U.S. patent number 3,873,389 [Application Number 05/305,933] was granted by the patent office on 1975-03-25 for pneumatic spreading of filaments.
This patent grant is currently assigned to Philco-Ford Corporation. Invention is credited to Clare G. Daniels.
United States Patent |
3,873,389 |
Daniels |
March 25, 1975 |
Pneumatic spreading of filaments
Abstract
Process and apparatus for pneumatically spreading thin graphite
or other carbon filaments from a tow bundle to form a sheet or tape
in which the filaments are maintained in parallelism. The process
includes passing the tow through at least one slot venturi spreader
in which the tow is pulled through the spreader in a direction
opposite to the direction of primary air flow through the venturi.
For certain purposes use is made of first and second spreader
units. Each of these units may have at least two side-by-side rows
of slot venturies and at least two stacked modules arranged in
modular array, whereby to process a plurality of tow bundles
simultaneously.
Inventors: |
Daniels; Clare G. (El Toro,
CA) |
Assignee: |
Philco-Ford Corporation
(Philadelphia, PA)
|
Family
ID: |
26900843 |
Appl.
No.: |
05/305,933 |
Filed: |
November 13, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
205878 |
Dec 8, 1971 |
3795944 |
|
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Current U.S.
Class: |
156/181; 28/283;
156/296; 156/441 |
Current CPC
Class: |
D01D
10/0481 (20130101); D02J 1/18 (20130101) |
Current International
Class: |
D01D
10/04 (20060101); D02J 1/00 (20060101); D02J
1/18 (20060101); D01D 10/00 (20060101); D04h
003/12 () |
Field of
Search: |
;19/65T,66T ;21/1CF
;226/7,97 ;156/166,178,180,181,296,441 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Fritsch; Daniel J.
Attorney, Agent or Firm: Sanborn; Robert D. Synnestvedt;
Carl R.
Parent Case Text
This is a division of application Ser. No. 205,878, filed Dec. 8,
1971, now U.S. Pat. No. 3,795,944.
Claims
I claim:
1. A process for forming a thin sheet of filamentary graphite
material, from a batch of tapes of such material, comprising:
forming a plurality of tapes of predetermined length substantially
equal to the length dimension of the desired sheet, by spreading
and collimating filaments of graphite tow by passing such tow
through slot venturi spreader means while causing air to flow
through the venturi spreader in a direction opposite to the
movement of tow through said venturi spreader; positioning the
resultant tapes in side-by-side coplanar relation in which they
define a sheet of the desired width and length; and impregnating
said tapes while in side-by-side coplanar relation with resinous
material to bond the same into a unitary sheet.
2. A process in accordance with claim 1, in which tow is provided
in a plurality of sections each of the desired predetermined
length; and the tapes are formed by passing each tow section
through slot venturi preblower means disposed upstream of the
recited slot venturi spreader means.
Description
BACKGROUND OF THE INVENTION
It is known in the art to utilize venturi jets to "fluff" or lay
open bundles of fibrous strands, commonly known as "tow", such, for
example, as filaments of viscose rayon for textile purposes, or
crimped cellulose fibers of the kind used in the manufacture of
cigarette filters. In such prior art the filaments are separated
for a number of purposes such as to desulphurize, wash, bleach or
dry them or, in the case of cigarette filters, to increase the
filtration efficiency. For such purposes there is no rigid
requirement for uniform unidirectional laying-down of the fibers in
such a way that the end product is of exact and predetermined
thickness. Particularly lacking in the prior art is teaching of
utilizing venturi jet means for spreading a tow of graphite, or
other carbon filaments, in order to form a heat resistant sheet or
tape of extreme thinness and great strength, and which is well
adapted for the manufacture of structural components subjected to
high temperature and stress, for example missile components, wing
panels, or tail assemblies of aircraft and the like.
Graphite filaments, per se, have been developed with high strength
and stiffness characteristics which are well adapted for use in
laminated, reinforced, plastic structural components. Usually such
graphite filaments have been manufactured for use by the textile
industry, utilizing pyrolysis of synthetic fibers (rayon,
polyacrylonitrile, etc.). Such fibers are available in loosely
twisted continuous tow bundles having a large number of individual
filaments, for example from 2,000 to 40,000 filaments which may be
about 0.00025 or 0.0003 inch in diameter, the tow being packaged in
bales or on spools. It has been my endeavor to provide for the
utilization of such graphite filaments in the manufacture of
laminated plastic components. For such use, the filaments must be
combined unidirectionally into uniform, ultrathin sheets or tapes,
in order to achieve maximum strength with minimum weight. Previous
attempts to combine the filaments in the manner needed to make such
components have not been notably successful, principally because of
difficulties encountered in collimating the individual filaments of
the tow without formation of gaps and angular overlaps.
SUMMARY OF THE INVENTION
With the foregoing in mind it is the primary object of the present
invention to provide for production of very thin sheets or tapes of
truly parallel graphite filaments, which tapes may be several
inches wide, of the order of a thousandth of an inch in thickness,
and almost completely free of gaps or regions of angular
overlap.
More specifically, my invention makes it possible to combine
graphite filaments into uniform thin sheets formed of
unidirectional filaments, and which sheets may, for various
applications, have considerable variation in thickness. By way of
example, thicknesses from about 0.001 to about 0.008 inch are very
useful. In accordance with an aspect of my invention it is possible
to form sheets from a batch of tapes of predetermined length
corresponding to the desired sheet length, or if desired to form
tape-like sheets by a continuous process in which a plurality of
extended tapes are formed simultaneously.
In summary, this invention is featured by the fact that it is
possible to make graphite sheets an order of magnitude thinner than
has previously been possible, with unusual uniformity of filament
dispersion, and with minimum damage -- such as results from
breaking, fuzzing, or knotting -- during the manufacturing
process.
In achievement of these objectives, I utilize spreader means
comprising a self-contained unit, preferably although not
necessarily including a plurality of modular, slot-type venturi
jets, and from which unit the tow is pulled in a direction opposed
to the direction of primary air flow through said jets. Preferably,
in the continuous process, I utilize separate preblower and final
spreader units and, in at least the final unit, the tow is pulled
in a direction as mentioned just above.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a diagrammatic view of a machine constructed in
accordance with the principles of this invention and adapted to
form sheet-like tapes by a continuous process, in which a plurality
of tapes are formed simultaneously and then combined into a single
sheet or tape and stored for use;
FIG. 2 is an enlarged, perspective view, with housing portions
broken away to facilitate illustration, showing modular preblower
and final spreader units of the kind preferably employed in the
machine of FIG. 1;
FIGS. 3A and 3B are sectional views of a single venturi module
included, respectively, in the preblower and the final spreader
illustrated in FIG. 2, FIG. 3A being a section looking at a single
module of the preblower in the direction of the thickness of the
tape being fabricated, and 3B being a section looking at a single
module of the final spreader in the direction of the thickness of
the tape; and,
FIGS. 4A and 4B are sectional views corresponding, respectively, to
FIGS. 3A and 3B, FIG. 4A showing the preblower module as it would
appear if viewed in the direction of the width of the tape, and
FIG. 4B showing the spreader as it would appear if viewed in the
direction of the width of the tape.
It should be understood that FIGS. 3A through 4B illustrate venturi
modules which gave very good results in practice and that the
actual modules were about three times the scale of these figures.
In the interest of clarity in illustration the thickness of the
tapes is shown greatly exaggerated in FIGS. 4A and 4B.
DETAILED DESCRIPTION OF THE INVENTION
With initial reference to FIG. 1 several graphite tow bundles, in
this case four, are shown at 10, 11, 12 and 13 being drawn by
suitable friction rollers, for example rollers of soft rubber, from
separate supply spools. The rollers, designated generally by the
reference numeral 14, may be driven by any suitable means (not
shown), and the supply spools appear at 15. The tapes, in response
to the pull of roller means 16 and 17 (right-hand portion FIG. 1),
at least one of which is surfaced with frictional material, are
drawn through the apparatus shown in the mid-portion of the figure.
In a preferred continuous process this apparatus comprises a first
slot-type venturi spreader 18, which serves as a preblower for
separating and effecting partial alignment of the individual
filaments of tow passed therethrough, and a second or final
slot-type venturi spreader 19 which is specially designed to
collimate the individual filaments of the spread tow to form them
into a smooth and regular tape of predetermined width and
thickness, and the filaments of which are substantially devoid of
gaps or angular overlaps. As is explained below, the second slot
venturi spreader is featured by the provision of air flow
therethrough in a direction opposite to the direction of movement
of tow through the venturi of said second spreader. As will be
explained later with reference to FIG. 2, both the preblower 18 and
the spreader 19 comprise slot venturi devices. Preferably a
plurality of such devices are arranged in modular array, in order
to process the tape bundles 10 to 13 simultaneously. In the region
between the units 18 and 19, where the tow bundles have been
partially fluffed or spread, said bundles are designated by the
numerals 10a, 11a, 12a and 13a and are shown as feeding into the
ingress end of the final spreader 19. In the latter unit the spread
tow is formed into very thin sheets of truly parallel graphite
filaments in which form they leave the final spreader, as shown in
FIG. 1 at 10b-13b, as thin ribbons the width of the exit openings.
In this particular case four tapes have been formed simultaneously
and they are combined into a single tape of predetermined width and
thickness, by passing them through a simple device having a
combining passage, for example the device shown at 20, after which
the resultant single tape T passes over an idler roller 21 and is
fed to a roller 22 which is submerged in a bath of suitable
impregnating material contained within a tank 23. Impregnating
materials of a variety of types can be used, depending upon the
specifications of the particular sheet or tape being fabricated.
Usually the material will be of plastic resin, epoxy, phenolic, or
polymide type, and the resin may be applied in a dip tank immersion
process, as shown, or by other processes, as desired. The combined
tape, after passing through the treatment tank 23, still subject to
the pull of friction rollers 16 and 17, is joined to a carrier tape
24 which may, for example, comprise parchment paper drawn from a
storage roll 25. The final tape is shown at T', after it has been
combined with the paper carrier which is applied merely to
facilitate handling and packaging. The impregnated final product is
then passed through suitable drying means, for example the drying
tube shown at 26, through which warm air is caused to flow. The
excess solvent is removed from the resin by the drying operation.
It will be understood that multiple or elongated drying tubes may
be utilized if additional drying time is required. The impregnated
tape mounted on the carrier paper exits the drying tube and is
wound on a reel 27 for storage and shipment.
It should be understood that while a machine has been described for
practicing a continuous process in which a plurality of tapes of
extended length are formed simultaneously, the invention is
primarily concerned with the nature of the venturi units 18 and 19
and with the manner in which they are used. In one aspect of my
invention, it is contemplated that use may be made of only a single
spreader through which the tape and the primary air move in
counterflow arrangement. Generally, in such practice of the
invention, repeated passes of tow would be made through the venturi
device. In accordance with this aspect of the invention a plurality
of tapes of predetermined length may be formed separately, after
which they may be positioned in side-by-side relation to form a
sheet of any desired width and then treated with plastic resin.
This may readily be accomplished by pouring the resin on the sheet
and spreading the same in any convenient manner, as for example by
applying a roller to the sheet to spread the impregnating material
uniformly thereover. Preferably, however, I utilize both a
preblower unit 18 and a spreader unit 19 in the practice of a
continuous process of the kind described with reference to FIG.
1.
FIG. 2 illustrates the preblower and spreader of the invention in
more detail, the view showing two passes of tow traversing the
preblower and spreader units, which units have been angled somewhat
in the figure to facilitate illustration. While the invention may
be embodied in, and described with reference to a single venturi
module, as has been done in FIGS. 3A to 4B, units of the kind
contemplated by the invention preferably comprise the FIG. 2
arrangement of a plurality of venturi devices stacked in modular
array. While the processing of four tapes in the apparatus shown
diagrammatically in FIG. 1 indicates that each of the devices 18
and 19 includes four modules, it should be borne in mind that the
number of modules is a matter of convenience. In one embodiment of
my invention I have found it convenient to provide 12 venturi
modules in each of the preblower and spreader units, this being
accomplished by combining two adjacent rows of venturi units each
of which is six units high.
Considering first the preblower unit 18 of FIG. 2, it will be seen
that this device is of rectangular box-like shape having side walls
28 and 29, bottom and top walls 30 and 31 and intermediate
partitions 32 which extend vertically, as the unit is viewed in
FIG. 2, to subdivide the housing into two stacks of six units. It
should be understood that the housing would include a left end wall
extending throughout the height thereof. This wall has been broken
away in the lower portion of FIG. 2 - as has the right end wall of
the spreader unit 19 - to show the details of interior
construction. A plurality of parallel plates 33 extend through the
length and width of the housing, and each pair of confronting
plates is provided with partially cylindrical segments 34a and 34b
which bridge the space between the side walls 28 and 29 of the
housing, and preferably extend through the intermediate partition
structure 32. Each confronting pair of segments defines the throat
of a slot type venturi through which the tow is moved during the
spreading operations. Each subcompartment, or module, is provided
with a thicker plate or block 35 which is provided, at 36, with an
aperture extending throughout the length thereof and through which
inletted tow (see 10 and 11) is fed toward the slot venturi where
it is fluffed and separated into individual filaments. The tow,
after fluffing or spreading in the venturi throat passes out of the
housing of unit 18, as is represented at 10a and 11a in FIG. 2.
Each subcompartment is provided with an air inlet conduit, and
several such conduits are designated with the numeral 37. As will
be explained below, with particular reference to FIGS. 3A through
4B, air under pressure is inletted to the space above and below the
feed block 35 and passes in laminar flow across the length of the
block and toward the throat of the slot venturi. In the preblower
18 this air flow is in the direction of movement of the tow.
Now with particular reference to the right hand portion of FIG. 2,
that is the portion which illustrates the final spreader 19, it
will be seen that this device, into which the tow 10a and 11a is
fed from the preblower 18, is similar in external configuration and
general interior layout to the preblower 18. When considered
specifically, however, it will be seen that the spreader is
significantly different in several respects. The tow enters the
spreader through the open space between adjoining plates. A pair of
such plates are shown in this figure at 38 and 39, and it will be
seen that these are of the same size and general configuration as
the plates employed in the device 18.
After entry between the confronting surfaces of plates 38 and 39
the partially spread tow (see tow 11a) moves to and through the
slot venturi passage defined by confronting segments 40 and 41
carried by plates 38 and 39. The tow then passes between a pair of
closely spaced plates 42 and 43, the right hand end of which plates
form an exit opening 44.
In particular accordance with this invention, air, which is
inletted under pressure through passages 45, is constrained by a
dam or wall 46 to flow toward the right hand end of spreader 19,
thence around the free edge of the confronting plates (see for
example plate 39) after which it flows between the surface of said
plate and the confronting surface of the plate 43 which defines an
exit. Air moving in this way then flows through the slot venturi
defined by segments 40 and 41 and exits from the left hand end of
the housing of unit 19. This pattern of air flow, as well as that
which prevails in the device 18, has been indicated by arrows in
the drawing.
It will be noted that in each spreader device each module has a
feed opening at one end and a diverging or expansion chamber toward
the other end. Also, in both devices, there is a slot venturi and
upper and lower sheets of air are introduced for flow therethrough.
It is important to note that in the spreader 19 the partially
spread tow enters the expansion chamber, or converging part of the
venturi against the flow of air through the venturi device. The tow
is further fluffed as it approaches the restriction of the venturi
nozzle and, after it passes through the nozzle, fluffing and
collimating continues as it encounters sheets of air flowing in
direction opposite to the direction of tow movement. The tow is
then virtually perfectly collimated into a thin sheet of fiber as
it is pulled through the final slit opening 44, for example by the
drive rollers shown at 16 and 17 in FIG. 1. It is this movement of
tow, in countercurrent to the direction of air flow through the
spreader, which particularly characterizes practice of this
invention.
In order further to facilitate understanding of the two spreaders,
that is, the preblower 18 and the final spreader 19, reference will
now be had to the single modules illustrated, on a larger scale, in
FIGS. 3A through 4B. As will now be understood, a plurality of
modules similar to those shown in these figures comprise the
stacked arrays shown in FIG. 2.
FIG. 3A illustrates the preblower spreader unit in section looking
in the direction of the thickness of the tape being fabricated,
that is, FIG. 3A shows the width of the fluffing tape developing,
for example, from tow bundle 10. FIG. 4A is taken at right angles
to FIG. 3A and shows the apparatus looking in the direction of the
width of the developing tape 10a, that is FIG. 4A shows the
thickness of the tape (exaggerated). Referring more particularly to
FIG. 4A, it will be seen that air under pressure is entering a pair
of plenum spaces 47 and 48 which lie outwardly of and are partially
defined by confronting plates 33. Air, after entering at 37, is
constrained by the walls 49 to flow rearwardly in the module, that
is toward the left end as viewed in FIG. 4A, where it turns
reversely and flows between the plates 33 and the block 35 through
which the tow is being introduced. The venturi-defining segments
34a and 34b also appear in this drawing, and the direction of tow
movement has been labelled on the drawing. With regard to FIG. 4A
it will be seen that a laminar flow of air occurs between the two
plates 33 and the confronting surfaces of block 35 from whence the
air passes through the throat of the slot venturi in the direction
of tow movement. The flowing air "picks up" the tow bundle and
converges with it into the slot venturi throat. As the air
diverges, in passing out of the venturi throat, it causes the
filament bundle to expand with the air (see central part of FIG.
3A), and the fluffed bundle 10a exits at the right end of device 18
and enters the left end of the spreader device 19. In the
transitional phase between the two devices, as appears to best
advantage by comparing FIGS. 3A and 3B, it is seen that the tow
while considerably fluffed or spread, is not yet collimated.
Collimation of the tow occurs in the spreader 19, largely in the
venturi throat, as will now be described in greater detail.
However, it should again be pointed out that while use of the
spreader, and the particular construction thereof, is
characteristic of the broader aspect of my invention, my preferred
continuous tape-producing process utilizes both the spreader and
the preblower.
In the spreader (FIGS. 3B and 4B) the partially cylindrical
segments which define the slot-like throat of the venturi have
again been identified, at 40 and 41, and the air is inletted under
pressure through passages two of which appear at 45. As was
described with reference to FIG. 2, the confronting plates within
the module bear numerals 38 and 39 and their adjacent faces carry
the segments 40 and 41. The outboard sides of these plates define a
pair of plenum chambers designated 50 and 51. The air is confined
by the dams shown at 52 and constrained to flow in each of the
plenums 50 and 51 across the outboard faces of the plates 38 and
39, whence the air returns in laminar flow across the exterior
surfaces of plates 42 and 43, the interior surfaces of which form
the exit opening 44 for the collimated tow 10b. This air flows
backwardly through the venturi throat, in countercurrent to the
direction of tow movement, and exits at the left end of the
spreader 19 as that device appears in FIG. 4B.
In summary regarding the operation of the final spreader, the
fluffed and partially aligned tow 10a enters the unit 19 opposing
the air flow direction in the venturi chamber. Since the tow is
flowing in the opposite direction, it must be pulled through the
spreading gun by the roller 27. As it passes through the venturi
restriction, it is recombined vertically, but not laterally,
resulting in a very thin ribbon the width of the exit orifice.
While shown of exaggerated thickness in the drawing, the actual
thickness of the collimated tape would be about 0.001 inch, a
dimension which is governed by choice of the gap at the venturi
throat, the width of the exit orifice, and, to some extent, by the
spacing between plates 42 and 43.
As the collimated tow enters the slot exit channel, defined by
plates 42 and 43, it leaves the primary air stream, although there
occurs a slight air flow through and out of the channel along with
the tow. This "back" air flow, in the same direction as the tow
ribbon, is a very minor flow as compared with the primary flow back
through the venturi, but further aids in collimating the
filaments.
I have found that much improved results, from the standpoint of the
tape smoothness, collimation and thinness of a graphite tape are
achieved when the primary air passes through the spreader in a
direction opposite to the direction of movement of the filaments
therethrough. In the spreading of a tow consisting of approximately
10,000 graphite filaments of a diameter in the region of 0.0003
inch, to make a tape 3 inches in width, and 0.001 inch in
thickness, the following structural dimensions and air pressures
have yielded very good results. In this apparatus, the tape should
be withdrawn from the spreader at a rate from about 25 to about 60
feet per minute.
In a system which proved to be very satisfactory certain
dimensions, as well as the input air pressures, are applicable to
both the preblower spreader and the final spreader modules. In
modules of both types the length of the modules was approximately
16 inches, the tow exit orifices were 3 inches wide (FIGS. 3A and
3B), although widths as small as 1/2 inch are useable depending on
the desired tape width. Air pressures between 20 and 100 psi,
measured at 1/4 inch diameter air inlet orifices, were found
satisfactory. The air pressure is adjusted by the operator until
proper spreading is achieved, which depends primarily upon the
degree of initial tangle in the tow, the desired spread width, and
to some degree upon the humidity. The main interior plates, which
extend substantially throughout, the length of modules of each
type, were about 151/2 inches in length typically 1/8 inch thick,
and were spaced from the top and bottom module walls to provide
plenum chambers 1/2 inch high, as those chambers are viewed in
FIGS. 4A and 4B. The spacing between confronting surfaces of these
plates was 7/8 inch, and in each type of module the slot of the
venturi throat was a 1/8 inch gap, presented between partially
cylindrical segments having a radius of about 31/2 inches and which
segments make contact with the plates through a distance equal to
31/4 inches.
In the preblower module (FIGS. 3A and 4A) the most restricted
section of the slot-like throat was spaced 95/8 inches from the end
of the module at which the tow is inletted, and the inlet block was
5/16 inch thick, leaving a 9/32 inch airspace between each side of
said block and the confronting surface of the main plate which
cooperates to form the plenum. The tow passage through the inlet
block was 0.230 inch in diameter, and the block extended into the
module 5 inches toward the venturi. The main interior plates were
spaced 1/2 inch from the end wall of the module, at the tow inlet
end.
In the final spreader module (FIGS. 3B and 4B) the restricted
venturi throat was spaced 95/8 inches from the tow outlet end of
the module. The plates which form the exit opening of the final
spreader were 1/4 inch in thickness, spaced apart 1/8 inch, and
they extended from the outlet end 5 inches toward the venturi. The
gap for air flow between each of these latter plates, and the
confronting plates which cooperate with the module wall structure
to define the plenum, was equal to 1/8 inch. The main interior
plates were spaced 1/2 inch from the end wall of the module at the
tow outlet end.
* * * * *