Support element for a feed roller and advancement member for a fiber material, carbonization line to produce carbon fibers and method for adjusting inclination of the feed roller

Abstract

A support element for a feed roller for a fibre material, preferably a precursor fibre, to be used in an oxidation or carbonization line for producing carbon fibres, including a base provided with means for attachment to a structure or frame of the oven, a support ring coupled with the base and having at least one passing-through opening for receiving one end of the feed roller, and adjustment means operatively interposed between the base and the ring, and configured to move the position of the ring with respect to the base along at least one adjustment direction, transverse to a central axis of the opening, in order to adjust the position of the ring as a function of the deformations of the roller.

Claims

1. A carbonization line for production of carbon fibers, comprising: a plurality of advancement members arranged in succession along a main direction of development of the carbonization line; a heating system interposed between two successive advancement members of the plurality of advancement members, wherein each of the two successive advancement members comprises: a support structure including at least one chosen from an upright and a cross member; a feed roller extending along an axial direction of extension, substantially horizontal, between first and second ends; first and second support elements rotatably associated with the first and second ends, respectively, wherein each of the first and second support elements comprises: a base attached to the at least one chosen from the upright and the cross member; a support ring coupled with the base and including a passing-through opening for receiving one of the first and second ends; an adjustment device operatively interposed between the base and the support ring, and configured to move a position of the support ring with respect to the base along at least one adjustment direction, transverse to a central axis of the opening, to adjust the position of the support ring as a function of deformations of at least one chosen from the feed roller, the structure and a support frame of the feed roller.

2. The carbonization line according to claim 1, wherein the adjustment device includes first and second adjustment devices configured to move the position of the support ring with respect to the base along a first adjustment direction and a second adjustment direction, substantially orthogonal to each other and both transverse to the central axis of the opening, to adjust the position of the support ring in a plane parallel to a direction of advancement of the fiber material.

3. The carbonization line according to claim 2, and further comprising a carrier connected to the support ring and slidably associated with the base to move, with respect to the base, along the first adjustment direction.

4. The carbonization line according to claim 3, wherein the support ring is slidably constrained to the carrier to move, with respect to the carrier, along the second adjustment direction.

5. The carbonization line according to claim 4, wherein the first adjustment device is operatively interposed between the base and the carrier, while the second adjustment device is operatively interposed between the carrier and the support ring.

6. The carbonization line according to claim 1, wherein the adjustment device is accessible by at least one chosen from mechanically and electronically from outside of the support element to allow an in line adjustment of the position of the support ring.

7. The carbonization line according to claim 1, wherein the adjustment device includes a screw extending respectively along the respective adjustment direction and rotatably coupled, respectively, with at least one chosen from the base and the support ring.

8. The carbonization line according to claim 1, wherein the adjustment device includes a locking body configured to constrain the position of the support ring with respect to the base.

9. The carbonization line according to claim 1, and further comprising a ball joint inserted in the opening, coupled with the one of the first and second ends, and configured to vary angle as a function of the deformation or inclination of the feed roller.

10. The carbonization line according to claim 1, and further comprising a protection septum constrained to the support ring, above the opening, and projecting from the support ring along the central axis to protect the one of the first and second ends and prevent windings of material fibers.

11. The carbonization line according to claim 10, wherein the protection septum comprises one at least partly tubular portion wound around the opening and projecting from the support ring along the central axis.

12. The carbonization line according to claim 1, and further comprising a plurality of the feed rollers arranged in columns with each other, othcr and a corresponding plurality of support elements.

13. The carbonization line according to claim 12, wherein at least two of the plurality of feed rollers are motorized.

14. A method for adjusting inclination of a feed roller for a fiber material, comprising providing: a base attached to at least one chosen from a structure and a frame of the carbonization line; a support ring coupled with the base and including a passing-through opening for receiving and supporting one end of the feed roller; an adjustment device operatively interposed between the base and the support ring, and configured to move a position of the support ring with respect to the base along at least one adjustment direction, transverse to a central axis of the opening, to adjust the position of the support ring as a function of deformations of at least one chosen from the feed roller, the structure and a support frame of the feed roller; actuating the feed roller to allow advancement of the fiber material; monitoring the inclination of the feed roller when a temperature changes; actuating the adjustment device for varying the position of the support ring during the advancement of the fiber material.

Description

(1) These and further features and advantages will become more apparent from the following exemplary, and therefore not limiting, description of a preferred, and therefore not exclusive, embodiment of a support element for a feed roller, a advancement member for a fibre material, and an oxidation or carbonization line to produce carbon fibres, as illustrated in the accompanying figures, in which:

(2) FIGS. 1a, 1b, 1c show schematic side views of a plant for the production of carbon fibre comprising an oxidation line, a carbonization line, and a plurality of finishing stations comprising a plurality of advancement members according to the present invention;

(3) FIGS. 2a and 2b show two alternative embodiments of an advancement member for a fibre material according to the present invention;

(4) FIG. 3 shows a perspective view of a feed roller supported by two support elements according to the present invention;

(5) FIG. 4 shows a detail of a feed roller supported by a support element according to the present invention, with some parts removed in order to highlight others;

(6) FIGS. 5-7 show perspective side views in longitudinal section of the support element according to the present invention, in a first embodiment;

(7) FIG. 8 shows a side view of the support element according to the present invention, in a second embodiment.

(8) With reference to the attached figures, the number 1 indicates a support element for a feed roller 106, 114 of a fibre material F in an oxidation or carbonization line according to the present invention.

(9) The oxidation or carbonization line is part of a plant for the production of carbon fibre, or a system comprising a first line, i.e. the oxidation line, and a second line, subsequent to the first, i.e. the carbonization line.

(10) The oxidation line comprises one or more ovens 100, 104 (or stations), each provided with a plurality of advancement members 102 for the fibre material F (precursor) and heating means 103 configured to obtain a predetermined temperature between these advancement members 102. More precisely, each furnace 100, 104 has a plurality of stations.

(11) Each advancement member 102, 113 thus includes a support structure 101 (or frame) having a pair of uprights 101a or a cross member 101b, which are rotatably coupled to feed rollers 106, 114.

(12) More precisely, each furnace or station of the oxidation line 100 comprises at least one pair of feed elements 102 facing each other and each comprising a plurality of feed rollers 106 arranged in cascade, preferably along a substantially vertical direction; note that each roller 106 of a advancement member 102 is functionally associated with a corresponding roller of the following member 102, defining both the returns for the fibre material F, which determine the reverse movement towards a next roller 106.

(13) Therefore, each furnace or station is configured for moving the fibre material F in continuous sections of forward and return travel, so as to retain the material inside the oven in continuous feeding, in which the number of sections depends on the number of rollers 106.

(14) In some embodiments, the rollers 106 of the member are totally or partially motorized, to allow a correct traction of the material and to determine a feeding at a controlled speed.

(15) Note that the oxidation furnace 100 does not has seals, as the heating, at increasing temperature in the various stations, is performed in the air.

(16) Note that, in a first embodiment (FIG. 2a), called compression embodiment, each oven 100 has two feed elements 102 facing and spaced apart from each other, wherein the distance between the central axes of the rollers 106 of an member and the central axes of the corresponding rollers 106 of the other member is greater than the distance between each upright of an member 102 and the corresponding upright of the other.

(17) Alternatively, in a second embodiment (FIG. 2b), called traction embodiment, the distance between the central axes of the rollers 106 of an member and the central axes of the corresponding rollers 106 of the other member is less than the distance between each upright of an member 102 and the corresponding upright of the other.

(18) Advantageously, this second embodiment allows to obtain a better operability of the line, since it ensures the lateral access to the fibre material F, which is difficult for the presence of the uprights (or in any case of the support structure) with the first option.

(19) On the contrary, the carbonization furnace 104 is a sealingly structure, because the desired reaction cannot take place in an oxygen-containing atmosphere (typically used gases are nitrogen or argon)

(20) More precisely, the carbonization furnace can comprise one or more furnaces 104a arranged in series.

(21) In the illustrated embodiment, for example, the carbonization furnace 104 includes three furnaces 104a arranged in succession and operating at respective operative temperatures, in which each temperature of a furnace is greater compared to the previous.

(22) Between each furnace and the next one at least one advancement member 113 is arranged, comprising a plurality of feed rollers defining a feeding and tensioning path of the fibre F.

(23) In particular, each advancement member 113 of the carbonization furnace 104 determines the release portion of the fibre F, which is directly associated with the input portion 104a of the same in the furnace (that is very important given the limited size of the access mouth of the furnace itself).

(24) Downstream of the carbonization furnace 104, the line preferably includes a plurality of finishing stations 107, which may vary in type, number and/or specifications depending on the type of fibre treated.

(25) The finishing stations 107 may include a surface treatment station 108 and/or a tank for electrolytic (or galvanic) treatment in which the fibre is dipped.

(26) In this station a plurality of rollers 106 are provided, in particular at least one input roller 106 and one release roller.

(27) Moreover, such finishing stations 107 may include a washing station 109, which is also provided with at least a tank 109a and, from a structural point of view, preferably similar to the surface treatment station 108. In this station, the bath contained in the tank 109a allows the removal of the electrolyte paired in the previous phase.

(28) Another finishing station 107 preferably arranged along the line is the contact drying station 110.

(29) This station 110 has also many feed rollers, some of which are heated, while others have a merely transport function.

(30) In the illustrated embodiments, the line also includes a sizing station 111 or for coupling a resin, again provided with a tank 111a and one more feed rollers of the fibre material.

(31) Following the sizing station 111, the line preferably comprises (in particular the finishing stations 107 comprise) a drying station 112, in which at least four rollers 106, two by two, so that the fibre travels on a square wave path having a significant height (>5 m), in which it is invested by a flow of hot air. Therefore, the (contactless) drying station 112 comprises convective heating means 112a.

(32) Note that, on such large lengths, the positioning of the rollers (upper or, preferably, lower rollers) is critical for the tensioning of the fibre F.

(33) Note that each of the feed rollers 106, 114, in all the lines, ovens and stations described above is rotatably connected to the respective frame 101 (upright 101a or cross member 101b) by means of a pair of support elements 1 each associated with one end 106a of the roller 106.

(34) Each support element 1 has a base 2 provided with means 2a for attachment to the structure or frame 101 of the furnace 100, preferably with an upright 101a or cross member of the advancement member 102, 113.

(35) The connecting means 2a are preferably passing-through holes (threaded or not threaded) able to be faced to respective seats made in the upright 101a or cross member 101b of the advancement member 102, 113, and fastened to them by means of threaded fasteners or other types of connection, preferably reversible.

(36) In addition, the element 1 comprises a support ring 3 coupled with the base 2 and having at least one passing-through opening 4 for receiving one end 106a of said feed roller 106, 114.

(37) Therefore, the opening 4 extends along a central axis A that is substantially parallel (at least in the undeformed stage) to an extending axis of the feed roller 106, 114.

(38) Preferably, the support element 1 comprises a bearing 5 inserted into the opening 4 and coupled with the end 106a of the roller 106, 114.

(39) Note that the bearing 5 includes an outer tubular body 5a (defining at least in part the ring 3) and an inner rotatable body 5b, which can be coupled (coupled in use) to the end 106a of the roller 106, 114 and freely rotatably in the outer tubular body 5a.

(40) The rotatable body 5b thus has a coupleable cavity, for an axial insertion, with the respective ends 106a of the feed roller 106, 114. Therefore, the rotatable body 5b is keyed on the end 106a of the roller 106, 114.

(41) In certain embodiments, the bearing 5 comprises (or is defined by) a ball joint configured to vary its angle, i.e. the position of the inner rotatable body 5b with respect to the outer tubular body 5a as a function of the deformation or inclination of the roller 106, 114.

(42) Advantageously, in this way the roller 106, 114 can rotate freely and without the creation of internal tensions, even in case of deformations, which lead to mate it with the support element 1 (in particular with the ring 3) in a not perfectly orthogonal way.

(43) According to a first aspect of the present invention, the support element comprises adjustment means 6, 7 operatively interposed between the base 2 and the ring 3.

(44) Therefore, the base 2 and the ring 3 are two separate bodies that are removably connected to each other, in other words connected so as to be able to vary their relative position to one another.

(45) Therefore, preferably, the support element 1 comprises at least one carrier 8 connected to the ring 3 and slidably associated with the base 2 to move, with respect to it, along said adjustment direction B, C.

(46) The base 2 thus has a guide 2a (in the form of a groove or a rail) slidingly constrained to the carrier 8 to allow its movement along the adjustment direction B, C.

(47) The adjustment means 6, 7 are configured to precisely move the position of the ring 3 with respect to the base 2 along at least one adjustment direction B, C, transverse to the central axis A of the opening 4, in order to adjust the position of the ring 3 as a function of the deformation of the roller 106, 114.

(48) More precisely, therefore, the adjustment means 6, 7 are operatively interposed at least between the base 2 and the carrier 8.

(49) Note that these adjustment means 6, 7 are accessible mechanically and/or electronically from the outside of the element 1 in order to allow an in line adjustment of the position of the ring 3.

(50) Advantageously, due to the subdivision of the element 1 in at least two distinct portions, which are removably connected to each other, and the action of the adjustment means 6, 7, the operator can evaluate the position and the orientation of the roller 106, 114, being able to act directly on the support element 1 to adjust it without interrupting the advancement of the fibre material F.

(51) This is clearly significantly advantageous, both in terms of time (one day for the adjustment of the line against at least one week with the prior art systems) and in terms of wasted material (due to the ability to act directly in line).

(52) Therefore, in this way the operator can simply and quickly optimize the position of the roller 106, 114.

(53) In the oxidation furnace 100 (FIG. 1a), such a specific configuration of the elements 1 thus allows to adapt the height of the support point of the roller both as a function of the thermal deformation (of the roller 106 itself or of the structure 101) and of the imperfections in supporting the structure, which can be therefore perfectly managed.

(54) In the carbonization furnaces (FIG. 1b), the support elements 1 according to the present invention are particularly useful at the end roller 114 of the advancement member 113, which faces the furnace 104a.

(55) Advantageously, in fact, the presence of a support element 1 that allows the vertical movement (along a single direction is sufficient) of the roller 114 allows a precise adjustment of the fibre material in the input portion 104a in the furnace.

(56) However, similar considerations can be made for all finishing stations 107, in which the ability to adjust the bearing/roller position allows to compensate for deformations due to machining, misalignment due to non-planarity of the support plane or of the support structure (in particular, in the case it is not machined), or to vary the tension of the material as a function of the type of material and processing.

(57) In this respect, it is noted that in FIG. 8 is illustrated an embodiment of such support element 1, preferably integrated in a frame 101 and provided with said vertical adjustment means 6.

(58) Moreover, thanks to the support element 1 according to the present invention, it is only necessary to start the line (thus actuating the roller 106, 114) to allow the advancement of the fibre material F, monitoring the inclination of the roller 106, 114 to vary the temperature (for example, viewing the transverse movement of the fibre) and actuating the adjustment means 6, 7 for varying the position of the support 1, all during the advancement of said fibre material F and without stopping the plant.

(59) Preferably, in the embodiments shown in greater detail, the support element 1 comprises first 6 and second 7 adjustment means configured to move the position of the ring 3 with respect to the base 2 along at least a first B and a second adjustment direction C, substantially orthogonal to each other and both transverse (preferably orthogonal) to the central axis A of the opening 4, in order to adjust the position of the ring 3 in all the plane parallel to the direction of advancement of the fibre material F.

(60) This is particularly advantageous in the oxidation furnace, in which the adjustment of the position of the rollers 106 may be required on at least two axes.

(61) Preferably, therefore, the carrier 8 is slidably associated with the base 2 to move, with respect to it, along the first direction of adjustment B and the ring 3, in turn, is slidingly coupled to the carrier 8 to move, with respect to it, along the second direction of adjustment C.

(62) Therefore, the first adjustment means 6 are operatively interposed between the base 2 and the carrier 8, while the second adjustment means 7 are operatively interposed between said carrier 8 and the ring 3.

(63) Preferably, the adjustment means 6, 7 are of the screw type.

(64) More precisely, the adjustment means (first 6 and/or second 7 means) comprise at least a screw 6a, 7a extending along the respective first B or second direction of adjustment C and rotatably coupled (by means of a threaded coupling), respectively, with the base 2 and/or the ring 3.

(65) The screw 6a, 7a is also pivotally coupled to the carrier 8.

(66) In the illustrated embodiment, the adjustment means 6, 7 are operated manually; preferably, each screw 6a, 7a is integrally coupled with an actuation nut 6b, 7b, selectively usable by the operator for rotating the screw 6a, 7a (and therefore for moving the ring 3).

(67) Alternatively, however, solutions in which the adjustment means are automated and/or of other nature (e.g., electric motors, linear actuators, spiral pairs, rack and pinion, or other types of known or unknown connections) are also comprised in the spirit of the present invention.

(68) Preferably, moreover, the adjustment means 6, 7 are provided with at least one locking member 6c, 7c configured to constrain the position of the ring 3 with respect to the base 2, once identified, by the operator, as the optimal one.

(69) In the illustrated embodiment, the locking member 6c, 7c is a lock-nut rotatably coupled with the screw 6a, 7a, which can be abutted against said ring 3 or said carrier 8 or said base 2 to fix the obtained position along the respective direction of adjustment B, C by maneuvering the screw 6a, 7a.

(70) Alternatively, in order to avoid a weak locking by the operator, in certain embodiments the locking of the position obtained along the adjustment direction B, C is achieved by designing, in a suitable manner, the coupling between the screw 6a, 7a and the bodies concerned (base 2, carrier 8, ring 3).

(71) More precisely, a little sliding, coarse thread is used, so that (given the acting loads), once the position is obtained, the same cannot be modified, except in the case of an appropriate and voluntary action by the operator.

(72) According to a further aspect of the present invention, the support element comprises a protection septum 9 firmly constrained to the ring 3, above said opening 4 (at least in the condition of use) and projecting from the same along said central axis A.

(73) Advantageously, in this way the end 106a of the roller 106, 114 rotatably coupled to the ring 3 is protected by a fix element (septum 9), on which any material F that were to move laterally towards the end 106a itself could move the windings of the fibre material at the end itself.

(74) Advantageously, in this way a current problem comprising considerable delays in the production and, sometimes, extensive damage to the structure is solved in a simple manner.

(75) Preferably, the protection septum 9 comprises a tubular portion 10 at least partially wound around said opening 4 and projecting from the ring 3 along said central axis A.

(76) In the illustrated embodiment, the portion 10 is completely tubular in shape, coaxial to the opening 4, and completely surrounds the end 106a of the roller 106, 114.

(77) The invention achieves the intended objects and provides important advantages.

(78) In fact, the use of support elements divided into more parts removably connected to one another and whose relative position is adjustable in a substantially direct manner allows to overcome many drawbacks of the prior art, enabling the optimization of the setting step of the line from many points of view.

(79) Furthermore, the preparation of a septum that protect and insulate the end portion of the (rotating) roller from the (translating) fibre material, prevents the windings thereof around the roller from creating blocks and damage to the structure.