KR20250068396A - Method and apparatus of manufacturing separator fabric - Google Patents

Abstract

A device for manufacturing a membrane fabric is disclosed. The device for manufacturing a membrane fabric may include: an extruder which heats and melts a material, supplies oil, mixes the oil with a molten resin, and discharges the molten resin mixed with the oil; a casting roller which rotates to spread the molten resin discharged from the extruder into a membrane sheet; a washing device configured to remove oil remaining on a surface of the membrane sheet moved from the casting roller; a plurality of first stretching rollers which rotate at different speeds and stretch the membrane sheet from which oil has been removed in a first direction; and a plurality of second stretching rollers which stretch the membrane sheet stretched in the first direction in a second direction perpendicular to the first direction.
A method for manufacturing a membrane fabric using a membrane fabric manufacturing device is further disclosed.

Description

METHOD AND APPARATUS OF MANUFACTURING SEPARATOR FABRIC

The present invention relates to a method and device for manufacturing a membrane fabric, and more specifically, to a method and device for manufacturing a membrane fabric capable of manufacturing a membrane fabric stretched to a desired stretching ratio by washing oil mixed in a resin to form pores inside a membrane before stretching a membrane sheet.

The sequential stretching method and the simultaneous stretching method are mainly used as wet separation membrane stretching methods. The sequential stretching method is a method in which the extruded sheet is stretched in the machine direction (MD) and the transverse direction (TD) perpendicular to the machine direction. In contrast, the simultaneous stretching method is a method in which the extruded sheet is stretched in the machine direction and the transverse direction simultaneously in one stretching machine.

MD stretching of the sequential stretching method is a stretching process in which the length of the extruded sheet increases in MD and the thickness decreases due to the difference in rotational speed between the stretching rollers as the extruded sheet passes through the heated stretching rollers. However, during extrusion, the oil contained in the sheet may not generate sufficient friction between the stretching rollers and the sheet, causing the sheet to slip. If the sheet slips, it is difficult to obtain the desired stretching ratio and product defects may occur. Therefore, it is necessary to minimize slippage between the stretching rollers and the separator sheet during MD stretching.

The information contained in this background section has been prepared to promote understanding of the background of the invention and may include matters that are not prior art and are already known to those skilled in the art.

An embodiment of the present invention provides a method and device for manufacturing a membrane fabric capable of manufacturing a membrane fabric stretched to a desired stretching ratio by washing oil remaining on the surface of a membrane sheet before stretching the membrane sheet.

A method for manufacturing a membrane fabric according to an embodiment of the present invention may include a material extrusion step of melting a material, mixing oil into the molten resin, and discharging the molten resin mixed with the oil as a membrane sheet; a washing step of removing oil remaining on the surface of the membrane sheet; a first stretching step of stretching the membrane sheet from which the oil has been removed in a first direction; and a second stretching step of stretching the membrane sheet in a second direction perpendicular to the first direction.

The above washing step can be performed by spraying the washing solution onto the separator sheet through at least one washing solution spray nozzle while transporting the separator sheet using at least one transport roller.

The at least one cleaning solution spray nozzle can spray the cleaning solution onto the membrane sheet passing over the at least one conveying roller.

At least one cleaning solution spray nozzle can spray cleaning solution on both sides of the membrane sheet.

The cleaning solution sprayed onto the above membrane sheet can be dried by hot air blown by at least one hot air nozzle.

The washing liquid remaining on the membrane sheet can be dried by at least one heating roller that transports and heats the membrane sheet.

According to another embodiment of the present invention, a device for manufacturing a membrane fabric may include: an extruder which heats and melts a material, supplies oil, mixes the oil into a molten resin, and discharges the molten resin mixed with the oil; a casting roller which rotates to spread the molten resin discharged from the extruder into a membrane sheet; a washing device configured to remove oil remaining on a surface of the membrane sheet moved from the casting roller; a plurality of first stretching rollers which rotate at different speeds and stretch the membrane sheet from which oil has been removed in a first direction; and a plurality of second stretching rollers which stretch the membrane sheet stretched in the first direction in a second direction perpendicular to the first direction.

The washing device may include at least one conveying roller for conveying the membrane sheet conveyed from the casting roller toward the first elongation roller; at least one washing liquid spraying nozzle configured to spray a washing liquid onto the membrane sheet conveyed by the at least one conveying roller; and at least one hot air nozzle configured to blow hot air onto the conveyed membrane sheet to dry the washing liquid sprayed onto the membrane sheet.

The above washing device may further include at least one heating roller for heating and drying the washing liquid remaining on the separator sheet.

In some embodiments, one cleaning solution spray nozzle is provided corresponding to one conveying roller, and each cleaning solution spray nozzle can spray the cleaning solution onto a membrane sheet passing over a corresponding conveying roller.

In other aspects, at least two spray nozzles and at least two conveying rollers are provided, one spray nozzle can spray the cleaning solution on one side of the separator sheet, and the other spray nozzle can spray the cleaning solution on the other side of the separator sheet.

The above washing device may be provided within a case, and a washing liquid discharge portion for discharging washing liquid may be provided on the bottom surface of the case, and an exhaust portion for discharging evaporated washing liquid may be provided on the top surface of the case.

According to the present invention, oil remaining on the surface of the membrane sheet can be washed away before stretching the membrane sheet, thereby manufacturing a membrane fabric stretched to a desired stretching ratio. Accordingly, the amount ratio can be reduced when manufacturing the membrane fabric.

In addition, the effects that can be obtained or expected by the embodiments of the present invention will be directly or implicitly disclosed in the detailed description of the embodiments of the present invention. That is, the various effects expected according to the embodiments of the present invention will be disclosed in the detailed description to be described later.

Embodiments of the present disclosure may be better understood by reference to the following description taken in conjunction with the accompanying drawings in which like reference numerals designate identical or functionally similar elements.
Figure 1 is a schematic diagram illustrating a membrane manufacturing device according to an embodiment of the present invention.
Figure 2 is a schematic diagram illustrating a cleaning device according to an embodiment of the present invention.
It should be understood that the drawings referenced above are not necessarily drawn to scale, but rather present rather simplified representations of various preferred features that illustrate the underlying principles of the present disclosure. For example, the specific design features of the present disclosure, including specific dimensions, orientations, locations, and shapes, will be determined in part by the particular intended application and usage environment.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present invention. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any one or all combinations of the associated listed items.

Additionally, it is understood that one or more of the methods or aspects thereof below may be executed by at least one controller. The term "controller" may refer to a hardware device including a memory and a processor. The memory is configured to store program instructions, and the processor is specifically programmed to execute the program instructions to perform one or more processes described in more detail below. The controller may control the operation of units, modules, components, devices, or the like, as described herein. It is also understood that the methods below may be executed by a device including the controller in conjunction with one or more other components, as will be appreciated by those skilled in the art.

Additionally, the controller of the present disclosure may be implemented as a non-transitory computer-readable storage medium containing executable program instructions that are executed by the processor. Examples of computer-readable storage media include, but are not limited to, ROM, RAM, compact disc (CD) ROM, magnetic tapes, floppy disks, flash drives, smart cards, and optical data storage devices. The computer-readable storage medium may also be distributed throughout a computer network so that the program instructions are stored and executed in a distributed manner, such as on a telematics server or a Controller Area Network (CAN).

According to the present invention, a method for manufacturing a membrane fabric includes an extrusion step of mixing oil into a molten resin and extruding the mixture into a membrane sheet; a washing step of removing oil remaining on the surface of the membrane sheet; a first stretching step of stretching the membrane sheet from which the oil has been removed in a first direction; and a second stretching step of stretching the membrane sheet in a second direction perpendicular to the first direction. By performing the washing step before the first stretching step of stretching the membrane sheet for the first time, the oil remaining in the membrane sheet can be removed. Accordingly, the phenomenon of the membrane sheet slipping from the stretching roller is minimized, and thereby a desired stretching ratio of the membrane sheet can be obtained. In addition, by securing the desired stretching ratio, the defect rate of the membrane fabric can be reduced.

The above washing step is performed by spraying the washing solution onto the membrane sheet through the washing solution spray nozzle while the membrane sheet is being transported using the transport roller. The washing solution spray nozzle can spray the washing solution onto the membrane sheet passing over the transport roller. That is, by spraying the washing solution onto the membrane sheet supported by the transport roller, the influence of the washing solution on the mobility of the membrane sheet can be minimized.

The cleaning solution sprayed onto the membrane sheet is first dried by hot air blown by the hot air nozzle, and then dried a second time by the heating roller. Therefore, the possibility of workers being exposed to harmful cleaning solutions is reduced.

Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings.

FIG. 1 is a schematic diagram illustrating a membrane manufacturing device according to an embodiment of the present invention, and FIG. 2 is a schematic diagram illustrating a washing device according to an embodiment of the present invention.

As illustrated in FIG. 1, a membrane manufacturing device according to an embodiment of the present invention includes an extruder (10), a die (20), a casting roller (30), a plurality of first elongation rollers (40), and a plurality of second elongation rollers (50).

An extruder (10) heats a material to melt it into resin, mixes oil into the resin, and discharges the molten resin mixed with the oil through a die (20). More specifically, a hopper is provided on one side of the extruder (10) to receive oil for forming pores in the material of the membrane fabric and/or the membrane sheet, and a heating screw may be rotatably mounted inside the extruder (10) to heat and melt the material supplied through the hopper into resin, mix oil into the molten resin, and transport the resin in the longitudinal direction. The material may be polyethylene (PE) or polypropylene (PP), and the oil may be liquid paraffin (LP), but is not limited thereto. The resin melted in the extruder (10) and mixed with oil flows to the die (20).

The above die (20) receives molten resin mixed with oil from the extruder (10) and pours the molten resin onto a casting roller (30). The discharge port of the die (20) is formed in the shape of a long slit to discharge the molten resin at a set width.

The casting roller (30) above rotates around an axis. Accordingly, the molten resin (32) discharged from the die (20) at a constant flow rate is spread into a thin thickness on the surface of the rotating casting roller (30), and thereby the molten resin (32) is manufactured into a separation membrane sheet (34) having a thin thickness and a set width. The separation membrane sheet (34) is transferred to a washing device.

The washing device can remove oil remaining on the surface of the separation membrane sheet (34) by transporting the separation membrane sheet (34) transferred from the casting roller (30) generally in the process direction (e.g., the first direction). As shown in FIG. 2, the washing device can include a case (60), at least one transport roller (61) arranged in the case (60), at least one washing liquid spray nozzle (62, 66), at least one hot air nozzle (68, 70), and at least one heating roller (72).

The case (60) surrounds at least one conveying roller (61), at least one cleaning solution spray nozzle (62, 66), at least one hot air nozzle (68, 70), and at least one heating roller (72), and the interior of the case (60) can be generally sealed or managed to have a negative pressure so that the cleaning solution (64) harmful to the human body does not leak outside the cleaning device. A cleaning solution discharge port (74) is provided on the bottom surface of the case (60), so that the cleaning solution (64) that has fallen on the bottom surface of the case (60) can flow out of the case (60) through the cleaning solution discharge port (74) and flow into a device for treating the cleaning solution. In addition, an exhaust port (76) is provided on the top surface of the case (60), so that the cleaning solution (64) evaporated in the cleaning device can flow into a device for treating the evaporated cleaning solution (64) located outside the case (60) through the exhaust port (76).

At least one transport roller (61) is positioned upstream in the process direction and transports the membrane sheet (34) transported from the casting roller (30) generally downstream in the process direction. In one example, at least two transport rollers (61) are spaced apart from each other and may be positioned on opposite sides with respect to the membrane sheet (34). That is, the first transport roller (61) may contact one surface of the membrane sheet (34), while the second transport roller (61) may contact the other surface of the membrane sheet (34). However, the number of transport rollers (61) is not limited to two.

At least one cleaning solution spray nozzle (62, 66) sprays cleaning solution (64) onto a membrane sheet (34) conveyed by at least one transport roller (61) to wash away oil remaining on the surface of the membrane sheet (34). At least one cleaning solution spray nozzle (62, 66) sprays cleaning solution (64) onto a membrane sheet (34) passing by at least one transport roller (61). That is, the cleaning solution spray nozzle (62, 64) sprays cleaning solution (64) onto the opposite surface of one surface of the membrane sheet (34) that is supported by contacting the corresponding transport roller (61).

The number of detergent spray nozzles (62, 66) may be equal to or smaller than the number of transport rollers (61), and one detergent spray nozzle (62) is arranged corresponding to one transport roller (61), and the other detergent spray nozzle (66) is arranged corresponding to the other transport roller (61).

In one example, at least two cleaning solution spray nozzles (62, 66) may be spaced apart from each other. When two cleaning solution spray nozzles (62, 66) are used, the first cleaning solution spray nozzle (62) is positioned to face the first transport roller (61) contacting one surface of the separator sheet (34) and sprays the cleaning solution (64) onto the other surface of the separator sheet (34), and the second cleaning solution spray nozzle (66) is positioned to face the second transport roller (61) contacting the other surface of the separator sheet (34) and sprays the cleaning solution (64) onto one surface of the separator sheet (34). Accordingly, the cleaning solution (64) may be sprayed onto both surfaces of the separator sheet (34). However, the number of cleaning solution spray nozzles (62, 66) is not limited to two.

At least one hot air nozzle (68, 70) is positioned downstream of at least one cleaning solution spray nozzle (62, 66) in the process direction and is configured to blow hot air onto the transported membrane sheet (34) to dry the cleaning solution sprayed onto the membrane sheet (34). That is, the cleaning solution spray nozzle (62, 66) is positioned to face the transport roller (61), and the hot air nozzle (68, 70) is positioned downstream of the transport roller (61) and the cleaning solution spray nozzle (62, 66). In one example, at least two hot air nozzles (68, 70) may be positioned spaced apart from each other. If two hot air nozzles (68, 70) are used, the first hot air nozzle (68) blows hot air to the other side of the membrane sheet (64) that is coated with the cleaning liquid (64) by the first cleaning liquid spray nozzle (62) downstream of the first cleaning liquid spray nozzle (62), and the second hot air nozzle (70) blows hot air to one side of the membrane sheet (64) that is coated with the cleaning liquid (64) by the second cleaning liquid spray nozzle (66) downstream of the second cleaning liquid spray nozzle (66). However, the number of hot air nozzles (68, 70) is not limited to two.

At least one heating roller (72) is positioned downstream of at least one hot air nozzle (68, 70) in the process direction to transport and heat the membrane sheet (34) in the process direction. Accordingly, the washing liquid (64) remaining on the membrane sheet (34) is heated and dried. The number of the heating rollers (72) is not particularly limited, and may be a sufficient number to remove most of the washing liquid (64) from the membrane sheet (34).

Referring again to FIG. 1, a plurality of first elongation rollers (40) are arranged downstream of the cleaning device in the process direction (e.g., the first direction). The plurality of first elongation rollers (40) rotate at different speeds and are heated to elongate the membrane sheet (34) in the first direction, thereby reducing the thickness of the membrane sheet (34).

A plurality of second elongation rollers (50) are arranged downstream of the plurality of first elongation rollers (40) in the process direction and configured to elongate the membrane sheet (34) in a second direction perpendicular to the first direction. In one example, the plurality of second elongation rollers (50) may include a pair of second elongation rollers (50) and at least one second elongation roller (50) arranged downstream and spaced apart from the pair of second elongation rollers (50) in the process direction. The pair of second elongation rollers (50) face each other and press the membrane sheet (34) therebetween, and at least one second elongation roller (50) may pull the membrane sheet (34) so that the membrane sheet (34) is elongated in the second direction. However, the configuration of the plurality of second elongation rollers (50) is not limited to the configuration exemplified herein.

A method for manufacturing a membrane fabric using a membrane fabric manufacturing device according to an embodiment of the present invention is described in detail.

As illustrated in FIG. 1, in the material extrusion step (S100), the material is supplied to the extruder (10), the material is melted within the extruder (10), and oil is mixed with the melted resin. The material may be polyethylene (PE) or polypropylene (PP), and the oil may be liquid paraffin (LP), but is not limited thereto. The resin melted in the extruder (10) and mixed with the oil flows to the die (20), and the melted resin (32) is discharged from the die (20) to the casting roller (30), and the melted resin (32) is spread on the surface of the rotating casting roller (30) to be manufactured into a membrane sheet (34).

In the washing step (S110), at least one transport roller (61) transports the membrane sheet (34), and at least one cleaning solution spray nozzle (62, 66) facing at least one transport roller (61) sprays cleaning solution (64) onto the membrane sheet (34) passing over the at least one transport roller (61) to wash away oil remaining on the surface of the membrane sheet (34). For example, the first cleaning solution spray nozzle (62) is arranged to face the first transport roller (61) contacting one surface of the membrane sheet (34) and sprays the cleaning solution (64) onto the other surface of the membrane sheet (34), and the second cleaning solution spray nozzle (66) is arranged to face the second transport roller (61) contacting the other surface of the membrane sheet (34) and sprays the cleaning solution (64) onto one surface of the membrane sheet (34). Accordingly, the cleaning solution (64) can be sprayed on both sides of the separator sheet (34).

In the above washing step (S110), at least one hot air nozzle (68, 70) is positioned downstream of at least one washing liquid spray nozzle (62, 66) in the process direction and blows hot air onto the transported membrane sheet (34) to dry the washing liquid sprayed onto the membrane sheet (34). For example, the first hot air nozzle (68) blows hot air onto the other surface of the membrane sheet (64) on which the washing liquid (64) has been applied by the first washing liquid spray nozzle (62) downstream of the first washing liquid spray nozzle (62), and the second hot air nozzle (70) blows hot air onto one surface of the membrane sheet (64) on which the washing liquid (64) has been applied by the second washing liquid spray nozzle (66) downstream of the second washing liquid spray nozzle (66).

In the above washing step (S110), at least one heating roller (72) is positioned downstream of at least one hot air nozzle (68, 70) in the process direction to transport and heat the membrane sheet (34) in the process direction. Accordingly, the washing liquid (64) remaining on the membrane sheet (34) is heated and dried.

In the first stretching step (S120), a plurality of first stretching rollers (40) rotate at different speeds and are heated to stretch the membrane sheet (34) in the first direction. In the washing step (S110) before the first stretching step (S120), oil remaining in the membrane sheet (34) is removed by the washing liquid (64), and since the washing liquid (64) is removed by the hot air nozzle (68, 70) and the heating roller (72), the phenomenon of the membrane sheet (34) slipping from the first stretching roller (40) is reduced. Accordingly, a desired stretching ratio can be obtained, and the defect rate is reduced.

In the second stretching step (S130), a plurality of second stretching rollers (50) stretch the separation membrane sheet (34) stretched in the first direction in a second direction perpendicular to the first direction.

Afterwards, the membrane sheet (34) is manufactured into a membrane fabric through a subsequent processing process.

Although preferred embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and includes all changes that can be easily modified and deemed equivalent by a person having ordinary skill in the art to which the present invention pertains from the embodiments of the present invention.

10: Extruder 20: Die
30: Casting roller 32: Molten resin
34: Separator sheet 40: First extension roller
50: 2nd extension roller 60: Case
61: Transfer roller 62, 66: 1st and 2nd washing liquid spray nozzle
64: Cleaning fluid 68, 70: 1st and 2nd hot air nozzles
72: Heating roller 74: Washing liquid discharge part
76: Exhaust

Claims (12)

A material extrusion step of melting a material, mixing oil into the molten resin, and discharging the molten resin mixed with the oil as a membrane sheet;
A washing step to remove oil remaining on the surface of the membrane sheet;
A first stretching step for stretching the oil-removed membrane sheet in a first direction; and
A second stretching step of stretching the above-mentioned membrane sheet in a second direction perpendicular to the first direction;
A method for manufacturing a membrane fabric comprising: In the first paragraph,
A method for manufacturing a membrane fabric, wherein the above washing step is performed by spraying a washing solution onto the membrane sheet through at least one washing solution spray nozzle while transporting the membrane sheet using at least one transport roller. In the second paragraph,
A method for manufacturing a membrane fabric, wherein at least one of the above-mentioned cleaning solution spray nozzles sprays a cleaning solution onto a membrane sheet passing over at least one conveying roller. In the second paragraph,
A method for manufacturing a membrane fabric, wherein at least one cleaning solution spray nozzle sprays a cleaning solution on both sides of a membrane sheet. In the second paragraph,
A method for manufacturing a membrane fabric, wherein the cleaning solution sprayed on the membrane sheet is dried by hot air blown by at least one hot air nozzle. In the second or fifth paragraph,
A method for manufacturing a membrane fabric, wherein the washing liquid remaining on the membrane sheet is dried by at least one heating roller that transports and heats the membrane sheet. An extruder that heats and melts a material, supplies oil, mixes the oil with the molten resin, and discharges the molten resin mixed with the oil;
A casting roller that rotates to spread the molten resin discharged from the extruder into a membrane sheet;
A washing device configured to remove oil remaining on the surface of a separator sheet moved from the casting roller;
A plurality of first elongation rollers that rotate at different speeds and elongate the oil-removed membrane sheet in a first direction; and
A plurality of second stretching rollers for stretching the membrane sheet stretched in the first direction in a second direction perpendicular to the first direction;
A device for manufacturing a membrane fabric including: In Article 7,
The above washing device
At least one transport roller for transporting the membrane sheet transported from the casting roller toward the first elongation roller;
At least one cleaning solution spray nozzle configured to spray a cleaning solution onto a membrane sheet conveyed by at least one conveying roller; and
At least one hot air nozzle configured to blow hot air onto the transported membrane sheet to dry the cleaning solution sprayed onto the membrane sheet;
A device for manufacturing a membrane fabric including: In Article 8,
A device for manufacturing a membrane fabric, wherein the washing device further includes at least one heating roller for heating and drying the washing liquid remaining on the membrane sheet. In clause 8 or 9,
One cleaning solution spray nozzle is provided corresponding to one transport roller,
A device for manufacturing a membrane fabric, wherein each cleaning solution spray nozzle sprays a cleaning solution onto a membrane sheet passing over a corresponding conveying roller. In Article 10,
At least two spray nozzles and at least two transport rollers are provided,
A device for manufacturing a membrane fabric, wherein one spray nozzle sprays a cleaning solution onto one side of a membrane sheet, and another spray nozzle sprays a cleaning solution onto the other side of the membrane sheet. In clause 8 or 9,
The above washing device is provided within the case,
A device for manufacturing a membrane fabric, wherein a cleaning solution discharge portion for discharging a cleaning solution is provided on the bottom surface of the case, and an exhaust portion for discharging evaporated cleaning solution is provided on the top surface of the case.

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