Glass fiber manufacturing method and glass fiber manufacturing apparatus

Abstract

To provide a method for producing a glass fiber by which the length of a cake in the axial direction can be controlled to a desired length.SOLUTION: The method for manufacturing a glass fiber includes a first winding step of forming a cylindrical first cake 41 by winding a glass strand S on a first collet 19 disposed at a winding position while traversing the glass strand S by a traverse 15, a replacement step of replacing the first collet 19 disposed at the winding position with a second collet 20 after the first winding step, and a speed control step of controlling a speed at which the traverse 15 moves away from the second collet 20 in the second winding step based on a measured value which is an axial length of the first cake 41 before the second winding step.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for producing glass fibers and an apparatus for producing glass fibers. [Background technology]

[0002] Conventionally, a method for manufacturing glass fibers includes a method in which a glass strand is traversed by a traverse and wound around a collet to form a cylindrical cake (see, for example, Patent Document 1). In this method for manufacturing glass fibers, when a cake is formed, the collet arranged at the winding position is replaced with the next collet on which a cake has not been formed, thereby enabling successive cakes to be formed. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2022-42722 Summary of the Invention [Problem to be solved by the invention]

[0004] However, if the axial length of the cylindrical cake formed by the above-described glass fiber manufacturing method deviates from the desired length, there is a problem that the cake becomes difficult to handle afterward. Also, for example, especially when the axial length of the cake is shorter than the desired length, there is a problem that the strands become densely packed and adhere to each other.

[0005] An object of the present invention is to provide a method and an apparatus for producing glass fiber that enable the axial length of the cake to be adjusted to a desired length. [Means for solving the problem]

[0006] [1] A method for manufacturing glass fibers that solves the above-mentioned problems includes a first winding step of forming a cylindrical first cake by winding a glass strand around a first collet arranged at a winding position while traversing the glass strand using a traverse; a replacement step of replacing the first collet arranged at the winding position with a second collet after the first winding step is completed; and a second winding step of forming a cylindrical second cake by winding the glass strand around the second collet arranged at the winding position while traversing the glass strand using the traverse; and a speed control step of controlling, before the second winding step, the speed at which the traverse separates from the second collet in the second winding step based on a measured value that is the axial length of the first cake.

[0007] According to this method, the speed at which the traverse separates from the second collet in the second winding process is controlled based on the measured value of the axial length of the first cake produced immediately before. Increasing the speed at which the traverse separates from the second collet reduces the axial length of the second cake formed, while decreasing the speed at which the traverse separates from the second collet increases the axial length of the second cake formed. Therefore, the axial length of the second cake can be adjusted to the desired length with high precision.

[0008] [2] In the method for producing glass fibers described in [1] above, in the speed control step, when the measured value is greater than a first reference value, the speed at which the traverse moves away from the second collet may be increased, and when the measured value is smaller than a second reference value, the speed at which the traverse moves away from the second collet may be decreased.

[0009] According to this method, when the measured value is greater than the first reference value, the speed at which the traverse separates from the second collet increases, resulting in a smaller axial length of the second cake formed. Conversely, when the measured value is smaller than the second reference value, the speed at which the traverse separates from the second collet decreases, resulting in a larger axial length of the second cake formed. Therefore, the axial length of the second cake can be adjusted to the desired length with high precision.

[0010] [3] In the method for producing glass fibers described in [2] above, the first reference value may be set to be greater than the second reference value, and in the speed control step, the speed at which the traverse moves away from the second collet may be controlled so that the axial length of the second cake is within a reference range that is less than the first reference value and greater than or equal to the second reference value.

[0011] According to this method, the first reference value is set to be larger than the second reference value, so that the axial length of the second cake can be set to a length within a reference range that is equal to or smaller than the first reference value and equal to or larger than the second reference value, thereby making it possible to set the axial length of the second cake to a desired length.

[0012] [4] In the method for producing glass fibers described in any one of [1] to [3] above, the measurement value may be measured by a sensor, and the speed at which the traverse moves away from the second collet may be controlled by a control unit connected to the sensor and to which the measurement value is input from the sensor.

[0013] According to this method, the axial length of the second cake can be automatically adjusted to a desired length with high precision by the sensor and the control unit.

[0014] [5] A glass fiber manufacturing apparatus that solves the above problem comprises: a traverse that moves the glass strand back and forth in a direction intersecting the extension direction of the glass strand; a first collet that, while positioned at a winding position, forms a cylindrical first cake by winding up the glass strand that has passed through the traverse; and a second collet that, when the first cake is formed, is positioned at the winding position by replacing the first collet positioned at the winding position, and, while positioned at the winding position, forms a cylindrical second cake by winding up the glass strand that has passed through the traverse. The glass fiber manufacturing apparatus also comprises: a sensor that measures a measurement value that is the axial length of the first cake; and a control unit that is connected to the sensor and controls the speed at which the traverse moves away from the second collet positioned at the winding position based on the measurement value input from the sensor.

[0015] According to this configuration, the sensor measures the axial length of the first cake. Then, the control unit controls the speed at which the traverse moves away from the second collet located at the winding position based on the measurement value input from the sensor. Therefore, the axial length of the second cake can be automatically adjusted to the desired length with high accuracy. [Effects of the Invention]

[0016] According to the glass fiber manufacturing method and glass fiber manufacturing apparatus of the present invention, the axial length of the cake can be adjusted to a desired length. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a schematic side view showing an apparatus for producing glass fibers according to one embodiment. [Figure 2] FIG. 2 is a schematic front view showing a part of the glass fiber manufacturing apparatus of one embodiment. [Figure 3] FIG. 3 is a schematic side view showing a glass fiber manufacturing apparatus according to one embodiment. [Figure 4] FIG. 4 is a schematic diagram for explaining the range of the glass strand relative to the distance between the traverse and the second collet. [Figure 5] FIG. 5 is a schematic diagram for explaining the range of the glass strand relative to the distance between the traverse and the second collet. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, an embodiment of a glass fiber manufacturing method and a glass fiber manufacturing apparatus will be described with reference to the drawings. Note that in the drawings, for the sake of convenience, parts of the machine may be shown exaggerated or simplified. Furthermore, the dimensional ratios of each part may differ from the actual ratios.

[0019] (Overall configuration of glass fiber manufacturing apparatus 11) 1, the glass fiber manufacturing apparatus 11 includes a bushing 12, an applicator 13, a gathering shoe 14, a traverse 15, a cradle 16, and a drive unit 17. The glass fiber manufacturing apparatus 11 also includes a rotation unit 18, a first collet 19, a second collet 20, a sensor 21, and a control unit 22.

[0020] The bushing 12 is a box-shaped container having a plurality of nozzles below it, into which molten glass is supplied and from which a plurality of glass filaments F are drawn downward. Note that Fig. 1 shows a schematic illustration of the plurality of glass filaments F collectively. In other words, Fig. 1 shows only the outermost portions of the plurality of glass filaments F, and illustrates the range through which the glass filaments F pass.

[0021] The applicator 13 has a drive roller and is a device that applies a sizing agent to the glass filaments F. The gathering shoe 14 is a device that gathers and bundles multiple glass filaments F to which the sizing agent has been applied, to form a glass strand S. The glass filaments F and the glass strand S are made of, for example, E-glass (general-purpose alkali-free glass), A-glass (alkali-resistant glass), C-glass (acid-resistant alkali-lime-containing glass), D-glass (low dielectric constant glass), S-glass (high strength, high elastic modulus glass), T-glass (high strength, high elastic modulus glass), H-glass (high dielectric constant glass), etc.

[0022] The traverse 15 is provided on a cradle 16 so as to be movable along a horizontal first direction X1 (see FIG. 2), which is a direction intersecting the extension direction of the glass strand S. The traverse 15 moves back and forth along the first direction X1 by the operation of a traverse drive device (not shown), thereby moving the glass strand S back and forth along the first direction X1. Note that in FIG. 2, the traverse 15 and the glass strand S when reversing their reciprocating movement are schematically shown by two-dot chain lines.

[0023] The cradle 16 is provided so as to be movable along a horizontal second direction X2 (see FIG. 1) perpendicular to the first direction X1. A drive unit 17 is drivingly connected to the cradle 16. The drive unit 17 is capable of moving the cradle 16 along the second direction X2. This allows the cradle 16 to be moved away from the first collet 19 as the winding diameter of the glass strand S on the first collet 19 increases. Furthermore, when the first collet 19 arranged at the winding position is replaced with the second collet 20, the cradle 16 can be moved to the winding start position of the glass strand S. Note that although the second direction X2 is horizontal in FIG. 1, it is not limited thereto. For example, the traverse 15 and the cradle 16 may be moved in a diagonal direction (diagonally upward or diagonally downward). In this case, the traverse 15 and the cradle 16 may be moved linearly or rotated in an arc.

[0024] The rotation device 18 is a device for replacing the first collet 19 arranged at the winding position with the second collet 20. The rotation device 18 includes a disk-shaped rotating body 31, two cylindrical mounting portions (shafts) 32 protruding from one surface 31a of the rotating body 31, and a partition plate 33 protruding from the surface 31a and separating the two mounting portions 32.

[0025] The two mounting portions 32 are provided parallel to each other and are arranged on the surface 31a at positions that are point-symmetrical about the rotation axis of the rotating body 31. A first collet 19 is attached to one of the mounting portions 32 closer to the traverse 15, and a second collet 20 is attached to the other mounting portion 32. Note that Fig. 1 illustrates the first collet 19 attached to one of the mounting portions 32 closer to the traverse 15 and positioned at the winding position.

[0026] The first collet 19, positioned at the winding position, rotates about the mounting portion 32 as an axis, thereby winding up the glass strand S that has passed through the traverse 15. A tubular bobbin (e.g., a paper tube) (not shown) is mounted on the first collet 19, and the glass strand S is wound around the first collet 19 via the bobbin. Mounting a bobbin is preferable because it makes it easier to remove the first cake 41 formed on the first collet 19, but this is not necessarily limited to this. The glass strand S may also be wound directly onto the first collet 19 without mounting a bobbin. The glass strand S is wound onto the first collet 19 while being traversed by the traverse 15, thereby forming the cylindrical first cake 41. Note that FIGS. 1 and 2 show a state in which the winding of the glass strand S onto the first collet 19 is completed and the first cake 41 has been formed.

[0027] 3, after the first cake 41 is formed, the second collet 20 is placed at the winding position by replacing the first collet 19 that is placed at the winding position. Specifically, after the first cake 41 is formed, the rotating body 31 of the rotating device 18 is rotated 180° about the rotation axis, so that the second collet 20 is placed at the winding position. At this time, the first collet 19 on which the first cake 41 has been formed is placed at the standby position where the second collet 20 was originally placed.

[0028] The second collet 20, which is positioned at the winding position, rotates around the mounting portion 32 as an axis, thereby winding up the glass strand S that has passed through the traverse 15. The glass strand S is wound onto the second collet 20 while being traversed by the traverse 15, thereby forming a cylindrical second cake 42. Note that FIG. 3 illustrates a state before winding of the glass strand S onto the second collet 20 begins, and before the second cake 42 is formed. Also, in FIG. 3, the second cake 42 that is subsequently formed on the second collet 20 is schematically illustrated by a two-dot chain line.

[0029] The first cake 41, which is placed in the standby position, is removed together with the bobbin from the first collet 19. Thereafter, by repeating the above-described operation, the first cake 41 is formed again on the first collet 19. In other words, after the first cake 41 is removed from the first collet 19 in the state shown in FIG. 3, the second collet 20 described above functions as the first collet 19, and the first collet 19 functions as the second collet 20.

[0030] (Configuration of Sensor 21) 2, the sensor 21 measures a measurement value Z, which is the axial length of the first cake 41. The sensor 21 of this embodiment includes, for example, a camera, and measures the measurement value Z by determining the positions of both ends of the axial direction of the first cake 41 from image data captured by the camera.

[0031] (Configuration of control unit 22) The control unit 22 is connected to the sensor 21 and controls the speed at which the traverse 15 moves away from the second collet 20 arranged at the winding position based on the measurement value Z input from the sensor 21.

[0032] In more detail, the control unit 22 of this embodiment controls the output setting of the drive device 17 and controls the speed at which the traverse 15 drives after the winding of the glass strand S onto the first collet 19 is completed and before the winding of the glass strand S onto the second collet 20 begins.

[0033] The control unit 22 stores a first reference value and a second reference value. When the measurement value Z is greater than the first reference value, the control unit 22 increases the speed at which the traverse 15 moves away from the second collet 20, and when the measurement value Z is smaller than the second reference value, the control unit 22 decreases the speed at which the traverse 15 moves away from the second collet 20. The first reference value in this embodiment is set to be greater than the second reference value. The control unit 22 controls the speed at which the traverse 15 moves away from the second collet 20 so that the axial length of the second cake 42 is within a reference range that is less than the first reference value and greater than or equal to the second reference value.

[0034] Here, as shown schematically in Figures 4 and 5, the glass strand S heading from the traverse 15 to the second collet 20 will have different axial ranges A and B when it reaches the second collet 20 depending on the distance between the traverse 15 and the second collet 20.

[0035] That is, as shown in FIG. 4, the axial range A of the glass strand S moving from the traverse 15 toward the second collet 20 when it reaches the second collet 20 is small when the distance between the traverse 15 and the second collet 20 is large. Also, as shown in FIG. 5, the axial range B of the glass strand S moving from the traverse 15 toward the second collet 20 when it reaches the second collet 20 is large when the distance between the traverse 15 and the second collet 20 is small. To utilize this phenomenon, the control unit 22 increases the speed at which the traverse 15 moves away from the second collet 20, for example, faster than a preset reference speed, when the measured value Z is greater than a first reference value. This increases the distance between the traverse 15 and the second collet 20, resulting in a decrease in the axial length of the second cake 42. Also, the control unit 22 decreases the speed at which the traverse 15 moves away from the second collet 20, for example, slower than a preset reference speed, when the measured value Z is smaller than a second reference value. This reduces the distance between the traverse 15 and the second collet 20, resulting in an increase in the axial length of the second cake 42.

[0036] (Glass fiber manufacturing method and its use) The glass fiber manufacturing method of this embodiment is carried out using the glass fiber manufacturing apparatus 11 described above.

[0037] The glass fiber manufacturing method includes a “first winding step,” a “replacing step,” and a “second winding step.” The glass fiber manufacturing method of this embodiment also includes a “speed control step.”

[0038] As shown in Figures 1 and 2, in the first winding process, the glass strand S is traversed by a traverse 15 and wound around a first collet 19 arranged at a winding position to form a cylindrical first cake 41.

[0039] 3, in the replacement process, after the first winding process is completed, the first collet 19 placed at the winding position is replaced with the second collet 20. Specifically, the rotor 31 of the rotation device 18 is rotated 180° around the rotation axis, thereby placing the second collet 20 at the winding position.

[0040] Next, in the second winding step, the glass strand S is traversed by the traverse 15 and wound around the second collet 20 disposed at the winding position, thereby forming a cylindrical second cake 42.

[0041] The speed control process is performed before the second winding process. In the speed control process, the speed at which the traverse 15 moves away from the second collet 20 in the second winding process is controlled based on the measurement value Z, which is the axial length of the first cake 41. In this embodiment, the measurement value Z is measured by the sensor 21, and the speed at which the traverse 15 moves away from the second collet 20 is controlled by the control unit 22, which is connected to the sensor 21 and receives the measurement value Z as input from the sensor 21. Specifically, in the speed control process, the control unit 22 controls the output setting of the drive device 17, thereby controlling the speed at which the traverse 15 moves away from the second collet 20.

[0042] More specifically, in the speed control process, when the measurement value Z is greater than a first reference value, the speed at which the traverse 15 moves away from the second collet 20 is increased, and when the measurement value Z is smaller than the second reference value, the speed at which the traverse 15 moves away from the second collet 20 is decreased. Specifically, the first reference value is set to be greater than the second reference value. Then, in the speed control process, the speed at which the traverse 15 moves away from the second collet 20 is controlled so that the axial length of the second cake 42 is within a reference range that is less than the first reference value and greater than or equal to the second reference value. Through these processes, the second cake 42 is formed.

[0043] Next, the effects of the above embodiment will be described below. (1) The speed at which the traverse 15 moves away from the second collet 20 in the second winding process is controlled based on the measured value Z, which is the axial length of the first cake 41 produced immediately before. Note that, if the speed at which the traverse 15 moves away from the second collet 20 is increased, the axial length of the second cake 42 to be formed becomes smaller, and if the speed at which the traverse 15 moves away from the second collet 20 is decreased, the axial length of the second cake 42 to be formed becomes larger. Therefore, the axial length of the second cake 42 can be set to the desired length with high precision. This makes it easier to handle the second cake 42 thereafter, for example.

[0044] (2) When the measurement value Z is greater than the first reference value, the speed at which the traverse 15 moves away from the second collet 20 is controlled to increase, so that the axial length of the formed second cake 42 is reduced. Also, when the measurement value Z is smaller than the second reference value, the speed at which the traverse 15 moves away from the second collet 20 is controlled to decrease, so that the axial length of the formed second cake 42 is increased. Therefore, the axial length of the second cake 42 can be set to the desired length with high precision.

[0045] (3) By setting the first reference value to be larger than the second reference value, the axial length of the second cake 42 can be set to a length within a reference range that is equal to or smaller than the first reference value and equal to or larger than the second reference value. Therefore, the axial length of the second cake 42 can be set to a desired length.

[0046] (4) The sensor 21 measures the measurement value Z, which is the axial length of the first cake 41. Then, the control unit 22 controls the speed at which the traverse 15 moves away from the second collet 20 arranged at the winding position based on the measurement value Z input from the sensor 21. Thus, the axial length of the second cake 42 can be automatically adjusted to the desired length with high precision.

[0047] This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility.

[0048] In the above embodiment, the speed control process controls the speed at which the traverse 15 moves away from the second collet 20 when the measurement value Z is greater than the first reference value or when the measurement value Z is smaller than the second reference value. However, this is not limited to this, and only one of the controls may be performed. For example, when the measurement value Z is greater than the first reference value, control may be performed to simply increase the speed at which the traverse 15 moves away from the second collet 20. In this way, the maximum axial length of the second cake 42 can be set to the desired length. Also, for example, when the measurement value Z is smaller than the second reference value, control may be performed to simply decrease the speed at which the traverse 15 moves away from the second collet 20. In this way, the minimum axial length of the second cake 42 can be set to the desired length.

[0049] In the above embodiment, the first reference value is set to be larger than the second reference value, and the axial length of the second cake 42 is controlled to be within the reference range, but this is not limited to this, and for example, the first reference value may be set to be the same as the second reference value.

[0050] The glass fiber manufacturing method of the above embodiment is described as being performed using the glass fiber manufacturing apparatus 11, but is not limited to this and may be performed using other manufacturing apparatuses. Specifically, for example, in the above embodiment, the speed at which the traverse 15 moves away from the second collet 20 is controlled by the sensor 21 and the control unit 22 to which the measurement value Z is input from the sensor 21, but is not limited to this. For example, the measurement value Z, which is the axial length of the first cake 41, may be measured manually. Also, for example, the speed at which the traverse 15 moves away from the second collet 20 may be controlled manually.

[0051] In the above embodiment, the traverse 15 may be changed to a traverse of another configuration (for example, a wire traverse) as long as it can reciprocate the glass strand S in a direction intersecting the extension direction of the glass strand S.

[0052] 1 to 3, the sensor 21 is illustrated below the rotation device 18, but this is not limiting and the sensor 21 may be disposed in another position. Furthermore, the sensor 21 in the above embodiment includes a camera and measures the measurement value Z from image data captured by the camera, but the sensor 21 may be configured in another way as long as it can measure the measurement value Z.

[0053] The embodiments and modifications disclosed herein are illustrative in all respects, and the present invention is not limited to these examples. That is, the scope of the present invention is defined by the claims, and it is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0054] 11. Glass fiber manufacturing equipment 15 Traverse 19 First Colette 20 The Second Colette 21 Sensors 22 Control Unit 41 First Cake 42 Second Cake F glass filament S Glass Strand Z measurement

Claims

1. a first winding step of winding the glass strand around a first collet disposed at a winding position while traversing the glass strand by a traverse to form a cylindrical first cake; a replacing step of replacing the first collet arranged at the winding position with a second collet after the first winding step is completed; a second winding step of winding the glass strand onto the second collet disposed at the winding position while traversing the glass strand by the traverse to form a cylindrical second cake; A method for producing glass fibers comprising: a speed control step of controlling a speed at which the traverse moves away from the second collet in the second winding step based on a measured value that is the axial length of the first cake before the second winding step; Glass fiber manufacturing method.

2. In the speed control step, when the measurement value is larger than a first reference value, the speed at which the traverse moves away from the second collet is increased, and when the measurement value is smaller than a second reference value, the speed at which the traverse moves away from the second collet is decreased. The method for producing the glass fiber according to claim 1 .

3. the first reference value is set to be greater than the second reference value, In the speed control step, a speed at which the traverse moves away from the second collet is controlled so that the axial length of the second cake is within a reference range that is equal to or less than the first reference value and equal to or more than the second reference value. The method for producing the glass fiber according to claim 2 .

4. The measurement value is measured by a sensor, and a speed at which the traverse moves away from the second collet is controlled by a control unit that is connected to the sensor and receives the measurement value from the sensor. The method for producing the glass fiber according to claim 1 .

5. a traverse that reciprocates the glass strand in a direction intersecting the extending direction of the glass strand; a first collet disposed at a winding position for winding the glass strand that has passed through the traverse to form a cylindrical first cake; a second collet that, when the first cake is formed, is placed at the winding position by replacing the first collet that is placed at the winding position, and forms a cylindrical second cake by winding the glass strand that has passed through the traverse while placed at the winding position; A glass fiber manufacturing apparatus comprising: a sensor for measuring a measurement that is an axial length of the first cake; a control unit connected to the sensor and configured to control a speed at which the traverse moves away from the second collet disposed at the winding position based on the measurement value input from the sensor; A glass fiber manufacturing apparatus comprising:

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