longitudinal direction after passing through the second guide roll.

[0019] In addition, the second guide roll of the multilayer sheet manufacturing device having a fabric layer and a long fiber layer mixed according to the present invention is located in the longitudinal direction ahead of the long fiber supply unit.

[0020] In addition, the first carrier film, the compound for the fabric layer, the woven body, the compound for the long fiber layer, and the second carrier film of the multilayer sheet manufacturing device having a mixed fabric layer and a long fiber layer according to the present invention are sequentially stacked from the bottom to the top in a vertical direction and face the roller part and are compressed by the roller part.

[0021] In addition, the multilayer sheet manufacturing device having a fabric layer and a long fiber layer mixed according to the present invention includes an upper roller section and a lower roller section spaced apart at a predetermined distance in the vertical direction, and the first carrier film, the compound for the fabric layer, the woven body, the compound for the long fiber layer, and the second carrier film are conveyed and inserted between the upper roller section and the lower roller section. Effects of the invention

[0022] Conventionally, as mentioned above, the process of producing a mixed multilayer sheet involved separately manufacturing the fabric layer and the long fiber layer, then inserting them into a mold to laminate them. This resulted in problems such as increased material processing and labor costs, quality degradation due to dual quality control, and quality deterioration caused by warping during the manual lamination process in the mold.

[0023] However, according to the present invention, a structure is formed in which a first carrier film, a compound for a fabric layer, a woven fabric, a long fiber, a compound for a long fiber layer, and a second carrier film are moved from the rear to the front in the longitudinal direction, and at the same time sequentially stacked from the bottom to the top in the vertical direction, thereby enabling the manufacture of a mixed multilayer sheet through a roller section, so that a mixed multilayer sheet can be manufactured in only one process. Therefore, unlike conventional methods, material processing costs and labor costs can be reduced, quality control can be unified to improve quality, and since a process of stacking manually in a mold is not required, warping cannot occur, thus providing the advantage of improved quality. Brief explanation of the drawing

[0024] Figure 1 illustrates the composition of a mixed multilayer sheet. FIG. 2 illustrates a multilayer sheet manufacturing apparatus according to the present invention. FIG. 3 illustrates a multilayer sheet manufactured using a multilayer sheet manufacturing device according to the present invention. Specific details for implementing the invention

[0025] The present invention will be described in detail below with reference to the drawings. The embodiments described below are provided as examples to ensure that the concept of the present invention is sufficiently conveyed to a person skilled in the art. Accordingly, the present invention is not limited to the embodiments described below and may be embodied in other forms. Furthermore, in the drawings, the size and thickness of the device, etc., may be exaggerated for convenience. Throughout the specification, the same reference numerals indicate the same components.

[0027] FIG. 2 illustrates a multilayer sheet manufacturing apparatus according to the present invention. Hereinafter, the configuration and effects of the multilayer sheet manufacturing apparatus according to the present invention will be explained with reference to FIG. 2.

[0028] A multilayer sheet manufacturing device according to the present invention includes a first compound supply unit (100), a second compound supply unit (200), a woven fabric supply unit (300), and a long fiber supply unit (400).

[0029] The first compound supply unit (100) includes a first roll (110), a first guide roll (120), and a first bath (130). A first carrier film (10) is wound on the first roll (110), and the first carrier film (10) that was wound is unwound by rotating it under the control of an operator. A compound (50) for the fabric layer is applied to the first carrier film (10), and it is removed after the sheet is completed.

[0031] The first guide roll (120) serves to support the first carrier film (10) that has been wound and then unwound, and at the same time, guides the first carrier film (10) toward the roller section (500). For example, as shown in FIG. 2, the first carrier film (10) is folded at the upper part of the first guide roll (120) and directed toward the roller section (500).

[0033] The first bath (130) serves to supply a fabric layer compound (50) to the first carrier film (10) being transported. Under control, the fabric layer compound (50) stored in the first bath (130) is applied to the upper surface of the first carrier film (10).

[0034] Accordingly, a structure is formed in which a compound (50) for the fabric layer is applied to the upper part of the first carrier film (10) and then transferred to the roller part (500).

[0036] Next, the woven fabric supply unit (300) will be described.

[0037] The woven material supply unit (300) includes a third roll (310), and the woven material (30) is wound on the third roll (310). At this time, it is preferable that the third roll (310) be positioned in front of the first bath (130). Due to this structure, a structure is formed in which the woven material (30) is supplied during the process of transporting the first carrier film (10), so that the entire process is carried out from the rear to the front in the longitudinal direction, and after the process is completed, a structure is formed in which the first carrier film (10), the compound for the fabric layer (50), and the woven material (30) are sequentially stacked from the bottom to the top in the vertical direction.

[0038] The woven body (30) is woven from reinforcing fibers, and since this is a known technology, a detailed description will be omitted. When the woven body (30) is supplied to the compound (50) for the fabric layer, a fabric layer can be formed.

[0040] Next, the second compound supply unit (200) will be described.

[0041] The second compound supply unit (200) includes a second roll (210), auxiliary guide rolls (220, 230), a second guide roll (240), and a second bath (250). A second carrier film (20) is wound on the second roll (210), and the wound second carrier film (20) is unwound by rotating it under the control of an operator. A compound (60) for a long fiber layer is applied to the second carrier film (20), and it is removed after the sheet is completed.

[0043] The second guide roll (240) serves to support the second carrier film (20) that has been wound and then unwound, and at the same time, guides the second carrier film (20) toward the roller section (500). For example, as shown in FIG. 2, the second carrier film (20) is bent at the bottom of the second guide roll (240) and directed toward the roller section (500).

[0044] At this time, as shown in FIG. 2, the first compound supply unit (100) forms a structure in which the first carrier film (10) moves from the rear to the front, and the second compound supply unit (200) moves the second carrier film (20) from the front to the rear, and then is folded again to move from the rear to the front. This has the advantage of allowing the device to be formed compactly, thereby minimizing the volume occupied within the manufacturing plant. Generally, to form a laminated sheet, all the materials to be laminated are supplied from the rear to the front and compressed. In this case, the device supplying the materials to be laminated located at the upper vertical position of the sheet must be positioned higher in the vertical direction than the device supplying the materials to be laminated located at the lower vertical position to avoid interference, which results in the problem of the device size becoming unnecessarily large. Therefore, this problem can be solved by constructing a structure such as that of the present invention.

[0046] The second bath (250) serves to supply the compound (60) for the long fiber layer to the second carrier film (20) being transported. Under control, the compound (60) for the long fiber layer stored in the second bath (250) is applied to the upper surface of the second carrier film (20). Additionally, it is preferable that the second bath (250) be located between the second roll (210) and the second guide roll (240).

[0047] At this time, with the compound (60) for the long fiber layer applied to the upper surface of the second carrier film (20), a structure is formed in which the structure moves from the front to the rear in the longitudinal direction, and then, starting from the second guide roll (240), a change of direction (reversal) occurs so that it moves from the rear to the front in the longitudinal direction and is transferred to the roller section (500). This is a method for forming the position and stacking structure of the supply section configured to minimize the device volume as described above.

[0048] The auxiliary guide rolls (220, 230) can prevent sagging of the second carrier film (20) that may occur structurally by causing the second guide roll (240) to reverse the conveying direction, and it is preferable for them to be positioned between the second roll (210) and the second guide roll (240) to support the second carrier film (20).

[0050] Next, the long fiber supply unit (400) will be described.

[0051] The long fiber supply unit (400) includes a first cutting roller (410) and a second cutting roller (420). The first cutting roller (410) and the second cutting roller (420) are spaced apart at a predetermined interval in the longitudinal direction, and it is preferable that the first cutting roller (410) and the second cutting roller (420) rotate in opposite directions to each other. For example, the first cutting roller (410) rotates clockwise and the second cutting roller (420) rotates counterclockwise.

[0052] In addition, a blade is formed on at least one of the first cutting roller (410) and the second cutting roller (420).

[0054] Accordingly, when the long fiber body (40a) passes between the first cutting roller (410) and the second cutting roller (420), the long fiber body (40a) is sucked into the space between the first cutting roller (410) and the second cutting roller (420) due to the mutually opposite rotation of the first cutting roller (410) and the second cutting roller (420), and at the same time is cut by the blade to form a long fiber (40).

[0056] At this time, the formed long fiber (40) falls and lands on the upper part of the woven body (30) being transported. More specifically, it lands on the upper part of the first carrier film (10) and the woven body (30), and as a result, the first carrier film (10), the woven body (30), and the long fiber (40) are sequentially stacked from the lower part to the upper part in the vertical direction while being transported from the rear to the front in the longitudinal direction.

[0057] To form this structure, the long fiber supply unit (400) is preferably located in front of the third roll (310), and more specifically, is located between the third roll (310) and the second guide roll (240) in the longitudinal direction.

[0058] At this time, as described above, the second carrier film (20) is converted from rear to front in the longitudinal direction in the conveying direction by the second guide roll (240). Due to this structure, the compound for the long fiber layer (60) undergoes an up-and-down inversion in its positional relationship with the second carrier film (20) starting from the second guide roll (240). That is, before the second carrier film (20) passes through the second guide roll (240), the structure is such that the second carrier film (20) and the compound for the long fiber layer (60) are sequentially stacked from bottom to top with respect to the vertical direction. However, after passing through the second guide roll (240), a structure is formed in which the compound for the long fiber layer (60) and the second carrier film (20) are sequentially stacked from bottom to top with respect to the vertical direction. At the same time, it comes into contact with the long fiber (40) being conveyed.

[0060] Accordingly, to summarize the above, a structure is formed in which a first carrier film (10), a compound for the fabric layer (50), a woven body (30), a long fiber (40), a compound for the long fiber layer (60), and a second carrier film (20) are sequentially stacked from the bottom to the top in the vertical direction, and simultaneously transported in the longitudinal direction.

[0062] After being transported in batches, the materials are inserted into a roller section (500), which is preferably composed of an upper roller section and a lower roller section and is inserted between the upper roller section and the lower roller section. Accordingly, the first carrier film (10), the compound for the fabric layer (50), the woven material (30), the long fiber (40), the compound for the long fiber layer (60), and the second carrier film (20) are compressed by the rotation of the upper roller section and the lower roller section. As a result, the woven material (30) is impregnated into the compound for the fabric layer (50) to form a fabric layer, and the long fiber (40) is impregnated into the compound for the long fiber layer (60) to form a long fiber layer. At the same time, a mixed multilayer sheet is manufactured in which the fabric layer and the long fiber layer are sequentially stacked from the bottom to the top in a vertical direction. The structure of the mixed multilayer sheet is illustrated in FIG. 3.

[0064] Conventionally, as mentioned above, the process of producing a mixed multilayer sheet involved separately manufacturing the fabric layer and the long fiber layer, then inserting them into a mold to laminate them. This resulted in problems such as increased material processing and labor costs, quality degradation due to dual quality control, and quality deterioration caused by warping during the manual lamination process in the mold.

[0066] However, according to the present invention, a structure is formed in which the first carrier film (10), the compound for the fabric layer (50), the woven fabric (30), the long fiber (40), the compound for the long fiber layer (60), and the second carrier film (20) are moved from the rear to the front in the longitudinal direction, and at the same time are sequentially stacked from the bottom to the top in the vertical direction, thereby allowing a mixed multilayer sheet to be manufactured by passing through the roller section (500), so that a mixed multilayer sheet can be manufactured in only one process. Therefore, unlike conventional methods, material processing costs and labor costs can be reduced, quality control can be unified to improve quality, and since a process of stacking manually in a mold is not required, warping cannot occur, thus improving quality.

[0068] The sensor unit (600) is preferably composed of a first sensor unit (610), a second sensor unit (620), and a third sensor unit (630).

[0069] At this time, it is preferable that the first sensor unit (610) detects between the first bath (130) and the third roll (310), the second sensor unit (620) detects between the third roll (310) and the long fiber supply unit (400), and the third sensor unit (630) detects between the long fiber supply unit (400) and the second guide roll (240).

[0071] The sensor unit (600) detects the compound for the fabric layer (50), the woven body (30), and the long fiber (40). At this time, during the process, there may be cases where the compound for the fabric layer (50), the woven body (30), and the long fiber (40) are not supplied smoothly due to an error. For example, if an error occurs where the woven body (30) is not supplied, the composition according to the present invention (compound for the fabric layer (50), woven body (30), and long fiber (40)) is supplied independently as described above, so the compound for the fabric layer (50) and the long fiber (40) are continuously supplied separately from the non-supply of the woven body (30), and thus the manufacturing process continues. Consequently, a sheet without the woven body (30) is completed, making the entire sheet unusable and potentially resulting in the waste of unnecessary materials.

[0073] Therefore, to prevent such problems in advance, the first sensor unit (610) detects the space between the first bath (130) and the third roll (310) to monitor in real time whether the compound (50) for the fabric layer is being supplied smoothly, the second sensor unit (620) detects the space between the third roll (310) and the long fiber supply unit (400) to monitor in real time whether the woven body (30) is being supplied smoothly, and the third sensor unit (630) detects the space between the long fiber supply unit (400) and the second guide roll (240) to monitor in real time whether the long fiber (40) is being supplied smoothly.

[0075] If any one sensor unit detects that a component is not being supplied, a system can be established that turns off the power to the entire device and warns the operator.

[0076] Each sensor part has a different longitudinal position and is positioned between the components supplied with the compound (50) for the fabric layer, the woven body (30), and the long fiber (40), so that it is possible to accurately detect which components are not being supplied, and the operator can intuitively know which components are not being supplied, thereby minimizing the time required for feedback and improving process efficiency.

[0078] Although the detailed description of the present invention has been explained with reference to preferred embodiments, those skilled in the art or those with ordinary knowledge in the relevant technical field will understand that various modifications and changes can be made to the present invention without departing from the spirit and technical scope of the invention as set forth in the claims below. Accordingly, the technical scope of the present invention should not be limited to the contents described in the detailed description of the specification, but should be determined by the claims. Explanation of the symbols

[0079] 100 : 1st compound supply unit, 200 : 2nd Compound Supply Unit, 300 : Woven fabric supply unit, 400 : Long fiber supply unit, 500 : Roller section, 600 : Sensor section.

Claims

Claim 1 A first compound supply unit for supplying a compound for a fabric layer; a second compound supply unit for supplying a compound for a long fiber layer; a woven body supply unit for supplying a woven body; and a long fiber supply unit for supplying long fibers; wherein the woven body is impregnated into the compound for the fabric layer supplied from the first compound supply unit to form a fabric layer, and simultaneously, the long fiber is impregnated into the compound for the long fiber layer supplied from the second compound supply unit to form a long fiber layer, so that the fabric layer and the long fiber layer are conveyed simultaneously and penetrate a roller unit simultaneously to form a multilayer sheet, and the first compound supply unit comprises a first roll on which a first carrier film is wound; and a first guide roll that guides the first carrier film supplied from the first roll toward the roller unit. The method comprises: a first bath for supplying the compound for the fabric layer to the first carrier film being transported; wherein the second compound supply unit comprises: a second roll on which the second carrier film is wound; a second guide roll that guides the second carrier film supplied from the second roll toward the roller unit; and a second bath for supplying the compound for the long fiber layer to the second carrier film being transported; wherein the woven body supply unit comprises: a third roll on which the woven body is wound; wherein the woven body is supplied from the third roll so as to be placed on top of the first carrier film on which the compound for the fabric layer is applied; and further comprises a sensor unit that controls the process by detecting the supply status of the compound for the fabric layer, the woven body, and the long fiber, wherein the sensor unit comprises: a first sensor unit located between the first bath and the third roll; a second sensor unit located between the third roll and the long fiber supply unit; and a third sensor unit located between the long fiber supply unit and the second guide roll.A multilayer sheet manufacturing apparatus comprising a fabric layer and a long fiber layer, characterized in that the first to third sensor units, which are positioned at different locations along the longitudinal direction, detect the supply status of a configuration detectable at each location, and when it is detected that any one of the configurations is not supplied, the power to the manufacturing apparatus is cut off and a warning signal is provided to the operator, thereby controlling the manufacturing process. Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 A multilayer sheet manufacturing apparatus comprising a fabric layer and a long fiber layer, wherein, in claim 1, the third roll is positioned longitudinally forward of the first bath, and the woven material is supplied during the longitudinal rearward to forward transfer of the first carrier film and the compound for the fabric layer. Claim 6 A multilayer sheet manufacturing apparatus comprising a fabric layer and a long fiber layer mixed therein, wherein the long fiber supply unit comprises: a first cutting roller rotating in one direction; and a second cutting roller rotating in the opposite direction to the first cutting roller and having a blade formed thereon, wherein when a long fiber body passes between the first cutting roller and the second cutting roller, the long fiber body is cut by the second cutting roller and the long fiber falls. Claim 7 A multilayer sheet manufacturing apparatus having a mixed fabric layer and a long fiber layer, wherein, in claim 6, the cut long fiber is placed on the first carrier film coated with the compound for the fabric layer and falls onto the upper part of the woven body being transported, and is transported together toward the roller section. Claim 8 A multilayer sheet manufacturing apparatus comprising a fabric layer and a long fiber layer, wherein, in claim 7, the long fiber supply unit is positioned longitudinally forward of the third roll, and the long fiber is supplied during the transfer from the rear to the front in the longitudinal direction of the first carrier film, the compound for the fabric layer, and the woven body. Claim 9 In claim 8, the second carrier film is transported from the front to the rear in the longitudinal direction, and the transport direction is reversed by the second guide roll so that the compound for the long fiber layer applied to the upper part of the second carrier film meets the upper part of the woven body being transported, and after passing through the second guide roll, moves from the rear to the front in the longitudinal direction, and a multilayer sheet manufacturing apparatus in which the woven layer and the long fiber layer are mixed. Claim 10 A multilayer sheet manufacturing apparatus comprising a fabric layer and a long fiber layer, wherein, in claim 9, the second guide roll is located longitudinally forward of the long fiber supply section. Claim 11 A multilayer sheet manufacturing apparatus comprising a fabric layer and a long fiber layer mixed therein, wherein, in item 10, the first carrier film, the compound for the fabric layer, the woven body, the compound for the long fiber layer, and the second carrier film are sequentially stacked from the bottom to the top in a vertical direction and are directed toward the roller part and compressed by the roller part. Claim 12 A multilayer sheet manufacturing apparatus having a mixed fabric layer and a long fiber layer, wherein, in claim 11, the roller section comprises an upper roller section and a lower roller section spaced apart at a predetermined distance in the vertical direction, and the first carrier film, the compound for the fabric layer, the woven body, the compound for the long fiber layer, and the second carrier film are conveyed and inserted between the upper roller section and the lower roller section.

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