Apparatus and method for manufacturing resin-impreganated cured sheet, and apparatus and method for manufacturing carbonaceous material sheet

Abstract

An object of the present invention is to provide an apparatus and a method for manufacturing a windable carbonaceous material sheet, which is obtained by continuously curing a long uncured fiber sheet which is obtained by using short fibers to make paper and which contains uncured resin to produce a resin-impregnated cured sheet, and then continuously carbonizing it, and its production process. For the object, a long uncured fiber sheet ( 1 a ) is conveyed by conveyance means which is equipped with one rotation belt set ( 2 ) comprising a drive roll ( 2 a ), a follower roll ( 2 b ), and an endless belt ( 2 c ) which is put on and around these rolls ( 2 a , 2 b ). A resin-impregnated cured sheet ( 1 b ) is produced by heating and pressurizing the uncured fiber sheet ( 1 a ) by resin curing means ( 3 ) which is arranged so as to nip the uncured fiber sheet through the endless belt ( 2 c ). Further, the resin-impregnated cured sheet is continuously conveyed in a horizontal direction, and then is carbonized by the apparatus for manufacturing a carbonaceous material sheet which is equipped with a carbonization treatment chamber for carbonizing a carbonizing material and guide rolls which are provided in the carbonization treatment chamber, so that a carbonaceous material sheet is continuously produced. Then, this is wound up. Accordingly, production efficiency is remarkably improved, and its handling property and conveying property are excellent.

1 . 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 the uncured 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 roll, and an endless belt which is put one and around the drive roll and follower roll.    
     
     
         2 . An apparatus for manufacturing a resin-impregnated cured sheet according to  claim 1 , further comprising 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.  
     
     
         3 . An apparatus for manufacturing a resin-impregnated cured sheet according to  claim 1  or  2 , wherein the conveyance means is equipped with at 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.  
     
     
         4 . An apparatus for manufacturing a resin-impregnated cured sheet according to any one of  claims 1  to  3 , wherein the resin curing means includes a pair of the heating and pressuring rolls which are arranged so as to nip the uncured fiber sheet through the endless belt.  
     
     
         5 . An apparatus for manufacturing a resin-impregnated cured sheet according to any one of  claims 1  to  3 , 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.  
     
     
         6 . An apparatus for manufacturing a resin- impregnated cured sheet according to any one of  claims 1  to  5 , wherein the resin curing means is equipped with at least a preheating section and a heating and pressuring section.  
     
     
         7 . A method for manufacturing a resin-impregnated cured sheet using the apparatus for manufacturing the resin-impregnated cured sheet according to any one of  claims 1  to  5 , characterized by including steps of continuously producing a long cured fiber sheet by curing the uncured resin of the long uncured fiber sheet and winding up the long cured fiber sheet.  
     
     
         8 . A method for manufacturing a resin-impregnated cured sheet according to  claim 7 , wherein the fiber-made sheet which is obtained by using short fibers to make paper contains a carbon short fiber and an organic polymer-based binder.  
     
     
         9 . An apparatus for manufacturing a carbonaceous material sheet by carbonizing a resin-impregnated cured sheet 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 being characterized by comprising a carbonization treatment chamber for carbonizing the resin-impregnated cured sheet while continuously transferring the resin-impregnated cured sheet in a horizontal direction, and guide rolls which are arranged in the carbonization treatment chamber.  
     
     
         10 . An apparatus for manufacturing a carbonaceous material sheet according to  claim 9 , further comprising a winding device in which a trimming cutter for trimming both side edges of the carbonaceous material sheet, a press roll for retaining a winding face pressure, and a winding shaft are arranged in order along a running path of the carbonaceous material sheet.  
     
     
         11 . A method for manufacturing a carbonaceous material sheet, characterized by including steps of: continuously producing a long resin-impregnated cured sheet by curing uncured resin of a 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 uncured 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 roll, 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 using the carbonization apparatus according to  claim 10 , and then winding up the carbonaceous material sheet.  
     
     
         12 . A method for manufacturing a carbonaceous material sheet according to  claim 11 , wherein the fiber-made sheet which is obtained by using short fibers to make paper contains a carbon short fiber and an organic polymer-based binder.  
     
     
         13 . A method for manufacturing a carbonaceous material sheet according to  claim 11  or  12 , wherein an average diameter of the carbon short fiber is less than 5 μm.  
     
     
         14 . A method for manufacturing a carbonaceous material sheet according to any one of  claims 11  to  13 , wherein a carbonization yield of the organic polymer-based binder is 40% by weight or less.  
     
     
         15 . A method for manufacturing a carbonaceous material sheet according to any one of  claims 11  to  14 , wherein the resin-impregnated cured sheet is produced by preliminarily heating the fiber sheet which is impregnated with the uncured resin and then heating and pressuring it.  
     
     
         16 . A method for manufacturing a carbonaceous material sheet according to  claim 15 , wherein a temperature at the heating and pressurizing is higher than a preheating temperature by 5° C. or more.