DE29812617U1 - Device for producing a fiber compact layer - Google Patents

Description

GRÜNECKER, KINKELtf EY.

VsCHIWANHOUSES

LAW FIRM

LAW FIRM MAXIMILIANSTRASSE 58 D-80538 MUNICH GERMANY

German Patent Office

Zweibrückenstr. 12
80297 Munich

Lawyers

Munich

dr. hermann schwanhäuser

dr. helmut eichmann

gerhard-barth

dr. ulrich 8lumenröder, llm.

christa niklas-falter

dr. michael schramm, dipl. phys.

dr. maximilian kinkeldey, llm.

Of Counsel

august grenecker
dr. gunter bezold
dr. walter langhoff

DR. WILFRIED STOCKMAIR (-1996)

Patent attorneys

European Patent Attorneys

MONKS

DR. HERMANN KINKELDEY

DR. KLAUS SCHUMANN

PETER H. JAKOB

WOLFHARD MEISTER

HANS HILGERS

DR. HENNING MEYER-PLATH

ANNELIE EHNOLD

THOMAS SCHUSTER

DR. KLARA GOLDBACH

MARTIN AUFENANGER

GOTTFRIED KUTZSCH

DR. HEIKE VOGELSANG-WENKE

REINHARD KNAUER

DIETMAR KUHL

DR. FRANZ-JOSEF ZIMMER

BETTINA K. REICHELT

DR. ANTON K. PFAU

DR. UDO WEIGELT

RAINER BERTRAM

JENS KOCH, M.S. (Uof PA) M.S. (ENSPM)

COLOGNE

DR. MARTIN DROPMANN

YOUR REF.

OUR REF.

DATE

G 3966 -829/il 15.07.1998

Applicant:

Lear Corporation GmbH & Co. Limited Partnership

Before the Schanz 1-5

65462 Ginsheim-Gustavsburg

Device for producing a fiber compact layer

MAXIMIUANSTRASSE 58

D-80538 MUNICH

TEL 089 / 21 23 50

FAX (GR 4) 089 / 21 86 92 93

FAX (GR 3) 089 / 22 02 87

http://www.grunecker.de

e-mail: postmaster@grunecker.de

DEUTSCHE BANK MUNICH

NO.17 51734

Bank code 700 700 10

SWIFT: DEUT DE MM KAISER-WILHELM-RING 13

D-50672 COLOGNE

TEL 0221 / 94 97 22 0

Fax 0221 / 94 97 22 2

Device for producing a fiber compact layer

The invention relates to a device for producing a fiber compact layer from a fiber mat that can be impregnated with a curing agent, which device has at least one curing agent supply device and a transport device that transports the fiber mat through it.

Such a device is known from practice and is used to produce a starting product, i.e. a fiber compact layer, from which a molded part is produced using appropriate shaping tools, for example for the interior lining of a motor vehicle. The fiber mat can be present as material wound on a roll, for example, and is pulled off the roll using the transport device and fed through the curing agent feed device. In this device, the fiber mat is soaked with curing agent in order to be able to produce molded parts with sufficient stability later. Excess curing agent can flow off the fiber mat or be stripped off of it. With the appropriate curing agent, the fiber compact layer produced in this way can be further processed immediately afterwards before the curing agent has completely hardened, or later and at another location using suitable shaping tools.

It should be noted that the fiber mats are made of a large number of fibers or threads that can be unevenly interwoven with one another, so that the density, i.e. the weave of the mat, is subject to fluctuations and at the same time, due to the different weave or density of the fiber material, different amounts of curing agent are absorbed locally by the mat. In the known device, such unevenness in the fiber mat and the impregnation with curing agent is only corrected or taken into account to an inadequate extent or not at all. Consequently, the fiber compact layer produced with the known device has similar unevennesses that make further processing of the fiber compact layer difficult or make it unsuitable for certain uses.

The invention is therefore based on the object of improving the known device in such a way that irregularities in the fiber mat are eliminated during its production in order to produce a uniformly good and multiply processable fiber compact layer. This object is achieved in connection with the features of the preamble of patent claim 1 in that a homogenizing and compacting device is arranged downstream of the curing agent feed device in the transport direction, which has at least one press roller that can be rotated about an axis of rotation transverse to the transport direction and a counterpressure element that forms a passage slot for the impregnated fiber mat with the press roller.

The homogenizing and compacting device, for example, evens out areas with a lower fiber density by compacting and homogenizing the fiber mat and at the same time determines the amount of curing agent that impregnates the fiber mat. In particular, fibers from the area surrounding the area with a lower fiber density are pushed toward this area so that uneven fiber densities are evened out. This fiber density equalization also ensures that the impregnation with curing agent is relatively even. The homogenizing and compacting device also serves to strip off excess curing agent, which can be returned to the curing agent feed device.

In this context, the pressing of the impregnated fiber mat is determined by the size of the passage slot through which the fiber mat is transported by the transport device. This is formed between the press roller and the counter-pressure element. The counter-pressure element can, for example, be a counter-pressure plate that supports the underside of the impregnated fiber mat, while the press roller is assigned to the opposite top side of the fiber mat. Of course, the arrangement of press roller and counter-pressure element can also be reversed. The speed of the press roller is preferably set so that its peripheral speed corresponds to the speed at which the impregnated fiber mat is transported through the passage slot by the transport device. However, it is also possible for this peripheral speed to be greater or lesser than the passage speed of the fiber mat for further compaction and homogenization, depending on requirements.

A corresponding transport device can be designed in a variety of ways. For example, the transport device can comprise a plurality of rollers that are arranged on both sides of the fiber mat or fiber compact layer, in particular in their edge areas. Furthermore, in a simple embodiment, the transport device can be formed by a take-up roller onto which the finished fiber compact layer is rolled and through whose movement the fiber mat can be pulled both by a corresponding feed roller and by the curing agent feed device and by the homogenizing and compacting device. Furthermore, the transport direction can have at least one first transport roller that can be rotated about an axis of rotation transverse to the transport direction and via which the molded mat can be fed to the curing agent feed device.

In order to ensure further transport after the curing agent supply device in a simple manner, the homogenizing and compacting device can be part of the transport device in order to move the impregnated fiber mat from the curing agent supply device and the produced fiber compact layer for further processing.

The curing agent can be supplied to the fiber mat in sufficient quantities, for example by a doctor blade, an application roller or the like. A simple and quick supply of the curing agent is achieved by a curing agent supply device which is formed by an immersion container containing the curing agent, through which the fiber mat can be guided by means of the transport device.

The dipping container can be designed as a largely closed container, which for example has an entry slot for the fiber mat and an exit slot for the impregnated fiber mat. In a simple embodiment, the dipping container can have an immersion opening at its upper end through which both the fiber mat and the impregnated fiber mat can be inserted and removed. In this context, it is considered advantageous if the transport device has at least first and second transport rollers arranged at a distance above the immersion opening and transport direction and a tension roller arranged between them and immersed in the curing agent. By means of the first transport roller

The fiber mat is fed to the tension roller and from there to the second transport roller. These three rollers can be arranged in the corners of a triangle, for example. The homogenizing and compacting device can be arranged downstream of the second transport roller in the transport direction.

In order to simplify the structure of the device, the second transport roller can be designed as a counter-pressure element for the press roller. The second transport roller and the press roller can rotate at the same speed or, depending on requirements, at least slightly different speeds.

In order to be able to easily vary the pressure of the impregnated fiber mat and thus its homogenization and compaction, the press roller and/or second transport roller can be mounted so that the passage slot can be adjusted. Such an adjustment can be made, for example, by bringing the two rollers closer together or by bringing just one roller closer to the other.

Depending on how the impregnated fiber mat or the produced fiber compact layer is guided before or after the homogenizing and compacting device, the press roller and the second transport roller can be arranged directly vertically one above the other or offset from one another. In order to transport the produced fiber compact layer essentially horizontally after the homogenizing and compacting device, the axes of rotation of the press roller and the second transport roller can be arranged vertically one above the other and parallel to one another.

In order to be able to determine certain properties of the fiber compact layer subsequent to the homogenizing and compacting device, a determining device can be arranged downstream of the homogenizing and compacting device at least for determining a degree of impregnation and/or a layer thickness of the fiber compact layer in the transport direction.

In order to be able to adjust the characteristics of the fibre compact layer determined by the determination device in comparison to specified target values, the passage slot of the homogenising and compacting device can be adjusted depending on

Signals from the detection device can be set. This makes it possible, for example, to produce a fiber compact layer with a desired layer thickness, with a desired degree of impregnation of the curing agent, a desired degree of compaction or the like.

In order to be able to determine the characteristics of the fiber compact layer in this context, the detection device can determine these characteristics acoustically, optically, electrically and/or magnetically. For this purpose, the detection device has corresponding signal generators and associated sensors. The change in the signal after passing through the fiber compact layer and/or the size of the signal allow conclusions to be drawn about certain characteristics or properties of the fiber compact layer, such as the above-mentioned characteristics of degree of impregnation and layer thickness. Such detection devices are known per se, so that further explanations are omitted.

For ecological reasons, it is advantageous if the fiber mat is made of natural fibers or threads, particularly those arranged in a random pattern. Fibers or threads with good properties for the production of fiber mats, which can also be produced in sufficient quantities and easily, are natural fibers or threads made of sisal and/or flax. Of course, it is also possible to mix natural fibers with artificially produced fibers or threads or, if necessary, to make a fiber mat only from artificially produced fibers or threads.

In order to be able to further process the fiber compact layer directly after the device according to the invention or at a later point in time and at a different location, the curing material can be a plastically deformable material. Olefin compounds or resins, acrylic compounds and/or resins and combinations of these materials are particularly suitable for this purpose.

In the following, an advantageous embodiment of the invention is explained in more detail with reference to the figures attached to the drawing.

Show it:

I t #

Fig. 1 is a side cross-sectional view of an embodiment of a device according to the invention, and

Fig. 2 a top view of a fiber mat.

Fig. 1 shows a simplified side cross-sectional view of a device 1 according to the invention for producing a fiber compact layer 2 from a fiber mat 4 impregnated with a curing agent 3. The fiber mat 4 can be pulled off a feed roller (not shown) and passed by means of a transport device 6 through a curing agent feed device 5 for impregnation with the curing agent 3. The transport device 6 has a first transport roller 13, a tension roller 18 and a second transport roller 17. The fiber mat 4 or the fiber compact layer 2 is guided horizontally in a transport direction 7 before and after the first and second transport rollers 21, 17.

The rollers 13, 17, 18 are each rotatable about axes of rotation arranged transversely to the fiber mat 4 or fiber compact layer 2, see the axes of rotation 21 and 19 of the first transport roller 13 and the second transport roller 17. The tension roller 18 is arranged in an immersion tank 14 forming the curing agent supply device 5. The tension roller 18 is immersed in the curing agent 3. First and second transport rollers 13, 17 are arranged above an immersion opening 16 at the upper end 15 of the immersion tank 4 at a distance from one another, with the tension roller 18 being arranged between the two transport rollers.

The second transport roller 17 simultaneously forms a counter-pressure element 12 to a press roller 10, whereby both rollers 10, 17 form a homogenizing and compacting device 8 through which the impregnated fiber mat 4 is passed to produce the fiber compact layer 2. An adjustable passage slot 11 is formed between the two rollers, in which the fiber mat 4 with a layer thickness 27 can be homogenized and compacted to produce the fiber compact layer 2 with a smaller layer thickness 28.

The homogenizing and compacting device 8 is another part of the transport device 6, whereby the two rollers 10, 17 rotate about axes 9, 19 and thereby

through the impregnated fiber mat 4 in the transport direction 7. The rotation axes 9, 19 are arranged vertically one above the other and parallel to each other.

In the transport direction 7, a detection device 20 is arranged downstream of the homogenizing and compacting device. This can acoustically, optically, electronically and/or magnetically determine properties of the fiber compact layer 2, such as degree of impregnation, layer thickness, etc., and transmit signals corresponding to these characteristics to a control device 26. In the control device 26, in particular, a comparison of the determined characteristics with predetermined characteristics is carried out and, in the case of a corresponding deviation, in the embodiment according to Fig. 1, the second transport roller 17 can be adjusted as a counterpressure element 12 in the direction of the press roller 10 to adjust the passage slot 11. This adjustment compensates for the deviations from the determined characteristics and predetermined characteristics.

The produced fiber compact layer 2 can be wound onto a take-up roll (not shown).

Fig. 2 shows a plan view of the fiber mat 4. In simplified form, a large number of fibers or threads 22, 23 made of sisal and flax in particular are shown in a random layer. The density of the fibers in the fiber mat 4 is uneven, with areas 24 having a density higher than an average density and areas 25 having a density lower than an average density. By means of the homogenizing and compacting device 8, see Fig. 1, an equalization between such areas 24 and 25 takes place, with the compaction in the passage slot 11 pressing fibers or threads from the areas 24 directly into the areas 25 or an indirect equalization between the areas 24 and 25 taking place via areas of the fiber mat 4 with a density essentially equal to an average density.

The homogenizing and compacting device 8 also serves to uniformly impregnate the fiber mat 4 with the curing agent 3 and to remove excess curing agent 3 from the impregnated fiber mat 4. The removed curing agent can be returned to the dipping tank 14.

Claims (16)

1. Device ( 1 ) for producing a fiber compact layer ( 2 ) from a fiber mat ( 4 ) that can be impregnated with a curing agent ( 3 ), which device ( 1 ) has at least one curing agent feed device ( 5 ) and a transport device ( 6) that transports the fiber mat (4 ) through it, characterized in that a homogenizing and compacting device ( 8 ) is arranged downstream of the curing agent feed device ( 5 ) in the transport direction ( 7 ), which has at least one rotatable press roller ( 10 ) and a counterpressure element ( 12 ) that forms a passage slot ( 11 ) for the impregnated fiber mat ( 4 ) with the press roller. 2. Device according to claim 1, characterized in that the press roller is rotatable about an axis of rotation ( 9 ) transverse to the transport direction ( 7 ). 3. Device according to claim 1 or 2, characterized in that the transport device ( 6 ) has at least one first transport roller ( 13 ) which can be rotated about an axis of rotation ( 21 ) transversely to the transport device ( 7 ), via which the fiber mat ( 4 ) can be fed to the curing agent feed device ( 5 ). 4. Device according to at least one of the preceding claims, characterized in that the homogenizing and compacting device ( 8 ) is part of the transport device. 5. Device according to at least one of the preceding claims, characterized in that the curing agent supply device ( 5 ) is an immersion container ( 14 ) containing the curing agent ( 3 ) through which the fiber mat ( 4 ) can be passed. 6. Device according to at least one of the preceding claims, characterized in that the dipping container ( 14 ) has an immersion opening ( 16 ) at its upper end ( 15 ) and the transport device ( 7 ) has at least the first and a second transport rollers ( 13 , 17 ) arranged at a distance above the immersion opening in the transport direction and a tension roller ( 18 ) arranged between them and immersed in the curing agent ( 3 ). 7. Device according to at least one of the preceding claims, characterized in that the second transport roller ( 17 ) is designed as a counter-pressure element ( 12 ) for the press roller ( 10 ). 8. Device according to at least one of the preceding claims, characterized in that the press roller ( 10 ) and/or the second transport roller ( 17 ) are adjustably mounted for adjusting the passage slot ( 11 ). 9. Device according to at least one of the preceding claims, characterized in that axes of rotation ( 9 , 19 ) of the press roller ( 10 ) and the second transport roller ( 17 ) are arranged vertically one above the other and parallel to one another. 10. Device according to at least one of the preceding claims, characterized in that a determination device ( 20 ) is arranged downstream of the homogenizing and compacting device at least for determining a degree of impregnation and/or a layer thickness of the fiber compact layer in the transport direction. 11. Device according to at least one of the preceding claims, characterized in that the passage slot ( 11 ) is adjustable in dependence on signals from the detection device ( 20 ). 12. Device according to at least one of the preceding claims, characterized in that the detection device ( 20 ) determines the degree of impregnation and/or layer thickness acoustically, optically, electrically and/or magnetically. 13. Device according to at least one of the preceding claims, characterized in that the fiber mat ( 4 ) is formed from natural fibers or threads arranged in particular in a random layer. 14. Device according to at least one of the preceding claims, characterized in that the natural fibers or threads are made of sisal and/or flax ( 22 , 23 ). 15. Device according to at least one of the preceding claims, characterized in that the curing agent ( 3 ) is a plastically and in particular thermoplastically deformable material. 16. Device according to at least one of the preceding claims, characterized in that the curing material is an olefin or acrylic compound, an olefin or acrylic resin or a combination of these materials.