U.S. patent application number 12/987777 was filed with the patent office on 2011-09-22 for apparatus and method for manufacturing resin-impregnated cured sheet, and apparatus and method for manufacturing carbonaceous material sheet.
This patent application is currently assigned to Mitsubishi Rayon Co., Ltd.. Invention is credited to Mitsuo Hamada, Kazushige Mihara, Makoto Nakamura, Toshihiko Nishida, Hidehiko Ohashi.
Application Number | 20110226431 12/987777 |
Document ID | / |
Family ID | 18710013 |
Filed Date | 2011-09-22 |
United States Patent
Application |
20110226431 |
Kind Code |
A1 |
Nishida; Toshihiko ; et
al. |
September 22, 2011 |
Apparatus and Method for Manufacturing Resin-Impregnated Cured
Sheet, and Apparatus and Method for Manufacturing Carbonaceous
Material Sheet
Abstract
An apparatus for manufacturing a resin-impregnated cured sheet
includes conveyance means for conveying a long uncured fiber sheet
which is obtained by using short fibers to make paper and which
contains uncured resin, wherein the conveyance means is equipped
with at least one rotation belt set comprising a drive roll, a
follower roll, and an endless belt which is put on and around the
drive roll and follower roll; resin curing means for curing the
uncured resin of the uncured fiber sheet; a winding device in which
a trimming cutter for trimming both side edges of the
resin-impregnated cured sheet; a press roll for retaining a winding
face pressure; and a winding shaft are arranged in order along a
running path of the resin-impregnated cured sheet.
Inventors: |
Nishida; Toshihiko;
(Hiroshima, JP) ; Ohashi; Hidehiko; (Hiroshima,
JP) ; Nakamura; Makoto; (Hiroshima, JP) ;
Hamada; Mitsuo; (Hiroshima, JP) ; Mihara;
Kazushige; (Hiroshima, JP) |
Assignee: |
Mitsubishi Rayon Co., Ltd.
Tokyo
JP
|
Family ID: |
18710013 |
Appl. No.: |
12/987777 |
Filed: |
January 10, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11701405 |
Feb 2, 2007 |
7959750 |
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12987777 |
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10872519 |
Jun 22, 2004 |
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11701405 |
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09903680 |
Jul 13, 2001 |
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10872519 |
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Current U.S.
Class: |
162/157.1 ;
162/164.1; 162/283 |
Current CPC
Class: |
B29K 2105/06 20130101;
B29C 70/502 20130101; B29C 70/44 20130101; Y10T 156/108 20150115;
B29C 43/48 20130101; B29C 43/52 20130101; B30B 5/062 20130101; B29K
2105/0854 20130101; B29C 35/06 20130101; B29C 70/504 20130101; Y10T
156/1712 20150115; B29C 2043/483 20130101; B29C 70/508
20130101 |
Class at
Publication: |
162/157.1 ;
162/283; 162/164.1 |
International
Class: |
D21H 13/50 20060101
D21H013/50; D21G 9/00 20060101 D21G009/00; D21H 17/33 20060101
D21H017/33 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 14, 2000 |
JP |
2000-214441 |
Claims
1-16. (canceled)
17. An apparatus for manufacturing a resin-impregnated cured sheet
comprising conveyance means for conveying a long uncured fiber
sheet which is obtained by using short fibers to make paper and
which contains uncured resin, wherein the conveyance means is
equipped with at least one rotation belt set comprising a drive
roll, a follower roll, and an endless belt which is put on and
around the drive roll and follower roll; resin curing means for
curing the uncured resin of the uncured fiber sheet; a winding
device in which a trimming cutter for trimming both side edges of
the resin-impregnated cured sheet; a press roll for retaining a
winding face pressure; and a winding shaft are arranged in order
along a running path of the resin-impregnated cured sheet.
18. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 17, wherein the conveyance means is equipped
with a least two upper and lower rotation belt sets which are
arranged in a paired manner so as to sandwich a conveyance path of
the uncured fiber sheet.
19. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 17, wherein the resin curing means includes a
pair of heating and pressuring rolls which are arranged so as to
nip the uncured fiber sheet through the endless belt.
20. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 18, wherein the resin curing means includes a
pair of heating and pressuring rolls which are arranged so as to
nip the uncured fiber sheet through the endless belt.
21. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 17, wherein the resin curing means is provided
with a heating liquid pressure device which is arranged so as to
nip the uncured fiber sheet through the endless belt.
22. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 17, wherein the resin curing means is equipped
with at least a preheating section and a heating and pressuring
section.
23. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 18, wherein the resin curing means is equipped
with at least a preheating section and a heating and pressuring
section.
24. An apparatus for manufacturing a resin-impregnated cured sheet,
according to claim 17, wherein the resin curing means is provided
with a heating liquid pressure device which is arranged so as to
nip the uncured fiber sheet through the endless belt.
25. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 27, wherein said apparatus further comprises a
winding device in which a trimming cutter for trimming with side
edges of the resin-impregnated cured sheet, a press roll for
retaining a winding face pressure, and a winding shaft are arranged
in order along a running path of the resin-impregnated cured
sheet.
26. An apparatus for manufacturing a resin-impregnated cured sheet
according to claim 17, wherein the resin curing means includes
pairs of the heating and pressuring rolls which are arranged so as
to nip the uncured fiber sheet through the endless belt.
27. A method for manufacturing a resin-impregnated cured sheet
using an apparatus adapted for the manufacture of a
resin-impregnated cured sheet that comprises: conveyance means for
conveying a long uncured fiber sheet which is obtained by using
short fibers to make paper and which contains uncured resin, the
conveyance means including upper and lower rotation belt sets each
comprising a drive roll, a follower roll, and an endless belt which
is put on and around the drive roll and follower roll; resin curing
means for curing the uncured resin of the uncured fiber sheet
including a continuous heating and pressurization device having an
inner space thereof, wherein said resin curing means includes a
pair of heating and pressuring rolls arranged for nipping said
uncured fiber sheet through said endless belts, whereby said method
includes nipping said uncured fiber sheet through said endless
belts using the pair of heating and pressuring rolls; a winding
device including a trimming cutter for trimming both side edges of
the resin-impregnated cured sheet; a press roll for retaining a
winding face pressure; and a winding shaft are arranged in order
along a running path of the resin-impregnated cured sheet, said
method including steps of: positioning a portion of the upper
endless belt above the uncured fiber sheet and positioning a
portion of the lower endless belt below the uncured fiber sheet
such that the sheet is disposed between the portions of the upper
and lower endless belts; advancing the portions of the endless
belts and the uncured fiber sheet disposed therebetween into the
inner space of the continuous heating and pressurization device;
introducing a fluid into the inner space of the continuous heating
and pressurization device above the upper endless belt and below
the lower endless belt, the fluid being at a temperature of about
350 degrees Celsius or less and a pressure between about
1.5.times.10.sup.4 N/m.sup.2 and about 1.0.times.10.sup.5
N/m.sup.2; contacting the fluid against the endless belts to heat
and compress the uncured fiber sheet through the endless belts to
produce a cured fiber sheet by curing the uncured resin of the
fiber sheet; and winding up the cured fiber sheet about the winding
shaft using the winding device and the press roll.
28. A method for manufacturing a resin-impregnated cured sheet
according to claim 27, wherein the uncured fiber sheet contains a
carbon short fiber and an organic polymer-based binder.
29. A method for manufacturing a resin-impregnated cured sheet
using an apparatus adapted for the manufacture of a
resin-impregnated cured sheet that comprises: conveyance means for
conveying a long uncured fiber sheet which is obtained by using
short fibers to make paper and which contains uncured resin, the
conveyance means including upper and lower rotation belt sets each
comprising a drive roll, a follower roll, and an endless belt which
is put on and around the drive roll and follower roll; resin curing
means for curing the uncured resin of the uncured fiber sheet
including a continuous heating and pressurization device having an
inner space thereof; a winding device including a trimming cutter
for trimming both side edges of the resin-impregnated cured sheet;
a press roll for retaining a winding face pressure; and a winding
shaft are arranged in order along a running path of the
resin-impregnated cured sheet, said method including steps of:
positioning a portion of the upper endless belt above the uncured
fiber sheet and positioning a portion of the lower endless belt
below the uncured fiber sheet such that the sheet is disposed
between the portions of the upper and lower endless belts;
advancing the portions of the endless belts and the uncured fiber
sheet disposed therebetween into the inner space of the continuous
heating and pressurization device; introducing a fluid into the
inner space of the continuous heating and pressurization device
above the upper endless belt and below the lower endless belt, the
fluid being at a temperature of about 350 degrees Celsius or less
and a pressure between about 1.5.times.10.sup.4 N/m.sup.2 and about
1.0.times.10.sup.5 N/m.sup.2; contacting the fluid against the
endless belts to heat and compress the uncured fiber sheet through
the endless belts to produce a cured fiber sheet by curing the
uncured resin of the fiber sheet; and winding up the cured fiber
sheet about the winding shaft using the winding device and the
press roll.
Description
CROSS-REFERENCED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 11/701,405, filed Feb. 2, 2007, which is a
divisional application of U.S. patent application Ser. No.
10/872,519, filed Jun. 22, 2004, which is a divisional application
of U.S. patent application Ser. No. 09/903,680, filed Jul. 13,
2001, claims the foreign priority benefit from Japanese Application
2000-214441 filed Jul. 14, 2000, and the complete disclosures of
each of the aforesaid prior applications is incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present invention relates to an apparatus and a method
for manufacturing, for example, a substrate of a flexible printed
circuit board and an electrode substrate of a fuel cell.
Specifically, the present invention relates to an apparatus and a
method that makes it possible to continuously produce a long
resin-impregnated cured sheet or a long carbonaceous material
sheet.
PRIOR ART
[0003] A substrate of a printed circuit board, which comprises
fiber reinforced plastics, is produced by using an organic fiber
reinforced pre-preg that is obtained by impregnating matrix resin
into a sheet made of para-aramid fiber and meta-aramid pulp or
fusion-liquid-crystal aromatic polyester fiber and pulp thereof,
for example, as described in Japanese Patent Application Laid-Open
No. 2000-77803 as a conventional technology. Alternatively, there
is a method of obtaining a flexible substrate by impregnating epoxy
resin into a dry sheet, which is obtained by integrating a mixed
web comprising aramid fiber and thermoplastic fiber such as
polyester or the like by means of a hot calendar. As to the
substrate of a printed circuit board, which is produced by these
conventional processes, a long printed circuit board is cut at a
desired dimension at a final stage of the production process and
then laminated to be stored, as disclosed in Japanese Patent
Application Laid-Open No. 5-24165. In addition, the term "flexible"
as mentioned above means that flexibility is locally imparted to a
substrate.
[0004] Further, as a porous electrode for a phosphoric acid type
fuel cell, the conventional mainstream has been a porous carbon
electrode, which is produced by impregnating thermosetting resin
into a short carbon fiber sheet made of carbon fiber, and after
curing the resin, sintering it to be carbonized.
[0005] Since the conventional substrate of a porous carbon
electrode has a large thickness and fragility, many of such
substrates are easy to be destructed when being bent. Further,
since the conventional electrodes are bonded at intersection
portions of carbon fibers at most, there are little numbers of
bonded points. Therefore, electroconductivity in a thickness
direction is not always high as compared with that in a direction
of the fiber axis. Furthermore, in order that the efficiency of
chemical-electrical energy conversion is raised by smoothing the
flow of gas and water in a fuel cell, when the porocity of the
substrate of the porous carbon electrode is raised, there raises a
problem that the electroconductivity itself is lowered.
[0006] Then, for example, a porous carbon electrode, which is
disclosed in Japanese Patent Application Laid-Open No. 1-160867,
uses a combination of a self-curing type resol-based phenol resin,
which is thermosettable, and a non self-curing type novolak-base
phenol resin, as a resin that can be carbonized. By thus adopting
two kinds of resins, only the resol-based phenol resin is cured at
the resin curing, and thereafter, the novolak-base phenol resin,
which has not been cured, flows between the fibers and enters the
gaps of the fibers, at the carbonization. Then, the resin is
carbonized, so that the conductivity of an electroconductive
substrate is enhanced.
[0007] Further, for example, as to the substrate of a porous carbon
electrode disclosed in Japanese Patent Application Laid-Open No.
7-142068, a carbonaceous milled fiber, which has a fiber length of
0.1 mm or less, exists in a thickness direction of the electrode
substrate at a matrix portion of the porous-structural electrode
substrate comprising a -carbon. Therefore, the fibers, which are
arranged in the thickness direction, are mutually bonded even at
portions other than the intersection portions. Accordingly, the
electrode substrate having such structure improves the whole
electroconductivity, in particular, the electroconductivity in the
thickness direction of the electrode substrate.
[0008] On the other hand, Japanese Patent Application Laid-Open No.
8-2979 discloses a porous carbon material with grooves for a
phosphoric acid type fuel cell. The carbon material can be obtained
by using a sheet containing a fiber capable of being made into
carbon fiber and/or a carbon fiber and a thermosetting resin which
can be carbonized or graphitized to make paper, heating, pressuring
and molding the sheet, then arranging it in a mold in which an
uneven portion is formed with a clearance, after the arrangement,
heating the sheet again to be expanded and perfectly cured, and
then baking it. According to the production method of the electrode
substrate, groove-shaped gas flow paths are formed with a high
precision. Furthermore, it is possible to obtain a substrate, which
has a light weight, with highly mechanical strength and excellent
in uniformity, thermal conductivity and gas permeability.
[0009] There is a solid polymer type fuel cell to be in place of
these phosphoric acid type fuel cells. Since the current density of
the porous electrode for the solid polymer type fuel cell is 4 to
20 times higher than that of the electrode for the phosphoric acid
type fuel cell, the feed amount of hydrogen and oxygen, and the
removal amount of water that has been formed by reaction are
increased. On the other hand, since the operational temperature of
the solid polymer type fuel is low, which is 100.degree. C. or so,
the water that has been formed is not evaporated but flows. As a
result, the feed path of the gas is choked by the water, therefore
the feed path of the gas is apt to be narrow.
[0010] Accordingly, in comparison with the porous electrode for the
phosphoric acid type fuel cell, the diffusion property and
permeability of gas, the strength and flexibility for enduring a
handling, and further, the strength for enduring the compression at
the production of the electrode or at the assembling of the
electrode, and the like are required for the porous electrode for
the solid polymer type fuel cell.
[0011] Japanese Patent Application Laid-Open No. 9-157052 discloses
a porous carbon plate for the solid polymer type fuel cell. Since
the porous carbon plate disclosed in this Publication is applied to
the solid polymer type fuel cell, the gas permeability in the
thickness direction is enhanced in particular. According to this
Publication, in order to enhance the gas permeability in the
thickness direction, there is obtained a sheet made of carbon short
fibers, in which the carbon short fibers are dispersed in a random
direction in a substantially two dimensional plane, the sheet being
impregnated with a desired amount of mixed resin in which the mix
ratio of a resol-based phenol resin to a novolak-base phenol resin
is 2:1 to 1:3, and heated to be carbonized.
[0012] Further, since the current density of the porous electrode
for the solid polymer type fuel cell is higher than that of the
porous electrode for the phosphoric acid type fuel cell, a
requirement for making the solid polymer type fuel cell into a
small size has been stronger. In order to realize it, it is
required to make the porous electrode thinner. The thickness of the
electrode of the solid polymer type fuel cell is 0.2 mm for an
automobile at present time, and about 0.3 mm for a stationary cell.
A porous carbon plate, which has a thickness of about 0.2 mm, is
disclosed in the above-mentioned Japanese Patent Application
Laid-Open No. 9-157052, but it is anticipated to make the plate
further thinner in the future.
[0013] However, as described above, the substrate is cut into a
short plate having a predetermined dimension at the final stage of
the production process of the printed circuit board, and then, it
is processed to a desired dimension in accordance with application
in various instruments to be used. Further, even the porous
electrode substrate has a short sheet form as described above, and
the substrate is generally cut into a predetermined electrode
dimension of about 15 cm.times.15 cm for use.
[0014] Thus, when the printed circuit board and the porous
electrode substrate are produced in short sheet forms, the
treatment and delivery thereof are inconvenient. Further, it cannot
but being cut again into an actual size at a site of fuel cell
assembly, therefore there occurs a uselessness of the material at
the cutting. To avoid such inconvenience, it is preferable to wind
up the printed circuit board and the electrode substrate in a roll
form as a long product, in order to improve the productivity of
various electronic devices using the printed circuit board or a
cell using the electrode substrate.
[0015] However, since a usual printed circuit board has a high
rigidity, it has been conventionally treated on the condition that
it is cut into a short plate at the final step of the production
process. Therefore, there has been no attempt to wind up the
printed circuit board in a roll form as a long product. For the
porous electrode substrate, the situation is the same, so that
there has been no attempt to wind up it in a roll form because of
lack of flexibility.
[0016] In particular, in case of the electrode substrate, it is not
considered at all in any of the above-mentioned publications that a
long electrode substrate is continuously produced. However, when a
long continuous carbon electrode substrate is produced in
accordance with the manufacturing method of a conventional porous
carbon electrode substrate as disclosed in these patent
publications, it is possible to produce a long carbon fiber sheet
made of carbon short fibers and continuously imparting
thermosetting resin to the long carbon fiber sheet However,
according to a general manufacturing of a porous carbon electrode
substrate, the carbon fiber sheet, to which the resin is applied,
is cut into a predetermined short sheet and then, is pressed with
heat to be cured by means of a hot press apparatus.
[0017] In order that the curing treatment is continuously carried
out to the long carbon fiber sheet, to which the thermosetting
resin is applied, using a batch-type hot press apparatus, it is
considered to take a so-called semi-batch-type treatment, in which
dancer rolls or the like are arranged respectively at the upstream
side and the downstream side of the batch-type curing apparatus,
the conveyance of the sheet is intermittently stopped at every
length thereof necessary for curing treatment, and the carbon fiber
sheet is intermittently cured. However, since the carbon fiber
sheet becomes extremely fragile after being pressed, the sheet is
apt to be broken at an edge of the hot press apparatus, namely, a
boundary portion between the face to be pressed and the adjacent
face that has been already pressed. Therefore, it is difficult to
obtain a high quality product.
[0018] The present invention is to overcome the above-mentioned
problems. One object of the invention is to provide a n apparatus
and a method for continuously manufacturing a flexible and windable
resin-impregnated cured sheet that is obtained by impregnating
resin into a long fiber sheet with and curing the sheet. Another
object of the invention is to provide an apparatus and a method for
continuously manufacturing a flexible and windable carbonaceous
material sheet that is obtained by impregnating carbonizable resin
into a long fiber sheet and carbonizing the sheet.
DISCLOSURE OF THE INVENTION
[0019] According to the present invention, there is mainly provided
an apparatus for manufacturing a resin-impregnated cured sheet,
characterized by comprising conveyance means for conveying a long
uncured fiber sheet, which is obtained by using short fibers to
make paper and which contains uncured resin; and resin curing means
for curing uncured resin of the uncured fiber sheet to be formed
into a resin-impregnated cured sheet, wherein the conveyance means
is equipped with at least one rotation belt set comprising a
driving roll, a follower roll, and an endless belt to be put on and
around the drive roll and the follower roll.
[0020] Since the apparatus for manufacturing the resin-impregnated
cured sheet can perform a curing treatment while continuously
conveying the long uncured fiber sheet, the curing can be carried
out uniformly over the uncured fiber sheet in a length direction
thereof. Accordingly, it is possible to produce a resin-impregnated
cured sheet that has uniform quality in the length direction with a
high productivity, without generating any local fragile portions or
broken portions.
[0021] The resin-impregnated cured sheet, which is manufactured
according to the above-mentioned apparatus, can be supplied to
users in a rolled form as, for example, a printed circuit board, so
that it is easy to be treated and is convenient for transport.
Further, even when it is used after being cut into pieces of
dimensions in accordance with various electric instruments, wasted
material is little so that the production efficiency can be also
improved.
[0022] Further, according to the present invention, it is
preferable, in addition to the above-mentioned feature, that the
apparatus further comprises a winding device in which a trimming
cutter for trimming both side edges of the resin-impregnated cured
sheet, a press roll for retaining a winding face pressure, and
winding shafts are arranged along a conveyance path of the
resin-impregnated cured sheet.
[0023] Before being winded after cured, the fiber sheet is reeled
on the winding shaft after the both side edges thereof are trimmed
by a trimming cutter. At the time of winding, since a peripheral
face of the wounded body is pressed by a press roll with a
preliminarily set pressuring force, the sheet can be continuously
reeled in good order with a fixed winding density, in cooperation
with the trimming.
[0024] Further, according to the present invention, it is
preferable that the conveyance means is equipped with at least two
rotation belt sets, which are arranged in a paired manner so as to
oppose to each other via the conveyance path of the uncured fiber
sheet.
[0025] Since the two rotation belt sets are arranged on and under
the uncured fiber sheet, the sheet can be sandwiched at a required
length by the endless belts. Therefore, a thickness of the
resin-impregnated cured sheet can be more precisely controlled and
the uniformity of the thickness thereof in the length direction can
be also enhanced.
[0026] When the uncured resin is thermosetting resin, heating means
is adopted as the resin curing means. In this case, the heating
system may be conductive heating such as heating rolls, or
convection heating, in which a heating area is provided, or radiant
heating such as far infrared radiation or the like. However, from a
viewpoint of reduction of heating loss, the conductive heating such
as heating rolls or the like is rather preferable.
[0027] In addition, it is preferable to arrange a plurality of
pairs of heating and pressuring rolls in the conveyance direction
of the uncured fiber sheet. In that case, a pitch between each pair
of the heating and pressuring rolls in the conveyance direction and
a diameter of the heating and pressuring roll can be determined in
consideration of a temperature change of the endless belt before
and after the heating and pressuring rolls, a pressure fluctuation
that is applied to the uncured fiber sheet itself, and the
like.
[0028] Further, a heating temperature (temperature at the curing)
and a pressure of the heating and pressing rolls can be suitably
set. However, when a uncured fiber sheet which is an intermediate
product of a carbonaceous material sheet is produced, it is
preferable that the temperature at the curing is 350.degree. C.; or
less, and the pressure is within a range of 1.5.times.10.sup.4 N/m
to 1.0.times.10.sup.5 N/m at linear lead.
[0029] Further, as the resin curing means of the present invention,
there may be provided a continuously heating liquid-pressure
apparatus that nips the uncured fiber sheet and the endless belts
by a fluid pressure, in place of the heating and pressuring
rolls.
[0030] The pressuring fluid, which is applied to the present
continuously heating liquid-pressure apparatus, is not limited to a
specific one as far as it satisfies a heat resistance that does not
cause any deterioration, alteration and the like at a desired
temperature. Therefore, it may be appropriately determined in
accordance with the desired temperature. In general, a
silicon-based oil, which is excellent in heat resistance, is
preferably used.
[0031] Gas can be used as the pressuring fluid, but a liquid is
usually advantageous because of its high thermal conduction
efficiency.
[0032] Since the continuously heating liquid-pressure apparatus
according to the present invention is different from the
above-mentioned heating and pressuring rolls in that it can
continuously impart face pressure while the sheet passes the
continuously heating liquid-pressure apparatus. Therefore, it is
preferably used when a long treatment time is required. Further, in
accordance with the requirement, a plurality of apparatuses may be
arranged in a face direction of the fiber sheet to be treated.
[0033] Furthermore, the heating and pressuring rolls may be
provided in combination with it.
[0034] According to a preferable embodiment of the continuously
heating liquid pressure apparatus, in order that the fiber sheet to
be treated is continuously and simultaneously heated and
pressurized through the endless belt, the pressuring fluid with
high temperature is introduced. The pressuring fluid with high
temperature is recycled, but occasionally is utilized by being
enclosed in the apparatus.
[0035] There is a preferable example of the continuously heating
liquid pressure apparatus, which is a "continuously pressuring
apparatus" that is manufactured and sold by Mitsubishi Rayon
Engineering Co., Ltd. The detail is disclosed in, for example,
Japanese Patent Publications No. 3-51205, No. 2-62371, and No.
2-62370.
[0036] Further, it is preferable that the resin curing means is
equipped with at least a preheating section and a heating and
pressuring section.
[0037] When the thermosetting resin is preliminarily softened at
the preheating section, the thickness of the resin-impregnated
cured sheet can be controlled well at the heating and pressuring
section which follows the preheating section. At this time, it is
preferable that the temperature at the preheating section is not
less than the temperature at which the viscosity of the
thermosetting resin becomes lowest. Further, it is preferable that
the temperature at the heating and pressuring section is higher
than the temperature at the preheating section by 50.degree. C. or
more. Thus, the thermosetting resin can be sufficiently cured.
[0038] Further, the present invention includes a method for
manufacturing a resin-impregnated cured sheet by means of the
above-mentioned apparatus for manufacturing the resin-impregnated
cured sheet, wherein the uncured resin of the long uncured fiber
sheet is cured, the long cured fiber sheet is continuously produced
and then wound up.
[0039] According to the method of the invention, the fiber-made
sheet, which is obtained by using short fibers to make paper, may
preferably contains a carbon short fiber and an organic
polymer-based binder.
[0040] The short fibers of the fiber sheet, which is obtained by
using short fibers to make paper, may be various synthetic fibers
such as polyacrylonitrile-based fibers, polyester-based fibers,
polyvinyl alcohol-based fibers or the like, or carbon fibers. In
addition to these fibers, glass fibers, aramid fibers or
ceramic-based fibers may be used for reinforcement.
[0041] The uncured fiber sheet is obtained by using these short
fibers added with organic polymer-based binders to make paper, and
then impregnating the obtained fiber sheet with the uncured resin
and drying it. As the uncured resin, it is preferable to use the
one that has agglomerating property or flowability at normal
temperature.
[0042] The carbonaceous material sheet is obtained by carbonizing
the resin-impregnated cured sheet. As the carbonization treatment
apparatus, a burning furnace for carbon fibers can be used. There
are a horizontal type burning furnace for transferring an object to
be treated in a horizontal direction and a vertical type burning
furnace for transferring an object to be treated in a vertical
direction. When the resin-impregnated cured sheet is carbonized, it
is possible to use a vertical type burning furnace. A vertical type
burning furnace has such an advantageous point that guide rolls do
not need to be provided. However, it is preferable to adopt a
horizontal type burning furnace in consideration of a sealing
property of atmosphere gas, a handling property at abnormality or
the like.
[0043] Accordingly, the present invention provides an apparatus for
manufacturing a carbonaceous material sheet by carbonizing a cured
sheet impregnated with resin, which is produced by curing a long
uncured fiber sheet which is obtained by using short fibers to make
paper and which contains uncured resin. The apparatus for
manufacturing the carbonaceous material sheet is mainly
characterized by comprising a carbonization treatment chamber for
continuously transferring the resin-impregnated cured sheet in a
horizontal direction and carbonizing it, and guide rolls which are
arranged in the same carbonization treatment chamber.
[0044] As the guide roll, it is preferable to employ a round bar or
a round pipe made of graphite. Even if it is such a simple
structure that both ends of each roll are supported by a roll
supporting stand made of graphite, the roll can easily rotate
because of the self-lubricating property of the graphite itself. In
addition, when a plurality of guide rolls are disposed, the roll
pitch can be suitably determined in accordance with the weight of a
curing paper impregnated with resin and the tensile force at the
carbonization treatment.
[0045] When the guide rolls are not provided in the carbonization
treatment chamber, the resin-impregnated cured sheet contacts with
a bottom face of the carbonization treatment chamber due to its
self weight, which causes a crack or a fragment. As a result, the
quality of the carbonaceous material sheet which is obtained by the
carbonization treatment is lowered.
[0046] The obtained long carbonaceous material sheet can be cut
into a predetermined length as required as, for example, a porous
carbon electrode substrate, but the curing and the carbonization
are continuously carried out as described above, so that the
obtained carbonaceous material sheet has uniform and adequate
flexibility in the length direction. Therefore, it can be wound up
in a roll form.
[0047] Thus, It is preferable that the apparatus of the present
invention comprises a winding device in which a trimming cutter for
trimming the both side edges of the carbonaceous material sheet, a
press roll for retaining the winding face pressure, and a winding
shaft are arranged in order along the running path of the
carbonaceous material sheet. As the winding device, a biaxial
turret winding device, by which winding bobbins can be easily
switched, is preferable for improving productivity.
[0048] Further, according to the present invention, there is mainly
provided a method for manufacturing a carbonaceous material sheet,
characterized by including: continuously producing a long cured
fiber sheet by curing uncured resin of the long uncured fiber sheet
by using an apparatus for manufacturing a resin-impregnated cured
sheet, comprising conveyance means for conveying a long uncured
fiber sheet which is obtained by using short fibers to make paper
and which contains uncured resin and resin curing means for curing
the resin of the uncured fiber sheet, wherein the conveyance means
is equipped with at least one rotation belt set comprising a drive
roll, a follower, and an endless belt which is put on and around
the drive roll and the follower roll; and continuously producing a
carbonaceous material sheet by carbonizing the long
resin-impregnated cured sheet by means of the above-mentioned
carbonization apparatus; and then winding up the carbonaceous
material sheet.
[0049] In order to impart an adequate flexibility to the
carbonaceous material sheet so that it can be wound up by a roll
having an outer diameter of 75 mm or more, it is preferable that
the sheet has a thickness of 0.05 to 0.5 mm, a bulk density of 0.35
to 0.8 g/cm.sup.2, and a bending strength of 45 MPa or more. It is
further preferable that as a short fiber, extremely fine short
fibers, each of which has an average diameter of less than 5 .mu.m
and a fiber length of 3 to 10 mm, are contained at 50% or more of
the total weight of fibers.
[0050] The short fibers of the fiber sheet which is obtained by
using short fibers to make paper may be, besides carbon fibers,
organic polymer fibers such as polyarylonitrile-based,
polyvinylalcohol, or polyester-based. In addition that, glass
fibers, aramid fibers, or ceramic-based fibers can be further used
for reinforcement.
[0051] As the uncured resin, a resin which has adherence property
or flowability at normal temperature is preferable. In particular,
when the carbonaceous material sheet is produced, a phenol resin, a
furan resin or the like that remains as an electroconductive
substance after the carbonization, is preferably used as the
uncured resin. The concentration of the resin is preferably from 5%
by weight or more to 70% by weight or less.
[0052] Further, according to the present invention, it is
preferable that the fiber-made sheet, which is obtained by using
short fibers to make paper, contains carbon short fibers and
organic polymer-based binders. Thus, when the carbon short fibers
are being made, a strength of the fiber-made sheet can be
secured.
[0053] The average diameter of the carbon short fiber is preferably
less than 5 .mu.m. Thus, smoothness of the carbonaceous material
sheet and reduction of electric resistance can be attained.
Furthermore, the length of the fiber is preferably 3 mm or more and
10 mm or less from a viewpoint of a dispersion property of the
papering.
[0054] Further, it is preferable that the carbonization yield of
the organic polymer-based binder is 40% by weight or less. Thus,
the gas permeability of the carbonaceous material sheet can be
secured. As the organic polymer-based binder, for example, a pulp
article or a short fiber of polyvinylalcohol is preferable. The
content rate of the organic polymer-based binders with respect to
the fiber-made sheet is preferably 5% by weight or more and 40% by
weight or less.
[0055] Further, according to the present invention, it is
preferable to produce the resin-impregnated cured sheet by
preliminarily heating a fiber sheet which is impregnated with the
uncured resin and then heating and pressuring it. As mentioned
above, the thickness of the resin-impregnated cured sheet can be
well controlled by softening thermosetting resin due to the
preheating and by the successive heating and pressuring.
[0056] Further, it is preferable that the temperature at the
heating and pressuring is higher than the preheating temperature by
50.degree. C. or more. Thereby, the thermosetting resin can be
sufficiently cured.
[0057] In this case, it is more preferable that the preheating
temperature is not less than a temperature at which the viscosity
of the thermosetting resin becomes the lowest.
BRIEF DESCRIPTION OF THE DRAWING
[0058] FIG. 1 is a schematic view of an apparatus for manufacturing
a preferred resin-impregnated cured sheet according to the present
invention.
[0059] FIG. 2 is a schematic view of an apparatus for manufacturing
another preferred resin-impregnated cured sheet according to the
present invention.
[0060] FIG. 3 is a schematic sectional view of a heating and
pressuring apparatus in an apparatus for manufacturing another
preferable resin-impregnated cured sheet according to the present
invention.
[0061] FIG. 4 is a schematic view of an apparatus for manufacturing
a preferred carbonaceous material sheet according to the present
invention.
[0062] FIG. 5 is a schematic view of a winding device of the
carbonaceous material sheet according to the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0063] The best mode for carrying out the present invention is
specifically illustrated below with reference to the drawings.
[0064] FIG. 1 schematically shows an apparatus 10 for manufacturing
a resin-impregnated cured sheet, which is a preferable first
embodiment of the present invention. According to the present
embodiment, illustrated is a case in which a resin impregnated
cured sheet which is impregnated with carbonizable thermosetting
resin and cured is produced, the resin-impregnated cured sheet
being an intermediate product in producing a carbonaceous material
sheet. However, the apparatus for manufacturing the
resin-impregnated cured sheet of the present invention should not
be limited to the one for manufacturing the resin-impregnated cured
sheet which is an intermediate product in producing a carbonaceous
material sheet, but it can be also used for producing a printed
circuit board or the like.
[0065] The apparatus 10 for manufacturing the resin-impregnated
cured sheet serves to continuously heat an uncured fiber sheet 1a
in which uncured thermosetting resin is imparted to a long
fiber-made sheet which is obtained by using short fibers to make
paper so that the thermosetting resin is cured and continuously
produce a long resin-impregnated cured sheet 1b.
[0066] The apparatus 10 for manufacturing the resin-impregnated
cured sheet is equipped with conveyance means for continuously
conveying a long sheet article 1 (the uncured fiber sheet 1a, the
resin-impregnated cured sheet 1b). In the conveyance means, there
are arranged a drive roll 2a at an upstream side in a conveying
direction, an follower roll 2b at a downstream side in the same
conveying direction, and at least one rotation belt set 2 which is
constituted by an endless belt 2c being put on and around the drive
roll 2a and the follower roll 2b. An upper face of the endless belt
2c is a conveying face of the sheet articles 1a and 1b. In the
present embodiment the drive roll 2a is arranged at the upstream
side in the conveying direction and the follower roll 2b is
arranged at the downstream side in the conveying direction, but the
drive roll 2a and the follower roll 2b may be inversely
arranged.
[0067] The apparatus 10 for manufacturing the resin-impregnated
cured sheet is further equipped with resin curing means 3 for
curing the thermosetting resin of the uncured fiber sheet 1a and
molding it into the resin-impregnated cured sheet 1b. As shown in
FIG. 1, as the resin curing means 3, three pairs of upper and lower
heating and pressuring rolls 3a, which are respectively disposed on
the sheet article 1 and under the endless belt 2c, are arranged in
the conveying direction of the sheet article 1 so as to nip the
sheet article 1 with the endless belt 2c. The heating and
pressuring rolls 3a are supported at both ends or multi-points
thereof. For a heat source of the heating and pressuring rolls 3a,
electricity, heating medium or the like can be appropriately
adopted.
[0068] A diameter of each of the heating and pressuring rolls 3a
and a pitch of the three pairs of the heating and pressuring rolls
3a are appropriately determined considering a temperature change of
the endless belt before and after the heating and pressuring rolls
3a, a pressure fluctuation which the sheet article 1 itself
receives or the like. Further, the temperature and the pressure of
a press of the heating and pressuring rolls are suitably set in
accordance with the thermosetting resin materials. For example,
when the resin-impregnated cured sheet 1b, which is an intermediate
product in producing the carbonaceous material sheet, is produced,
it is preferable that the temperature range at curing the
carbonizable resin is 350.degree. C. or less, and the pressure is
1.5.times.10.sup.4 N/m.sup.2 or more and 1.0.times.10.sup.5
N/m.sup.2 or less at linear load.
[0069] FIG. 2 schematically shows an apparatus 11 for manufacturing
a resin-impregnated cured sheet according to a modified example of
the above-mentioned preferable first embodiment according to the
present invention. The same reference numerals are imparted to the
same structures as the above-mentioned embodiment, so the detailed
description is omitted.
[0070] In the apparatus 11 for manufacturing the resin-impregnated
cured sheet, a pair of upper and lower rotation belt sets 2, each
of which is constituted of a drive roll 2a, a follower roll 2b and
an endless belt 2c which are put on and around the drive roll 2a
and the follower roll 2b, are arranged so as to sandwich the sheet
article 1a, 1b which are being conveyed. That is, the sheet article
1a, 1b are conveyed while being sandwiched by the respective
endless belts 2c of the upper and lower rotation belt sets 2.
[0071] In the present apparatus 11, two heating and pressuring
rolls 3a are arranged so as to nip the sheet article 1 which is
sandwiched by the upper and lower endless belts 2c, from the
outside of the endless belt 2c.
[0072] Thus, because the two rotation belt sets 2 are arranged on
and under the sheet article 1, the sheet article 1 is sandwiched by
the endless belts 2c at not only the installation positions of the
heating and pressuring rolls 3a but also at a required length.
Therefore, a thickness of the obtained resin-impregnated cured
sheet 1b can be accurately controlled so that the uniformity of the
thickness in the longitudinal direction can be enhanced.
[0073] FIG. 3 shows another preferable embodiment of the resin
curing means for continuously heating and pressuring a
thermosetting resin which is impregnated in an uncured fiber sheet.
As the detail of the resin curing means, for example, a
"continuously pressuring apparatus", which is disclosed in Japanese
Patent Publication No. 2-62371 and which is also manufactured and
sold by Mitsubishi Rayon Engineering Co., Ltd., can be applied, as
already described. The continuously heating and pressuring device
30 as the resin curing means nips the uncured fiber sheet 1a and
the endless belt 2c by a fluid having high temperature and high
pressure to heat and pressurize it.
[0074] The continuously heating and pressuring device 30 as
illustrated is equipped with metal box bodies 31, each of which has
front, back and lateral side wall portions 31a and an opening face
facing a rear face of each of the pair of upper and lower endless
belts 2c. At a bottom portion 31b of the metal box body 31, there
is formed an introduction port 31c which introduces a heating fluid
having high temperature and high pressure from outside into a
pressuring space between the metal box body 31 and the rear face of
the endless belt 2c, and a discharge port 31d for discharging the
heating fluid to outside.
[0075] Further, the metal box body 31 has a seal portion 32 at a
continuous end face of an opening side of all the side wall
portions 31a. The seal part 32 is equipped with a
sliding-member-fitting groove 32a which is continuously formed
along the end face of the opening side of the side wall portions
31a, and a sliding member 33 which is slidably fit into the
sliding-member-fitting groove 32a. A suction path 32a-1 for fluid
for damper, which lowers the pressure of a space portion between
the bottom face of the sliding-member-fitting groove 32a and an
fitting end face of the sliding member 33, is formed at the side
wall portions 31a of the metal box body. Springs may be provided at
the space portion in place of the suction of the fluid for damper.
In this case, the suction path 32a-1, a suction source which is not
shown here, supply pipes for the purpose and the like can be
excluded.
[0076] Further, in the sliding member 33, formed is a
fluid-for-seal path 33a, which communicates between the end face
opposing to the endless belt 2c and the fit face with the
sliding-member-fitting groove 32a and which opens in a slit form at
the end face opposing to the endless belt 2c. A fluid-for-seal
introducing path 32a-2 for introducing the fluid for seal from
outside is formed at the corresponding part of the
sliding-member-fitting groove 32a which opposes to the introducing
side end portion of the fluid-for-seal path 33a. The metal box body
31 is fixedly supported by a frame body of the apparatus, which is
not shown here.
[0077] The pressuring fluid having high temperature, which is
applied to the present apparatus, should not be limited to a
specific one as far as it has such heat resistance that does not
generate deterioration, change of quality or the like at a desired
temperature. Therefore, it can be appropriately selected in
accordance with the curing temperature of resin. In general,
silicon-based oil, which is good in heat resistance, is used. Gas
can be used as the pressuring fluid, but a liquid is usually
advantageous because of its high heat conductance efficiency.
[0078] The fluid having high temperature is introduced into the
inner space of the metal box body 31 from the introduction port 31c
of the metal box body 31, and discharged to outside from the
discharge port 31d. In the example as illustrated, the high
pressured fluid which is discharged from a flow pump not shown
here, and is provided at the outside, is heated to a desired
temperature by a heating apparatus not shown here. Then, the
pressured fluid having high temperature is introduced into the
inside of the metal box body 31, discharged to outside through the
discharge port 31d, and returned back to the fluid pump. In the
present invention, the heating and pressuring fluid can be also
sealed in the metal box body 31 instead of being circulated. In
this case, it is required to provide the metal box body 31 with a
heating apparatus having a control mechanism for heating
temperature.
[0079] When the pressured fluid having high temperature is
introduced into the inner space of the metal box body 31, at the
same time, the fluid for seal is simultaneously introduced from the
above-mentioned fluid-for-seal introducing path 32a-2 through the
fluid-for-seal path 33a of the sliding member 33 and gushed at high
pressure from the end face of the sliding member 33 opposing to the
endless belt 2c. The pressured fluid having high temperature
introduced into the inner space of the metal box body 31 is
prevented from being leaked out to the outside of the metal box
body 31, owing to the gushing of the fluid for seal.
[0080] Thus, since the heating and pressuring fluid is introduced
into the inner space of the metal box body 31, the uncured fiber
sheet 1a which is being conveyed via the endless belt 2c is
continuously and uniformly heated and pressurized simultaneously by
the heating and pressuring fluid through the endless belt 2c. As a
result, the thermosetting resin is cured; and the resin-impregnated
cured sheet 1b having uniform thickness is continuously produced.
At the curing treatment, the above-mentioned sliding member 33
which is slidingly fit into the sliding-member-fitting groove 32a
formed in the metal box body 31 always makes a slight gap with
respect to the endless belt 2c by combination of the damper
function between the sliding-member-fitting groove 32a and the
sliding member 33 and the gushing of the fluid for seal. Therefore,
since the sliding member 33 does not slide in contact with the rear
face of the endless belt 2c, the endless belt 2c is prevented from
being damaged.
[0081] In particular, the continuously heating and pressuring
device 30 according to the present embodiment is different from the
heating and pressuring rolls 3a in the embodiment shown in FIG. 1
in that the sheet article 1 is only pressurized by the fluid
pressure while passing through the device 30 so that the device can
continuously impart a face pressure. Therefore, any mechanical
sliding action does not act on the surface of the endless belt 2c,
and moreover, it is preferable when the treatment time is long.
Furthermore, if required, a plurality of pairs of devices can be
arranged in the conveying direction of the sheet article or the
width direction thereof. Further, the above-mentioned heating and
pressuring rolls 3a can be used in combination with the present
embodiment.
[0082] As described above, since the apparatus 10 for manufacturing
the resin-impregnated cured sheet according to the present
invention can simultaneously heat and pressurize the long sheet
article 1 while continuously conveying it, the long sheet article 1
can be uniformly heated and pressurized in the length direction
thereof. As a result, the resin-impregnated cured sheet 1b having
uniform quality in the length direction can be produced with a high
productivity, without generating any fragment, any local fragile
portion or the like.
[0083] FIG. 4 schematically shows an apparatus 20 for manufacturing
a carbonaceous material sheet, which is a second embodiment of the
present invention.
[0084] The apparatus 20 for manufacturing the carbonaceous material
sheet is the one that carbonizes the resin of the long
resin-impregnated cured sheet 1b and continuously produces a
carbonaceous material sheet 1c.
[0085] The apparatus 20 for manufacturing the carbonaceous material
sheet employs a horizontal baking furnace which conveys a sheet
article (the long resin-impregnated cured sheet 1b, the
carbonaceous material sheet 1c) in a horizontal direction and
carbonizes it. A plurality of guide-roll-supporting stands 5a are
disposed with a constant interval on a bottom wall 4a of a
carbonization treatment chamber 4 in the horizontal baking furnace,
and guide rolls 5b are supported on the guide-roll-supporting
stands 5a at both ends or a plurality of points. The sheet article
1b, 1c is conveyed in a horizontal direction on an upper face of a
plurality of the guide rolls 5b. The reference numeral 4b in the
Figure shows a ceiling plate of the carbonization treatment
chamber.
[0086] The guide roll 5b has a simple structure in which both ends
of a round bar made of graphite or a round pipe are only supported
by the supporting stands 5a made of graphite. The guide roll 5b can
be easily rotated because of the self lubricity of the graphite
itself.
[0087] Further, a pitch of the plurality of the guide rolls 5b can
be suitably determined in accordance with a weight and a tensile
force of the sheet article 1b, 1c at the time of the carbonization
treatment such that the sheet article 1b, is do not contact with
the bottom wall 4a of the carbonization treatment chamber 4 and do
not rub it. Further, the temperature in the carbonization treatment
chamber 4 is set to be at 100.degree. C. or more when the
carbonaceous material sheet 1c is produced.
[0088] Since the guide rolls 5b are provided in the carbonization
treatment chamber 4, the resin-impregnated cured sheet 1b and the
carbonaceous material sheet 1c can run steadily at a predetermined
height over the full length of the treatment chamber 4. As a
result, the resin-impregnated cured sheet 1b and the carbonaceous
material sheet 1c are prevented from contacting with the bottom
wall 4a of the carbonization treatment chamber 4 by its own weight
to cause any inductive factors for a crack or a fragment.
Therefore, the carbonaceous material sheet 1c with good quality can
be produced.
[0089] FIG. 5 schematically shows one example of a preferable
winding device 13 according to the present invention.
[0090] In a winding section of the winding device 13, disposed is a
double-axis-turret winder 6, which is equipped with a winding
bobbin 6a under winding up and stand-by bobbins 6b.
[0091] The winding device 13 is further equipped with a trimming
cutter 7 for trimming both ends in the width direction of the long
carbonaceous material sheet 1c on the upstream side of the turret
winder 6. Further, the device is equipped with a press roll 8 in
the vicinity of the winding bobbin 6a for constantly keeping a
winding face pressure of the carbonaceous material sheet 1c with
respect to the winding bobbin 6a. The press roll 8 may be disposed
so as to contact with the winding face, or alternatively it may be
disposed without contacting with the winding face.
[0092] The carbonaceous material sheet 1c obtained after being
finished with the carbonization treatment is cut at the both ends
in the width direction thereof by the trimming cutter 7 so that the
end faces are made even, and then is wound up on the winding bobbin
6a in a state that the winding face pressure is kept constant by
the press roll 8.
[0093] The present invention will be specifically described below
with reference to Examples and Comparative Examples.
[0094] The same articles as mentioned below were adopted for a
fiber-made sheet and thermosetting resin in Examples and
Comparative Examples below.
(Fiber-Made Sheet)
[0095] Sheet article made of carbon short fibers:
[0096] width=350 mm, thickness=0.5 mm
Average diameter of carbon short fiber: 4 .mu.m Average fiber
length of carbon short fiber: 3 mm Binder: PVA short fiber, carbon
fiber ratio containing 15% by weight
(Thermosetting Resin)
[0097] The above-mentioned fiber-made sheet was immersed in a
methanol solution of 20% by mass of a phenol resin (PHENOLITE
J-325; manufactured by Dai Nippon Ink Chemicals Co., Ltd.), and 120
weight of it was adhered with respect to 100 weight of carbon
fibers.
Example 1
[0098] The apparatus for manufacturing a resin-impregnated cured
sheet as shown in FIG. 2 was employed, in which two upper and lower
rotation belt sets 2 were set so as to sandwich the conveyance path
of a sheet article and in which 6 pairs of heating and pressuring
rolls 3a were arranged in the conveyance direction with a constant
interval. All of the heating and pressuring rolls 3a were set to
have a diameter of 160 mm, and the pitch of the pair of the heating
and pressuring rolls 3a was set to be 220 mm in the conveyance
direction of the sheet article. The temperature of the heating and
pressuring rolls 3a was set at 300.degree. C., the nip pressure
condition was 5.times.10.sup.4 N/m, the residential time from the
first pair of the heating and pressuring rolls to the sixth pair of
the heating and pressuring rolls was set to be 2 minutes, and the
curing treatment was continuously carried out at a treatment speed
of 0.6.6 m/min.
[0099] Then, the apparatus for manufacturing a carbonaceous
material sheet as shown in FIG. 4 was used, in which a horizontal
baking furnace having the guide rolls 5b for the resin-impregnated
cured sheet inside the carbonization treatment chamber 4 is
adopted, so that carbonization treatment was carried out. The guide
rolls 5b were set to have a diameter of 12 mm, and the pitch of the
guide rolls was set to be 30 mm in the conveyance direction of the
sheet article. The maximum temperature of the inside of the
treatment chamber 4 was set to at 2000.degree. C., and the
residential time of the treatment chamber 4 was set to be 10
minutes. After the continuous carbonization treatment, the obtained
carbonaceous material sheet was wound up in a roll form by the
winding device shown in FIG. 5.
[0100] The obtained carbonaceous material sheet had no problem of a
crack, a fragment or the like, and was a high quality sheet
excellent in its handling property with a high bending strength.
Further, a long carbonaceous material sheet can be continuously
produced, so that productivity is also high.
Example 2
[0101] An apparatus for manufacturing a resin-impregnated cured
sheet, which was equipped with a preheating section, heating and
pressuring rolls, and two sets of endless belts, was used. Hot wind
of 200.degree. C. was flown into the preheating section, such that
the belt temperature was set at 135.degree. C. Further, the press
was carried out by the successive first heating and pressuring roll
at 300.degree. C. and under a line pressure of 6.6.times.10.sup.4
N/m, so that the curing treatment was continuously carried out.
[0102] Then, the carbonization treatment was carried out and the
carbonaceous material sheet obtained was wound up in a roll form in
the same manner as in Example 1.
[0103] The obtained carbonaceous material sheet had no problem of a
crack, a fragment or the like, and was excellent in its handling
property with a bending strength of 82 Mpa, so that it had a good
quality. Further, it was verified that productivity is also high
since a long carbonaceous material sheet can be continuously
produced.
Example 3
[0104] The curing treatment was continuously carried out in the
same condition as in Example 1 in the apparatus for manufacturing
the resin-impregnated cured sheet of Example 1, except that the
heating and pressuring device shown in FIG. 3 was used as the resin
curing means in place of the heating and pressuring rolls, the nip
pressure was set to be 5.times.10.sup.4 N/m.sup.2, and the
residential time in the device was set to be 2 minutes.
[0105] Then, carbonization treatment was carried out and the
carbonaceous material sheet obtained was wound up in a roll form in
the same manner as in Example 1.
[0106] The obtained carbonaceous material sheet had smooth surface
and uniform thickness, had no crack, fragment or the like, and was
excellent in its handling property with a bending strength of 85
Mpa. Thus, it has a good quality. Further, since a long
carbonaceous material sheet can be continuously produced,
productivity is also extremely high.
Comparative Example 1
[0107] A long carbonaceous material sheet was produced in a
condition similar to Example 1, except that a hot press was adopted
as the apparatus for manufacturing the resin-impregnated cured
sheet, and the curing treatment was carried out on the long uncured
fiber sheet by semi-batch-type.
[0108] The production was carried out by changing various
conditions concerning the treatment temperature, pressure, and
treatment time by the hot press. However, under any of the
conditions, the carbonaceous material sheet as a final product
produced by the carbonization treatment was very fragile at a press
boundary line, its quality was lowered, the flexibility was
deficient, and the handling property was poor.
Comparative Example 2
[0109] A long carbonaceous material sheet was produced in a
condition similar to Example 1, except that the carbonization was
carried out using a horizontal baking furnace in which no guide
rolls 5b were provided.
[0110] The obtained carbonaceous material sheet obtained had naps,
which appeared to be generated by being rubbed with the bottom wall
of the baking furnace, on the surface thereof. Further, fragments
occur at the end portions of the carbonaceous material sheet in the
width direction thereof orthogonal to the conveyance direction, so
that its quality and product yield were low.
[0111] As described above, since the apparatus for manufacturing a
resin-impregnated cured sheet of the present invention is applied,
the heating and pressuring can be continuously and simultaneously
carried out with respect to a long uncured fiber sheet which is
continuously conveyed. Therefore, the productivity and the handling
property of the carbonaceous material sheet can be remarkably
improved as compared with a conventional batch-type curing process.
Further, it is possible to produce a carbonaceous material sheet
having a good quality, without generating any crack or fragment in
the carbonaceous material sheet, by using the apparatus for
manufacturing a carbonaceous material sheet of the present
invention. Since such a long carbonaceous material sheet can be
continuously produced, the productivity can be improved, and the
long carbonaceous material sheet with a high quality can be
supplied in a rolled form.
* * * * *