RECYCLED CARBON FIBER NONWOVEN FABRIC MANUFACTURING SYSTEM INCLUDING CHUTE CARDING MACHINE

Abstract

Disclosed is a chute carding machine used in a recycled carbon fiber nonwoven fabric manufacturing system, wherein the chute carding machine includes a main chamber oriented in a vertical direction and having an inner space formed therein, a mixed raw material introduction unit is installed at the uppermost part of an inner space of the main chamber, a first carding unit is installed under the mixed raw material introduction unit, a second carding unit is installed under the first carding unit, and a web shaping unit is installed under the second carding unit.

Claims

1. A recycled carbon fiber nonwoven fabric manufacturing system is configured such that: a resin, which becomes a raw material for regenerated carbon fiber nonwoven fabric, is weighed and fed into a first weighing hopper, and the resin fed into the first weighing hopper is primarily scutched in the first weighing hopper; recycled carbon fiber (RCF), which is mixed with the resin and becomes the raw material for the recycled carbon fiber nonwoven fabric, is weighed and fed into a second weighing hopper, and the recycled carbon fiber (RCF) fed into the second weighing hopper is also primarily scotched in the second weighing hopper; the resin and the recycled carbon fiber (RCF) that have passed through the first weighing hopper and the second weighing hopper, respectively, are fed into and mixed by a scutcher such that the resin and the recycled carbon fiber (RCF) are mixed into a mixed raw material, and the mixed raw material is secondarily scutched by the scutcher; the mixed raw material secondarily scutched by the scutcher is transferred to a door opener so as to be opened; the mixed raw material opened by the door opener is transferred to a mixing tank so as to be further mixed therein; the mixed raw material mixed in the mixing tank is transferred to a chute carding machine so as to be further processed thereby; the mixed raw material transferred to the chute carding machine is carded into a web by a carding means disposed in an upper part of a main chamber of the chute carding machine; the web is dropped to a web shaping unit disposed vertically under the carding means and laminated thereon into an initial nonwoven fabric, which is a web laminate; the initial nonwoven fabric, which is the web laminate, is transferred into an upper punching machine, and is processed by the upper punching machine, which punches the initial nonwoven fabric up and down a plurality of times; the initial nonwoven fabric processed by the upper punching machine is transferred into a lower punching machine, and is processed by the lower punching machine, which punches the initial nonwoven fabric up and down a plurality of times, whereby nonwoven fabric is manufactured; the chute carding machine comprises an introduction chamber to which a mixed raw material feeding pipe is connected so as to communicate therewith; a mixed raw material storage unit configured to temporarily store the mixed raw material is formed in the introducing chamber; a mixed raw material transfer regulator is installed in a lower part of the mixed raw material storage unit, and a weight sensor configured to sense a weight of the mixed raw material passing through the mixed raw material transfer regulator is installed in the mixed raw material transfer regulator; the carding means comprises a first carding unit; the first carding unit comprises: a pair of first feed rollers configured to rotate in opposite directions; and a pair of first carding rollers installed vertically under the pair of first feed rollers; one end of a first die spring is coupled to a bracket coupled to one of the pair of first carding rollers to support the first carding rollers; the other end of the first die spring is coupled to a mixed raw material transfer duct, and the mixed raw material transfer duct is coupled to the main chamber; the pair of first feed rollers and the pair of first carding rollers are operated by power from a first feed carding roller motor; the pair of first feed rollers has the same diameter; the pair of first carding rollers has the same diameter; and the web shaping unit comprises: a mesh net rotating motor; an endless mesh net configured to be circularly moved by rotational force of the mesh net rotating motor; a part of the mesh net that is circularly moved having a horizontal surface; a drafter roller configured to rotate about a roller rotation axis at a fixed position in contact with an upper surface of the web laminate laminated on the horizontal surface of the mesh net; and a blowing intake passage formed continuously along a bottom of the horizontal surface of the mesh net, wherein air in the blowing intake passage is discharged out of the blowing intake passage by a blower connected to the blowing intake passage so as to communicate therewith, thereby negatively pressurizing the bottom of the mesh net such that the web laminate laminated on the horizontal surface of the mesh net is adsorbed on an upper surface of the mesh net.

2. The recycled carbon fiber nonwoven fabric manufacturing system according to claim 1, wherein a roller rotating shaft is formed on left and right axial centers of the drafter roller so as to protrude therefrom; the roller rotating shaft is rotatably coupled to a roller support bar; a support hole configured to support the roller rotating shaft is formed in one end of the roller support bar; a plurality of height adjustment holes is formed in the other end of the roller support bar; and a bolt is inserted into a specific one of the height adjustment holes of the roller support bar such that the roller support bar can be fastened to a support frame, whereby a height of the drafter roller is adjusted.

3. The recycled carbon fiber nonwoven fabric manufacturing system according to claim 2, wherein a motor is installed on a motor installation frame outside the mixed raw material feeding pipe so as to shake the mixed raw material feeding pipe; a cam configured to convert a rotating motion of the motor into a shaking motion is installed on a rotating shaft of the motor; a through-shaft is installed through the mixed raw material feeding pipe; a first fixing bolt is fastened to one end of the through-shaft; a second fixing bolt is fastened to the other end of the through-shaft; and the through-shaft protruding outwardly of the first fixing bolt and the cam are connected to each other via a connecting bar.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0167] FIG. 1 shows machines used in respective recycled carbon fiber nonwoven fabric manufacturing processes of a first embodiment of the present invention, arranged in process order;

[0168] FIG. 2 is a sectional view of the main part of a weighing hopper of the present invention;

[0169] FIG. 3 is a sectional view of the main part of a scutcher of the present invention;

[0170] FIG. 4 is a sectional view of the main part of a door opener of the present invention;

[0171] FIG. 5 is a sectional view of the main part of a mixing tank of the present invention;

[0172] FIG. 6 is a sectional view of the main part of a carding machine of a first embodiment of the present invention;

[0173] FIG. 7 is an enlarged sectional view of a part of a feeding tank of the carding machine of the first embodiment of the present invention;

[0174] FIG. 8 is a sectional view of the main part of a horizontal shaping machine of a first embodiment of the present invention;

[0175] FIG. 9A is a sectional view conceptually showing the main part of an upper punching machine of a first embodiment of the present invention;

[0176] FIG. 9B shows the detailed structure of a needle of the present invention;

[0177] FIG. 10 is a sectional view conceptually showing the main part of a lower punching machine of a first embodiment of the present invention;

[0178] FIG. 11 is a sectional view of the main part of a winder of the present invention;

[0179] FIG. 12 shows RCF used as a raw material of the present invention;

[0180] FIG. 13 shows a resin used as the raw material of the present invention;

[0181] FIG. 14 shows machines used in respective recycled carbon fiber nonwoven fabric manufacturing processes of a second embodiment of the present invention, arranged in process order;

[0182] FIG. 15 is a side sectional view showing the main internal structure of a chute carding machine applied to the second embodiment of the present invention;

[0183] FIG. 16 is a front sectional view showing the main internal structure of the chute carding machine applied to the second embodiment of the present invention;

[0184] FIG. 17 is an enlarged view of a first carding unit of the chute carding machine shown in FIG. 15;

[0185] FIG. 18 is an enlarged view of a raw material inlet pipe of the chute carding machine shown in FIG. 15 and related configurations;

[0186] FIG. 19 is an enlarged view of a mesh net and a drafter roller of the chute carding machine shown in FIG. 15 and related configurations;

[0187] FIG. 20 is a sectional view of an upper punching machine applicable to the second embodiment of the present invention;

[0188] FIG. 21 is a sectional view of a lower punching machine applicable to the second embodiment of the present invention; and

[0189] FIG. 22 is a side sectional view showing the main internal structure of a second carding unit applied to a second embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0190] A first embodiment of the present invention will be described first.

[0191] Recycled carbon fiber nonwoven fabric of the present invention is manufactured by mixing recycled carbon fiber (hereinafter referred to as RCF) and a resin.

[0192] In the present invention, polypropylene (hereinafter referred to as PP) or polyethylene (hereinafter referred to as PE) is mainly used as the resin, but other types of resins may also be used.

[0193] The RCF and the resin, which are raw materials for the recycled carbon fiber nonwoven fabric of the present invention, are compressed in the form of fiber lumps and transported to a manufacturing plant, as shown in FIGS. 12 and 13.

[0194] That is, the RCF and the resin in the form of fiber that have been compressed and transported are agglomerated in the form of fiber lumps.

[0195] Meanwhile, as used in the present invention, terms such as scutching, opening, web, carding, and mixed raw material may be defined as follows.

[0196] Scutching refers to that a compressed fiber-like resin or RCF that has been compressed and transported in a shipping box, etc. is torn and inflated by a scutching roller to remove any contaminants therefrom and cleanly inflate the same.

[0197] Opening refers to stretching a mixed raw material that has been subjected to scutching by breaking through the agglomerated fibers in the mixed raw material while removing debris and unwound fiber lumps.

[0198] In the present invention, the mixed raw material is opened by scutching, and is web-carded by opening.

[0199] A web refers to a small piece of thin fiberboard organized into a fiber network, formed by releasing the mixed raw material, including carbon fiber and resin, which has been subjected to scutching and opening, using a carding machine of the present invention, and the web may be laminated in a horizontal shaping machine to become initial nonwoven fabric, which is preliminary nonwoven fabric.

[0200] Meanwhile, carding refers to a process in which the mixed raw material is transferred to a carding machine 5 or a chute carding machine 50 and the mixed raw material is processed and manufactured into a web by the carding machine or the chute carding machine 50.

[0201] In the present invention, the resin and the RCF which have undergone a first process are fed into and mixed by scutcher 2 to become a mixed raw material in which the resin and the RCF are mixed.

[0202] The mixed raw material described in the specification of the present invention refers to a mixed raw material in which the resin and the RCF are mixed.

[0203] In addition, since it is possible to manufacture 100% recycled carbon fiber nonwoven fabric using only the RCF without the resin in the present invention, a sole raw material may be used in a system of the present invention instead of the mixed raw material.

[0204] In the present invention, a method of manufacturing nonwoven fabric using recycled carbon fiber includes the following processes.

[0205] The first embodiment of the present invention will be described with reference to FIGS. 1 to 13.

[0206] RCF and a resin, which are raw materials for recycled carbon fiber nonwoven fabric of the present invention, are compressed in a storage container and transported to a manufacturing plant.

[0207] The RCF and the resin in the form of fiber that have been compressed and transported are agglomerated to form a lump, and the RCF and the resin are processed by various machines described below.

[0208] FIG. 1 shows machines used in respective recycled carbon fiber nonwoven fabric manufacturing processes of a first embodiment of the present invention, arranged in process order, and FIGS. 2 to 11 show the main structures of the machines used in the respective processes. The present invention will be described with reference thereto.

[0209] Specifically, a recycled carbon fiber nonwoven fabric manufacturing method of the present invention will be described with reference to FIG. 1.

[0210] As shown in FIG. 1, raw materials (a resin and RCF) of the recycled carbon fiber nonwoven fabric of the present invention are processed while being sequentially transferred to a weighing hopper 1, a scutcher 2, a door opener 3, a mixing tank 4, a carding machine 5, a horizontal shaping machine 6, and punching machines 7 and 8 to manufacture recycled carbon fiber nonwoven fabric, and the recycled carbon fiber nonwoven fabric may be wound and packaged by a winder 9.

[0211] Specifically, the recycled carbon fiber nonwoven fabric manufacturing method of the present invention may include: [0212] a first process in which a resin and RCF, which are raw materials for recycled carbon fiber nonwoven fabric, are weighed by a weighing hopper 1 and are each weighed and primarily scutched by the weighing hopper 1; [0213] a second process in which the resin and the RCF that have undergone the first process are fed into and mixed by a scutcher 2 to become a mixed raw material in which the resin and the RCF are mixed and the mixed raw material is secondarily scutched by the scutcher 2; [0214] a third process in which the mixed raw material that has undergone the second process is transferred to a door opener 3 and the mixed raw material is opened by the door opener; and [0215] a fourth process in which the mixed raw material that has undergone the third process is transferred to a mixing tank 4 by blowing force and mixed in the mixing tank.

[0216] The recycled carbon fiber nonwoven fabric manufacturing method of the present invention may further include a fifth process in which the mixed raw material that has undergone the fourth process is transferred to a carding machine 5 and is carded by the carding machine 5 in the form of a web.

[0217] The recycled carbon fiber nonwoven fabric manufacturing method of the present invention may further include a sixth process in which the web manufactured in the fifth process is transferred to a horizontal shaping machine 6, and the web is distributed and laminated on an upper surface of a horizontal shaping conveyor 6-CNB of the horizontal shaping machine to manufacture initial nonwoven fabric on the horizontal shaping conveyor 6-CNB.

[0218] The recycled carbon fiber nonwoven fabric manufacturing method of the present invention may further include a seventh process in which: [0219] the initial nonwoven fabric laminated on the horizontal shaping conveyor 6-CNB in the sixth process is transferred to an upper punching machine 7; and [0220] the initial nonwoven fabric is vertically punched in a direction from an upper surface to a lower surface thereof using a plurality of needles 7-ND formed on a punching plate 7-PL of the upper punching machine 7 such that laminates of the initial nonwoven fabric formed and laminated by the web are mutually coupled to each other to manufacture nonwoven fabric.

[0221] The recycled carbon fiber nonwoven fabric manufacturing method of the present invention may further include an eighth process in which: [0222] the nonwoven fabric manufactured in the seventh process is transferred to a lower punching machine 8; and [0223] the nonwoven fabric is vertically punched in a direction from a lower surface to an upper surface thereof a plurality of times using a plurality of needles 8-ND coupled to a punching plate 8-PL of the lower punching machine 8 such that laminates of the nonwoven fabric formed and laminated by the web are further mutually coupled to each other to manufacture nonwoven fabric.

[0224] The eighth process performed by the lower punching machine 8 may be omitted.

[0225] That is, the nonwoven fabric manufactured in the seventh process performed by the upper punching machine 7 may be immediately transferred to a winder 9, in which the nonwoven fabric may be wound around a paper tube, packaged, and shipped as a product.

[0226] Meanwhile, the recycled carbon fiber nonwoven fabric manufacturing method of the present invention may further include a ninth process in which the nonwoven fabric that has undergone the eighth process is transferred and wound on the paper tube installed in the winder.

[0227] As shown in FIGS. 9A and 9B, the upper punching machine 7 is provided with a needle guide plate 7-GDP configured to guide repetitive up-and-down reciprocating motion of the plurality of needles 7-ND.

[0228] The needle guide plate 7-GDP is a rectangular plate, in which through-holes are vertically formed in number corresponding to the number of the needles such that each of the plurality of needles 7-ND can pass through a corresponding one of the through-holes.

[0229] The needle guide plate 7-GDP serves to guide the needles 7-ND such that the needles can penetrate the initial nonwoven fabric without shaking during the punching process of the needle guide plate.

[0230] That is, upon punching of the punching plate 7-PL of the upper punching machine 7, each of the plurality of needles 7-ND passes through a corresponding one of the plurality of through-holes formed in the needle guide plate 7-GDP, vertically penetrates the initial nonwoven fabric, and the carbon fiber present in a lower part of the initial nonwoven fabric is hooked by needle arrowheads 7-NDPC formed on the lower ends of the needles 7-ND and pulled up to the uppermost end of the initial nonwoven fabric, thereby coupling upper and lower layers of the initial nonwoven fabric.

[0231] Each of the needle arrowheads 7-NDPC is formed in a V-shape such that the carbon fiber is caught by the needle arrowheads 7-NDPC, wherein the carbon fiber may be caught by the needle arrowheads when the needles 7-ND move upward, and the carbon fiber may be released from the needle arrowheads 7-NDPC when the needles 7-ND move downward.

[0232] Meanwhile, 8,000 to 12,000 needles 7-ND may be formed on one punching plate 7-PL of the upper punching machine 7.

[0233] The lower punching machine 8, which will be described below, is identical in conceptual structure, basic principle of punching, and effect to the upper punching machine 7 except that punching directions thereof are different from each other.

[0234] Meanwhile, a needle support plate 7-NPL is provided under the needle guide plate 7-GDP of the upper punching machine 7 so as to be spaced apart from the needle guide plate by a certain distance.

[0235] The needle support plate 7-NPL is a rectangular plate, in an upper surface of which a plurality of needle insertion holes 7-NHO is vertically formed such that each of ends of the plurality of needles 7-ND can be inserted into a corresponding one of the needle insertion holes.

[0236] Upon downward punching of the punching plate 7-PL of the upper punching machine 7, each of the ends of the plurality of needles 7-ND may be inserted into a corresponding one of the plurality of needle insertion holes 7-NHO.

[0237] The needles 7-ND, the plurality of vertical through-holes formed in the needle guide plate 7-GDP, and the needle insertion holes 7-NHO are formed so as to correspond to each other, and therefore the numbers of the three configurations are equal.

[0238] The weighing hopper 1 shown in FIGS. 1 and 2 may include a first weighing hopper 1-1 configured to allow a resin to be fed thereinto and a second weighing hopper 1-2 configured to allow RCF to be fed thereinto such that the resin and the RCF can be fed into the respective weighing hoppers.

[0239] That is, the weight of the resin to be fed into the weighing hopper may be adjusted by measuring the weight of the resin fed into the first weighing hopper 1-1.

[0240] In addition, the weight of the RCF to be fed into the weighing hopper may be adjusted by measuring the weight of the RCF fed into the second weighing hopper 1-2.

[0241] The RCF may be mixed so as to account for 30 wt % to 70 wt % based on the total weight % of the resin and the RCF.

[0242] Meanwhile, as shown in FIGS. 12 and 13, the resin, which is the raw material for the renewable carbon fiber nonwoven fabric of the present invention, is agglomerated into fiber lumps, and the RCF is also agglomerated into fiber lumps.

[0243] As shown in FIGS. 1 and 2, the first weighing hopper 1-1 is provided with a first conveyor 1-1CV having a first inclined surface that increases in altitude in the direction of progress of the resin lumps fed into the weighing hopper and a second conveyor 1-2CV on which the resin lumps that have passed through the first conveyor are loaded so as to be transferred to the scutcher.

[0244] The second conveyor 1-2CV also has a second inclined surface that increases in altitude in the direction of the progress of the resin lumps.

[0245] The inclination angle 2 of the second inclined surface with respect to a horizontal plane is 2 to 2.5 times the inclination angle 1 of the first inclined surface with respect to the horizontal plane, wherein the inclination angle 1 of the first inclined surface with respect to the horizontal plane may be set to 17 to 22.

[0246] The inclination angle 2 of the second inclined surface with respect to the horizontal plane may be set to 34 to 55.

[0247] When the inclination angles are set as described above, transfer and scotching of the RCF and the resin may be the most efficiently performed.

[0248] As described above, the inclination angles must be set such that the altitude of each of the first inclined surface and the second inclined surface gradually increases to ensure that the resin lumps or the RCF lumps are not transferred all at once and an appropriate amount of the resin lumps or the RCF lumps to be efficiently scotched can be transferred.

[0249] The reason that the inclination angle 2 of the second inclined surface with respect to the horizontal plane is set to 2 to 2.5 times the inclination angle 1 of the first inclined surface with respect to the horizontal plane, as described above, is that it is necessary to prevent the resin lumps or the RCF lumps from being transferred to a raw material scutching roller 1-TR installed adjacent to an upper part of the second conveyor 1-2CV all at once due to gravity, thereby preventing inefficiency of scutching.

[0250] Meanwhile, the second weighing hopper 1-2 is provided with a first conveyor 1-1CV having a first inclined surface that increases in altitude in the direction of progress of the RCF lumps fed into the weighing hopper and a second conveyor 1-2CV on which the RCF lumps that have passed through the first conveyor are loaded so as to be transferred to the scutcher.

[0251] The second conveyor 1-2CV also has a second inclined surface that increases in altitude in the direction of progress of the RCF lumps.

[0252] The inclination angle 2 of the second inclined surface with respect to the horizontal plane is 2 to 2.5 times the inclination angle 1 of the first inclined surface with respect to the horizontal plane, wherein the inclination angle 1 of the first inclined surface with respect to the horizontal plane may be set to 17 to 22.

[0253] A plurality of spikes is installed on an upper surface of each of the first conveyor and the second conveyor such that the resin lumps or the RCF lumps can be transferred in a state of being caught by the spikes.

[0254] The reason that the inclination angle 1 of the first inclined surface of the first conveyor 1-1CV with respect to the horizontal surface is less than the inclination angle 2 of the second inclined surface with respect to the horizontal surface is that the resin lumps or the RCF lumps are transferred on the first inclined surface of the first conveyor 1-1CV while scutching of the resin lumps or the RCF lumps is not performed. Even if the inclination angle 1 is less than the inclination angle 2, therefore, work efficiency is not reduced.

[0255] However, the inclination angle 1 of the first inclined surface with respect to the horizontal plane must be set as described above in order to prevent the resin lumps or the RCF lumps being transferred all at once, thereby improving the work efficiency.

[0256] As described above, the weighing hopper 1 is constituted by the first weighing hopper 1-1 into which the resin is fed and the second weighing hopper 1-2 into which the RCF is fed.

[0257] However, the first weighing hopper 1-1 and the second weighing hopper 1-2 are identical in internal structure and operation to each other except that only the raw material (the resin) fed into the first weighing hopper 1-1 and the raw material (the RCF) fed into the second weighing hopper 1-2 are different from each other.

[0258] Meanwhile, although the first weighing hopper 1-1 into which the resin is fed and a second weighing hopper 1-2 into which the RCF is fed are separately provided in the present invention, no resin may be fed into the first weighing hopper 1-1 when manufacturing nonwoven fabric using only 100% carbon fiber without mixing the resin.

[0259] As shown in FIG. 2, a weight sensor 1-1SN is installed at an outlet of the first conveyor 1-1CV to adjust the weight of the resin lumps or the RCF lumps to be transferred.

[0260] In order to measure the weight of the resin lumps or the RCF lumps scotched and transferred on the second conveyor 1-2CV before transfer of the resin lumps or the RCF lumps to the scutcher 2, a load cell 1-1RDS is installed in an outlet passage 1-SPV of the weighing hopper, whereby only an appropriate amount of the resin or the RCF can be transferred to the scutcher 2.

[0261] As shown in FIG. 2, a raw material scutching roller 1-TR is installed at an upper end of the second conveyor 1-2CV so as to be adjacent to the second conveyor 1-2CV to scutch the resin or the RCF transferred by the second conveyor 1-2CV.

[0262] In addition, a raw material transfer roller 1-LR is installed at an inner upper part of the outlet passage 1-SPV of the weighing hopper so as to be adjacent to the second conveyor 1-2CV to transfer the resin or the RCF scutched on the second conveyor 1-2CV to the scutcher 2 through the outlet passage 1-SPV.

[0263] As shown in FIG. 3, a cylindrical roller 2-RR is installed in a casing of the scutcher 2, and a plurality of spikes 2-SPK is formed on a cylindrical outer circumference of the cylindrical roller 2-RR so as to protrude therefrom.

[0264] The cylindrical roller 2-RR is capable of rotating about the axial center of the cylinder, and the resin and the RCF transferred from the weighing hopper 1 may be mixed into a mixed raw material while colliding with the plurality of spikes 2-SPK on the cylindrical outer circumference of the cylindrical roller 2-RR or the cylindrical outer circumference, and scotching may be performed.

[0265] As described above, the resin and the RCF fed into the scutcher 2 are scutched while being rotated in a state of being caught by the rotating cylindrical roller and the plurality of spikes 2-SPK.

[0266] As shown in FIG. 4, a cylindrical worker having a plurality of teeth formed on a cylindrical surface is disposed in a casing of the door opener 3.

[0267] Five workers, e.g., a first worker 3-1WKR to a fifth worker 3-5WKR, are installed, wherein the cylindrical workers slide with each other in the state in which circumferential outer circumferences thereof are adjacent to each other.

[0268] The first worker 3-1WKR to the third worker 3-3WKR may be installed with the circumferential outer circumferences abutting each other.

[0269] The fourth worker 3-4WKR is installed vertically on the third worker 3-3WKR so as to abut the cylindrical outer circumference of the third worker 3-3WKR such that the fourth worker can apply downward force to the third worker 3-3WKR.

[0270] The fifth worker 3-5WKR is installed on the fourth worker 3-4WKR so as to abut the cylindrical outer circumference of the fourth worker.

[0271] The fifth worker 3-5WKR is installed such that the cylindrical outer circumference thereof abuts the casing of the door opener, and the fifth worker 3-5WKR may applying force to a side surface of an upper part of the fourth worker 3-4WKR.

[0272] The mixed raw material processed in the scutcher 2 may be transferred through a chute 3-STR of the door opener and may be loaded and transferred on a conveyor 3-KBR of the door opener.

[0273] The mixed raw material transferred by the conveyor 3-KBR of the door opener may be opened while passing between the cylindrical outer circumferences of the cylindrical outer circumference of the first worker 3-1WKR to the third worker 3-3WKR abutting each other, whereby opening of the mixed raw material may be very efficiently performed.

[0274] Meanwhile, a sensor 3-SNR is installed in the chute 3-STR of the door opener to block a chute passage when the mixed raw material accumulates in the chute.

[0275] As shown in FIG. 5, an inclined conveyor 4-CBR of the mixing tank 4 is installed in the casing of the mixing tank 4 so as to be inclined at a certain angle 3 from the horizontal plane, and a plurality of spikes 4-SPK is installed on an upper surface of the inclined conveyor 4-CBR.

[0276] A first vita roller 4-2IBT is installed at an upper end above the inclined conveyor 4-CBR to prevent agglomeration of the mixed raw material being transferred, and a second vita roller 4-2BT is installed at an upper exit end above the inclined conveyor 4-CBR to transfer the mixed raw material to the exit.

[0277] The inclination angle 3 of the inclined conveyor 4-CBR in the mixing tank with respect to the horizontal plane may be set to 55 and 70, in which case the mixed raw material can be mixed most efficiently.

[0278] Meanwhile, the mixed raw material processed by and transferred from the door opener 3 is loaded and transferred on a horizontal conveyor 4-CBH of the mixing tank and are transferred to and loaded on the inclined conveyor 4-CBR.

[0279] The inclined conveyor 4-CBR may be rotated continuously and repeatedly, and the mixed raw material loaded on the inclined conveyor 4-CBR may be re-mixed for a period of time until the mixed raw material is matured in the casing of the mixing tank while a vortex 4-SKW is generated on the inclined conveyor 4-CBR.

[0280] The carding machine of the present invention will be described in detail with reference to FIGS. 6 and 7.

[0281] The carding machine of the present invention is a carding apparatus for processing and webbing the mixed raw material fed into the carding machine while allowing the mixed raw material to pass through a roller and cylinder unit 300.

[0282] The carding machine of the present invention shown in FIGS. 6 and 7 is a carding machine specialized for installation in the recycled carbon fiber nonwoven fabric manufacturing system, and is also an apparatus specialized for producing recycled carbon fiber nonwoven fabric.

[0283] The carding machine 5 shown in FIG. 6 may include a base 100, a feeding tank unit 200, a roller and cylinder unit 300, a cover unit 400, and a conveyor unit 500.

[0284] The feeding tank unit 200 and installed on an upper surface of the base 100 so as to vertically protrude therefrom, and a casing of a feeding tank 200FT is plate-shaped.

[0285] The interior of the feeding tank 200FT is a hollow 200MS, and the hollow is plate-shaped.

[0286] The mixed raw material processed in the mixing tank 4 is transferred into the hollow 200MS of the feeding tank 200FT through a transfer passage formed in an upper part of the feeding tank unit 200 by blowing force.

[0287] The mixed raw material loaded into the feeding tank 200FT is transferred to a lower part of the feeding tank 200FT by blowing force applied from an upper part of the hollow 200MS of the feeding tank 200MS in a downward direction and by shaking of a pair of shaking panels 200SP installed in the feeding tank 200.

[0288] The mixed raw material is transferred to the roller and cylinder unit 300 of the carding machine, in which the mixed raw material may be processed into a web.

[0289] Since the hollow 200MS of the feeding tank 200FT is plate-shaped, as described above, the mixed raw material accumulated in the feeding tank is also accumulated in a plate shape, and the mixed raw material accumulated in the feeding tank is transferred to the lower part of the feeding tank by the blowing force applied from the upper part of the interior of the feeding tank in the downward direction by the shaking force of the shaking panels 200SP installed in the feeding tank and is moved to the roller and cylinder unit 300 for efficient processing.

[0290] As shown in FIG. 7, a motor 200M and a cam 200C are installed on an upper part of the feeding tank 200FT, one side of a connecting rod 200B is installed on a motor shaft 200MS of the motor 200M, and the other side of the connecting rod 200B is in contact with the cam 200C, whereby the rotational motion of the motor 200M is converted into a shaking motion, and as the motor 200M rotates, the pair of shaking panels 200SP connected to the cam 200C may be shaken.

[0291] The mixed raw material may be transferred to the lower part of the feeding tank 200FT by the blowing force applied from the upper part of the hollow 200MS of the feeding tank in the downward direction and by the shaking of the shaking panels 200SP installed in the feeding tank.

[0292] The web manufactured by the carding machine 5 is discharged while being divided into an upper web 6A-WEB that is discharged to an upper conveyor 500-UC of the carding machine and a lower web 6B-WEB that is discharged to a lower conveyor 500-BC of the carding machine.

[0293] This has the revolutionary effect of providing a plurality of discharge passages in the carding machine such that the discharge of the web is not delayed due to a bottleneck phenomenon.

[0294] The web manufactured by the carding machine, as described above, may be transferred and loaded in a bogie 6-CAR of the horizontal shaping machine 6 shown in FIG. 8.

[0295] The bogie 6-CAR is installed on a cable 6-RIL disposed above a horizontal shaping conveyor 6-CNB of the horizontal shaping machine 6.

[0296] The bogie 6-CAR installed on the cable 6-RIL is disposed in a space above the horizontal shaping conveyor 6-CNB so as to be spaced apart therefrom.

[0297] The interior of the bogie 6-CAR has a certain space, and a lower bottom of the space of the bogie is provided with a plurality of holes through which the web is downwardly dropped and discharged.

[0298] The bogie 6-CAR may repeatedly reciprocate in leftward and rightward directions to distribute and laminate the web on an upper surface of the horizontal shaping conveyor 6-CNB such that the initial nonwoven fabric can be manufactured on the horizontal shaping conveyor 6-CNB.

[0299] Meanwhile, as shown in FIG. 6, a pair of mixed raw material transfer rollers 200RR is installed at a lower outlet of the feeding tank 200FT of the carding machine of the present invention.

[0300] Each of the mixed raw material transfer rollers 200RR may have a plurality of teeth formed along a circumferential surface thereof, whereby the mixed raw material discharged from the lower part of the feeding tank may be easily discharged using the teeth.

[0301] The mixed raw material transferred by the mixed raw material conveying rollers 200RR is distributed by a licker-in roller 6-RKI rotating about the shaft center of the roller, and a certain amount of the mixed raw material may be transferred to a circumferential surface of a cylinder roller 6-SS rotating about the shaft center of the roller.

[0302] The mixed raw material transferred to the circumferential surface of the cylinder roller 6-SS, as described above, may be processed into a web while passing between the plurality of worker rollers 6-WRK, a strip bar roller 6-STB, and the cylinder roller 6-SS, each of which rotates about the shaft center of the roller.

[0303] The licker-in roller 6-RKI, the strip bar roller 6-STB, an upper doffer roller 6-DPA, a lower doffer roller 6-DPB, the plurality of worker rollers 6-WRK, the strip bar roller 6-STB, and the cylinder roller 6-SS are all cylindrical flat rollers and are not provided with protrusions or the like formed on the surfaces thereof.

[0304] The web processed while passing between the plurality of worker rollers 6-WRK, the strip bar roller 6-STB, and the cylinder roller 6-SS, which are installed in the carding machine of the present invention, as described above, is divided into an upper web 6A-WEB and a lower web 6A-WEB, which are discharged. This is one of the main technical features of the present invention.

[0305] That is, the web processed while passing between the worker rollers 6-WRK, the strip bar roller 6-STB, and the cylinder roller 6-SS is attracted to the upper doffer roller 6-DPA, and the upper web 6A-WEB is discharged along an upper part of the upper conveyor 500-UC.

[0306] On the other hand, the web processed while passing between the worker rollers 6-WRK, the strip bar roller 6-STB, and the cylinder roller 6-SS is attracted to the lower doffer roller 6-DPB, and the lower web 6B-WEB is discharged along an upper part of the lower conveyor 500-BC.

[0307] A cleaning roller 6-HAS is installed on the upper doffer roller 6-DPA so as to abut a circumference of the upper doffer roller 6-DPA, wherein the cleaning roller 6-HAS performs a function of cleaning the upper doffer roller.

[0308] Similarly, a cleaning roller is installed on the lower doffer roller 6-DPB so as to abut a circumference of the lower doffer roller 6-DPB, wherein the cleaning roller performs a function of cleaning the lower doffer roller.

[0309] A scrim ball roller 6-SCB is installed so as to abut a circumference of the upper doffer roller 6-DPA in a direction in which the web is discharged from the upper doffer roller 6-DPA, and another scrim ball roller 6-SCB is further installed so as to abut a circumference of the scrim ball roller 6-SCB in a direction in which the web is discharged.

[0310] The two scrim ball rollers 6-SCB perform a function of pulling the web discharged from the upper doffer roller 6-DPA such that the web comes out uniformly.

[0311] Meanwhile, two scrim ball rollers are installed for the lower doffer roller 6-DPB in the same structure as the scrim ball rollers installed for the upper doffer roller 6-DPA.

[0312] A cobbox 6-CBX is installed so as to abut an outer circumference of the scrim ball roller 6-SCB installed closest to the discharge passage from which the web is discharged.

[0313] The cobbox 6-CBX has a vibration means installed therein so as to vibrate, and transmits vibration force to the scrim ball roller to perform a function of brushing off the web attached to the outer circumference of the scrim ball roller.

[0314] In the present invention, as described above, the plurality of discharge passages is provided such that the web processed by the carding machine can be discharged efficiently, whereby the production capacity of nonwoven fabric per unit time may be increased.

[0315] That is, the present invention has the innovative effect that the discharge passage of the web manufactured by the carding machine is provided in plural, whereby the discharge of the web is not delayed by a bottleneck phenomenon.

[0316] The carding machine 5 of the present invention includes a base 100, a feeding tank unit 200, a roller and cylinder unit 300, and a conveyor unit 500.

[0317] The recycled carbon fiber nonwoven fabric of the present invention is defined as recycled carbon fiber nonwoven fabric manufactured using some steps or all steps of the manufacturing method described above.

[0318] Next, a second embodiment of the present invention will be described.

[0319] The present invention provides a recycled carbon fiber nonwoven fabric manufacturing system including a first weighing hopper, a second weighing hopper, a scutcher, a door opener, a mixing tank, a chute carding machine, an upper punching machine, and a lower punching machine.

[0320] Since the system according to the present invention is a system including an assembly of a plurality of unit apparatuses, such as a scutcher, as described above, the system according to the present invention is expressed as a recycled carbon fiber nonwoven fabric manufacturing system.

[0321] However, since all of the plurality of unit apparatuses of the present invention can also be regarded as a nonwoven fabric manufacturing apparatus, the present invention may also be expressed as a recycled carbon fiber nonwoven fabric manufacturing apparatus.

[0322] Accordingly, the recycled carbon fiber nonwoven fabric manufacturing system described in the following description of the present invention may be expressed or defined as a recycled carbon fiber nonwoven fabric manufacturing apparatus.

[0323] Consequently, the present invention relates to a recycled carbon fiber nonwoven fabric manufacturing apparatus including a first weighing hopper, a second weighing hopper, a scutcher, a door opener, a mixing tank, a chute carding machine, an upper punching machine, and a lower punching machine.

[0324] The second embodiment of the present invention is shown in FIGS. 14 to 22.

[0325] The overall configuration of the recycled carbon fiber nonwoven fabric manufacturing system of the second embodiment of the present invention is shown in FIG. 14.

[0326] As shown in FIG. 14, in the second embodiment of the present invention, only the chute carding machine 50 is installed instead of the carding machine 5 and the horizontal shaping machine 6 of the first embodiment of the present invention.

[0327] That is, if the carding machine 5 and the horizontal shaping machine 6 are excluded from the first embodiment of the present invention and the chute carding machine 50 is disposed in the place of the carding machine 5 and the horizontal shaping machine 6, the second embodiment of the present invention is configured.

[0328] Therefore, the second embodiment of the present invention will be described based on the chute carding machine 50.

[0329] Except for the chute carding machine, the other configurations constituting the second embodiment, namely, the weighing hopper 1, the scutcher 2, the door opener 3, the mixing tank 4, the upper punching machine 7, the lower punching machine 8, and the winder 9, are identical to those of the first embodiment.

[0330] Therefore, the detailed configurations of the weighing hopper 1, the scutcher 2, the door opener 3, the mixing tank 4, and the winder 9, which are also applied to the second embodiment, are the same as those of the first embodiment of the present invention, and therefore a description thereof will be omitted.

[0331] For the above configurations of the first embodiment and the second embodiment of the present invention that are identical, the configuration for the first embodiment described above may be applied to the second embodiment of the present invention.

[0332] However, in the following description of the second embodiment of the present invention, where the first embodiment is specifically changed or added, the configuration of the second embodiment may be different from that of the first embodiment.

[0333] The overall configuration of the recycled carbon fiber nonwoven fabric manufacturing system of the second embodiment of the present invention is shown in FIG. 14.

[0334] As shown in FIG. 14, the recycled carbon fiber nonwoven fabric manufacturing system of the second embodiment of the present invention is configured such that: a resin, which becomes a raw material for regenerated carbon fiber nonwoven fabric, is weighed and fed into a first weighing hopper 1-1, and the resin fed into the first weighing hopper 1-1 is primarily scutched in the first weighing hopper 1-1; and [0335] recycled carbon fiber (RCF), which is mixed with the resin and becomes the raw material for the recycled carbon fiber nonwoven fabric, is weighed and fed into a second weighing hopper 1-2, and the recycled carbon fiber (RCF) fed into the second weighing hopper 1-2 is also primarily scotched in the second weighing hopper 1-2.

[0336] Meanwhile, the resin may not be fed into the first weighing hopper 1-1, and only the recycled carbon fiber (RCF) may be fed into the second weighing hopper 1-2.

[0337] This is because, when manufacturing 100% recycled carbon fiber (RCF) nonwoven fabrics, it is not necessary to feed the resin.

[0338] Therefore, the raw material processed by the recycled carbon fiber nonwoven fabric manufacturing system may be a mixed raw material or a sole raw material, but in the following description of the invention, the term mixed raw material will be generally used, and when it is necessary to refer to the sole raw material, the term sole raw material will be used.

[0339] The resin and the recycled carbon fiber (RCF) that have passed through the first weighing hopper 1-1 and the second weighing hopper 1-2, respectively, are fed into and mixed by a scutcher 2 such that the resin and the recycled carbon fiber (RCF) are mixed into a mixed raw material, and the mixed raw material is secondarily scutched by the scutcher 2.

[0340] The mixed raw material secondarily scutched by the scutcher 2 is transferred to a door opener 3 so as to be opened.

[0341] The mixed raw material opened by the door opener 3 is transferred to a mixing tank 4 so as to be further mixed therein.

[0342] The mixed raw material mixed in the mixing tank 4 is transferred to a chute carding machine 50 so as to be further processed thereby.

[0343] The mixed raw material transferred to the chute carding machine 50 is carded into a web in an upper part of a main chamber 50-CB of the chute carding machine.

[0344] The web is dropped to a web shaping unit 50-4 disposed under the main chamber 50-CB of the chute carding machine 50 and laminated thereon into an initial nonwoven fabric, which is a web laminate WEBL.

[0345] The initial nonwoven fabric, which is the web laminate WEBL, is transferred into an upper punching machine 7, and is processed by the upper punching machine 7, which punches the initial nonwoven fabric up and down a plurality of times.

[0346] The initial nonwoven fabric processed by the upper punching machine 7 is transferred into a lower punching machine 8, and is processed by the lower punching machine, which punches the initial nonwoven fabric up and down a plurality of times, whereby nonwoven fabric is manufactured.

[0347] The main chamber 50-CB of the chute carding machine 50, shown in FIG. 15, has a height of 5 M to 6 M.

[0348] The main chamber 50-CB, which is a body of the chute carding machine, is upright as a whole. At the uppermost part of the main chamber 50-CB, a mixed raw material feeding pipe 50-INP is horizontally connected to the upright main chamber so as to communicate therewith.

[0349] The uppermost part of the main chamber 50-CB is a mixed raw material introduction unit 50-1.

[0350] The mixed raw material fed into an inlet 50-MO formed in the mixed raw material introduction unit 50-1 is transferred by blowing force and gravity, is continuously carded by a first carding unit 50-2 and a second carding unit 50-3, and is transferred to a web shaping unit 50-4 so as to be processed.

[0351] The first carding unit 50-2 and the second carding unit 50-3 constitute a carding means of the present invention.

[0352] Referring to FIGS. 15 to 16, the chute carding machine 50 includes a main chamber 50-CB oriented in a vertical direction and having an inner space formed therein.

[0353] The uppermost part of the inner space of the main chamber 50-CB forms a mixed raw material introduction unit 50-1.

[0354] A first carding unit 50-2 is installed under the mixed raw material introduction unit 50-1.

[0355] A second carding unit 50-3 is installed under the first carding unit 50-2.

[0356] A web shaping unit 50-4 is installed under the second carding unit 50-3.

[0357] The main chamber 50-CB includes an introduction chamber 50-IN forming the mixed raw material introduction unit 50-1, a chamber constituting the first carding unit 50-2, a chamber constituting the second carding unit 50-3, and a chamber constituting the web shaping unit 50-4, all of which are connected to each other so as to communicate with each other to form a single main chamber 50-CB.

[0358] That is, since the mixed raw material (which may be a sole raw material of recycled carbon fiber (RCF)) fed into the inlet 50-MO formed in the mixed raw material introduction unit 50-1 is carded while being transferred downwardly in the main chamber 50-CB by blowing force and gravity and is transferred to the web shaping unit 50-4 disposed at the lowermost part, the main chamber 50-CB may function and act as a very large pipe (housing).

[0359] As shown in FIG. 16, an outer auxiliary frame 50-SF on which a manager can ride to maintain and manage the main chamber 50-CB is installed on the outer periphery of the main chamber 50-CB.

[0360] Since the main chamber 50-CB is upright and has a height of 5 M to 6 M, a manager may ride on the outer auxiliary frame 50-SF, which is constituted by a ladder or the like, for maintenance and management of the nonwoven fabric manufacturing system, and maintain and manage the manufacturing system.

[0361] As shown in FIG. 18, the mixed raw material introduction unit 50-1 includes a mixed raw material feeding pipe 50-INP having an inlet 50-MO into which the mixed raw material transferred from the mixing tank 4 is fed.

[0362] The mixed raw material feeding pipe 50-INP is connected to the introduction chamber 50-IN so as to communicate therewith.

[0363] A motor 50-MT is installed on a motor installation frame 50-FR outside the mixed raw material feeding pipe 50-INP so as to shake the mixed raw material feeding pipe 50-INP.

[0364] A cam 50-CAM configured to convert the rotating motion of the motor into a shaking motion is installed on a rotating shaft of the motor 50-MT.

[0365] A through-shaft 50-SFT is installed through the introducing chamber 50-IN, a first fixing bolt 50-BTA is fastened to one end of the through-shaft 50-SFT, and a second fixing bolt 50-BTB is fastened to the other end of the through-shaft 50-SFT.

[0366] The through-shaft 50-SFT protruding outwardly of the first fixing bolt 50-BTA and the cam 50-CAM are connected to each other via a connecting bar 50-BAR.

[0367] In the above structure, the rotation of the rotating shaft of the motor 50-MT is converted into a shaking motion by the cam 50-CAM eccentrically connected to the rotating shaft of the motor 50-MT, the shaking motion is transmitted to the connecting bar 50-BAR, the shaking motion of the connecting bar 50-BAR is transmitted to the through-shaft 50-SFT, and the shaking motion of the through-shaft 50-SFT shakes the mixed raw material feeding pipe 50-INP, whereby the mixed raw material or the sole raw material fed into the mixed raw material feeding pipe 50-INP is not jammed in the mixed raw material feeding pipe 50-INP and is transferred smoothly by blowing force applied into the mixed raw material feeding pipe 50-INP and shaking of the mixed raw material feeding pipe.

[0368] As shown in FIGS. 15 to 16, a mixed raw material storage unit 50-STR configured to temporarily store the mixed raw material is formed in the introducing chamber 50-IN.

[0369] A mixed raw material transfer regulator 50-CRU is installed in a lower part of the mixed raw material storage unit 50-STR, and a weight sensor 50-SEN configured to sense the weight of the mixed raw material passing through the mixed raw material transfer regulator 50-CRU is installed in the mixed raw material transfer regulator 50-CRU.

[0370] In the above structure, the mixed raw material or the sole raw material transferred from the mixing tank 4 is temporarily stored in the mixed raw material storage unit 50-STR (only the sole raw material may be stored), and a controller (not shown) of the recycled carbon fiber nonwoven fabric manufacturing system performs control such that only a preset amount of weight sensed by the weight sensor 50-SEN is transferred to the lower carding unit.

[0371] The first carding unit 50-2 shown in FIGS. 15 and 17 includes: [0372] a pair of first feed rollers 50A-FER configured to rotate in opposite directions; [0373] a pair of first carding rollers 50A-WKR installed vertically under the pair of first feed rollers 50A-FER; and [0374] a first large-diameter main roller 50A-MSD installed vertically under the pair of first carding rollers 50A-WKR.

[0375] An imaginary vertical line passing through the center axis of rotation of the first large-diameter main roller 50A-MSD passes through a contact point where the pair of first carding rollers 50A-WKR contact each other and also passes through a contact point where the pair of first feed rollers 50A-FER contact each other.

[0376] The first large-diameter main roller 50A-MSD rotates in the state in which an outer circumference of the first large-diameter main roller 50A-MSD is in contact with outer circumferences of the pair of first carding rollers 50A-WKR to card the mixed raw material or the sole raw material.

[0377] One end of a first die spring 50A-SPR is coupled to a bracket coupled to one of the pair of first carding rollers 50A-WKR to support the first carding rollers 50A-WKR.

[0378] The other end of the first die spring 50A-SPR is coupled to a mixed raw material transfer duct 50A-DUK.

[0379] The mixed raw material transfer duct 50A-DUK is coupled to the main chamber 50-CD.

[0380] The pair of first feed rollers 50A-FER and the pair of first carding rollers 50A-WKR are operated by power from a first feed carding roller motor 50A-PKM.

[0381] The first large-diameter main roller 50A-MSD is operated by power from a first large-diameter main roller motor 50A-MSM.

[0382] Spike bodies 50-SPKM, each having a plurality of spikes formed thereon, are implanted and formed on an outer circumferential surface of the first large-diameter main roller 50A-MSD at certain intervals.

[0383] Next, the operation of the first carding unit will be described.

[0384] In the first carding unit 50-2, the mixed raw material or the sole raw material (hereinafter, the mixed raw material or the sole raw material is referred to as the raw material) introduced from above the pair of first feed rollers 50A-FER passes between the pair of first feed rollers 50A-FER rotating in opposite directions and is transferred to the lower part by the frictional force of the feed rollers.

[0385] The pair of first carding rollers 50A-WKR, which receives and cards the raw material supplied from the pair of feed rollers, is provided vertically under the pair of first feed rollers 50A-FER.

[0386] The pair of first carding rollers 50A-WKR transfers the raw material in a direction toward an upper outer circumference of the rotating first large-diameter main roller 50A-MSD, and cards the raw material while rotating in contact with the first large-diameter main roller 50A-MSD.

[0387] The raw material is carded while passing between the pair of first feed rollers, passing between the pair of first carding rollers, and passing between lower surfaces of the pair of first carding rollers and an upper surface of the first large-diameter main roller 50A-MSD.

[0388] One end of the first die spring 50A-SPR is coupled to the bracket coupled to one of the pair of first carding rollers 50A-WKR to support the first carding rollers 50A-WKR.

[0389] The other end of the first die spring 50A-SPR is coupled to the mixed raw material transfer duct 50-DUK, which is coupled to the main chamber 50-CD.

[0390] The pair of first feed rollers 50A-FER and the pair of first carding rollers 50A-WKR are rotated by power from the first feed carding roller motor 50A-PKM.

[0391] The first large-diameter main roller 50A-MSD is rotated by power from the first large-diameter main roller motor 50A-MSM.

[0392] Next, the operation of the first die spring 50A-SPR will be described.

[0393] The first die spring 50A-SPR restricts the horizontal movement of one of the first carding rollers 50A-WKR and controls the frictional force between the first carding roller 50A-WKR and the first large-diameter main roller 50A-MSD.

[0394] Specifically, the length of a control bolt 50-BOLT coupled to the first die spring 50A-SPR may be adjusted to adjust the maximum distance between the pair of first carding rollers 50A-WKR and to adjust a change in the frictional force between the first carding roller 50A-WKR and the first large-diameter main roller 50A-MSD.

[0395] Accordingly, a system manager of the present invention may adjust the setting position of the first die spring 50A-SPR according to the type of raw material, the size of the nonwoven fabric, and the like.

[0396] As shown in FIGS. 22 and 15, the second carding unit 50-3 is installed under the first carding unit 50-2, and the second carding unit 50-3 includes: [0397] a pair of second feed rollers 50B-FER configured to rotate in opposite directions; [0398] a pair of second carding rollers 50B-WKR installed vertically under the pair of second feed rollers 50B-FER; and [0399] a second large-diameter main roller 50B-MSD installed vertically under the pair of second carding rollers 50B-WKR.

[0400] An imaginary vertical line passing through the center axis of rotation of the second large-diameter main roller 50B-MSD passes through a contact point where the pair of second carding rollers 50B-WKR contact each other and also passes through a contact point where the pair of second feed rollers 50B-FER contact each other.

[0401] The second large-diameter main roller 50B-MSD rotates in the state in which an outer circumference of the second large-diameter main roller 50B-MSD is in contact with outer circumferences of the pair of second carding rollers 50B-WKR, and the raw material is carded between lower surfaces of the pair of second carding rollers 50B-WKR and an upper surface of the second large-diameter main roller 50B-MSD by frictional force of the rollers. One end of a second die spring 50B-SPR is coupled to a bracket coupled to one of the pair of second carding rollers 50B-WKR to support the second carding rollers 50B-WKR.

[0402] The other end of the second die spring 50B-SPR is coupled to a mixed raw material transfer duct 50B-DUK, and the mixed raw material transfer duct 50B-DUK is coupled to the main chamber 50-CD.

[0403] The pair of second feed rollers 50B-FER and the pair of second carding rollers 50B-WKR are operated by power from a second feed carding roller motor 50B-PKM.

[0404] The second large-diameter main roller 50B-MSD is operated by power from a second large-diameter main roller motor 50B-MSM.

[0405] Spike bodies 50-SPKM, each having a plurality of spikes formed thereon, may not be implanted and formed on an outer circumferential surface of the second large-diameter main roller 50B-MSD at certain intervals.

[0406] Since the plurality of spikes is not formed on the outer circumferential surface of the second large-diameter main roller 50B-MSD, carding may be performed more precisely.

[0407] That is, carding may be performed more roughly and loudly on the first large-diameter main roller with the spikes, and carding may be performed more precisely on the second large-diameter main roller 50B-MSD without the spikes, thereby increasing the carding efficiency.

[0408] Meanwhile, a blower 50-BRR is installed above one side of the second large-diameter main roller 50B-MSD so as to be adjacent to the second large-diameter main roller 50B-MSD.

[0409] An air discharge pipe 777 is formed at the blower 50-BRR so as to protrude therefrom in one direction.

[0410] An end outlet of the air discharge pipe 777 is installed so as to be oriented toward a lower part of a side surface of the second large-diameter main roller 50B-MSD.

[0411] An imaginary center axis line 777-1 of the air discharge pipe 777, representing the center of a path flow along which air is discharged as a continuous line, passes while abutting an outer circumference of the lower part of the side surface of the second large-diameter main roller 50B-MSD.

[0412] In this configuration, the strong blowing force discharged from the air discharge pipe 777 may very efficiently drop the mixed raw material or the sole raw material adhered to the lower part of the side surface of the second large-diameter main roller 50B-MSD, thereby improving the production efficiency of the system.

[0413] The second carding unit 50-3 is generally identical in configuration and operation to the first carding unit 50-2, except for the installation location of the components. In the second carding unit 50-3, however, the second carding unit 50-3 is further provided with a blower 50-BRR configured to apply blowing force in a tangential direction of a cylinder of the second large-diameter main roller 50B-MSD.

[0414] In addition, no spikes may be installed on the surface of the second large-diameter main roller 50B-MSD.

[0415] The blower 50-BRR applies blowing force in the direction tangential to the lower part of the cylinder of the second large-diameter main roller 50B-MSD to drop the web attached to the lower part of the side surface of the second large-diameter main roller 50B-MSD, thereby increasing the processing efficiency and improving the productivity of the recycled carbon fiber nonwoven fabric.

[0416] Meanwhile, the vertical distance from an outer circumferential end of a lower side of the first large-diameter main roller 50A-MSD to an outer circumferential end of an upper side of the second feed roller 50B-FER is 0.8 times the diameter of the first large-diameter main roller 50A-MSD.

[0417] Since the first large-diameter main roller 50A-MSD and the second feed roller 50B-FER are spaced apart from each other, as described above, the mixed raw material whose temperature is increased by friction processing on the first large-diameter main roller 50A-MSD is cooled by air flowing in the mixed raw material transfer duct 50A-DUK and is transferred to the next carding means, thereby improving the processing efficiency.

[0418] The web shaping unit 50-4 shown in FIGS. 19 and 15 includes: [0419] a mesh net rotating motor 50-MEMT; [0420] a mesh net 50-MESH configured to be circularly moved by rotational force of the mesh net rotating motor 50-MEMT; [0421] a part of the mesh net 50-MESH that is circularly moved having a horizontal surface; [0422] a drafter roller 50-DRFR configured to rotate about a roller rotation axis 50-SFAC at a fixed position in contact with the web laminated on the horizontal surface of the mesh net 50-MESH; and [0423] a blowing intake passage 50-AISK formed continuously along the bottom of the horizontal surface of the mesh net 50-MESH.

[0424] The air in the blowing intake passage 50-AISK is discharged out of the blowing intake passage 50-AISK by a blower connected to the blowing intake passage 50-AISK so as to communicate therewith, thereby negatively pressurizing the bottom of the mesh net 50-MESH such that the web laminated on the horizontal surface of the mesh net 50-MESH is adsorbed on an upper surface of the mesh net 50-MESH.

[0425] A plurality of through-holes through which air can flow is formed in the blowing intake passage 50-AISK, which communicates with the bottom of the mesh net 50-MESH therethrough.

[0426] Since the web is adsorbed on the mesh net using the air, as described above, it is possible to increase the strength and density of the tissue of the recycled carbon fiber nonwoven fabric that is manufactured and to manufacture high-quality nonwoven fabric through punching of the nonwoven fabric.

[0427] In the present invention, instead of adsorbing the web on the upper surface of the mesh net 50-MESH, an air discharge means configured to discharge air to the top of the mesh net 50-MESH through the blowing intake passage 50-AISK may be installed under the mesh net 50-MESH in order to facilitate separation of the web laminate WEBL seated on the mesh net 50-MESH.

[0428] As air is discharged to the top of the mesh net through the air discharge means, it is possible to facilitate separation of the web laminate WEBL seated on the mesh net.

[0429] This is because the web laminate WEBL seated on the mesh net must be moved for a subsequent process using the upper punching machine and thus must be easily separated from the top of the mesh net.

[0430] Meanwhile, the mesh net 50-MESH is an endless mesh net.

[0431] The mesh net 50-MESH may be circularly moved by a first roller pulley ROP-1, a second roller pulley ROP-2, a third roller pulley ROP-3, a fourth roller pulley ROP-4, a first tension adjustment roller ROP-TA, and a second tension adjustment roller ROP-TB, and the tension of the mesh net may be adjusted.

[0432] The endless mesh net means a closed loop mesh net, like a belt that rotates on a plurality of roller pulleys.

[0433] A mechanism configured to circularly move the mesh net 50-MESH includes: [0434] a first roller pulley ROP-1 installed on the axis of the mesh net rotating motor 50-MEMT; [0435] a second roller pulley ROP-2 installed spaced apart from the first roller pulley ROP-1 in a horizontal direction; [0436] a third roller pulley ROP-3 installed spaced apart from the second roller pulley ROP-2 in a downward direction; and [0437] a fourth roller pulley ROP-4 installed spaced apart from the first roller pulley ROP-1 in the downward direction.

[0438] The mesh net 50-MESH is disposed on outer circumferences of the first roller pulley ROP-1 to the fourth roller pulley ROP-4.

[0439] A second tension adjustment roller ROP-TB may be installed outside the mesh net 50-MESH disposed between the first roller pulley ROP-1 and the fourth roller pulley ROP-4 to adjust the tension of the mesh net, and a first tension adjustment roller ROP-TA may be installed outside the mesh net 50-MESH disposed between the second roller pulley ROP-2 and the third roller pulley ROP-3 to adjust the tension of the mesh net.

[0440] A second mixed raw material transfer regulator 50-CRUS is installed in a duct configured to allow the first carding unit 50-2 and the second carding unit 50-3 to communicate with each other therethrough.

[0441] A second weight sensor configured to sense the weight of the mixed raw material passing through the second mixed raw material transfer regulator may be installed in the second mixed raw material transfer regulator 50-CRUS.

[0442] Thus, a system controller may control the second mixed raw material transfer regulator 50-CRUS to control the weight of the raw material that is transferred into the duct.

[0443] A roller rotating shaft 50-SFAC is formed on the left and right axial centers of the drafter roller 50-DRFR so as to protrude therefrom.

[0444] The roller rotating shaft 50-SFAC is rotatably coupled to a roller support bar 50-RCBA.

[0445] A support hole configured to support the roller rotating shaft 50-SFAC is formed in one end of the roller support bar 50-RCBA.

[0446] A plurality of height adjustment holes 50-HCTH is formed in the other end of the roller support bar 50-RCBA.

[0447] A bolt 50-BOLT may be inserted into a specific one of the height adjustment holes 50-HCTH of the roller support bar 50-RCBA such that the roller support bar can be fastened to a support frame 50-FRAM, whereby the height of the drafter roller 50-DRFR may be adjusted.

[0448] The thickness of the web laminate WEBL laminated on the mesh net may be easily adjusted by adjusting the installation height of the drafter roller 50-DRFR.

[0449] The mesh net 50-MESH of the web shaping unit 50-4 may be made of recycled carbon fiber nonwoven fabric.

[0450] When the mesh net is made of recycled carbon fiber nonwoven fabric, the mesh net has excellent tensile strength, durability, and strength. When air adsorption occurs under the mesh net, the adhesion between the web laminate WEBL laminated on the mesh net and the upper surface of the mesh net is excellent. When there is no air adsorption under the mesh net, the web laminate WEBL laminated on the mesh net is easily separated from the surface of the mesh net.

[0451] That is, the desorption effect of the web laminate WEBL laminated on the mesh net is very good.

[0452] Meanwhile, the pair of first feed rollers and the pair of second feed rollers have the same diameter.

[0453] In addition, the pair of first carding rollers and the pair of second carding rollers have the same diameter.

[0454] In addition, the first large-diameter main roller and the second large-diameter main roller have the same diameter.

[0455] The diameter ratio of the first carding roller to the first feed roller to the first large-diameter main roller is 1:1.2:3.5.

[0456] When the diameter of the large-diameter main roller is 3.5 times the diameter of the carding roller, as described above, the raw material falling between the outer circumferences of the pair of carding rollers does not free-fall in the vertical direction, but falls on the upper circumferential surface of the large-diameter main roller, which is installed vertically under the pair of carding rollers, the raw material falling on the upper circumferential surface of the large-diameter main roller is carded in a state of being sandwiched between the lower outer circumferences of the pair of carding rollers and the upper circumferential surface of the large-diameter main roller, whereby the carding time is increased and the carding efficiency is improved.

[0457] In the first embodiment, the longitudinal length of the needle 7-ND is long, as shown in FIG. 9A. In the second embodiment, however, the longitudinal length of the needle 7-ND may be short such that, when the punching plate 7-PL having the plurality of needles formed thereon maximally punches the initial nonwoven fabric in the downward direction, the lower surface of the punching plate 7-PL comes into completely tight contact with the upper surface of the needle guide plate 7-GDP, as shown in FIG. 20.

[0458] In addition, the needle support plate 7-NPL, the punching plate 7-PL, and the needle guide plate 7-GDP may be heated by a heating means (not shown) such that the initial nonwoven fabric or the nonwoven fabric can be punched while being heated during the punching process.

[0459] Alternatively, punching may be performed in the state in which the needle support plate 7-NPL, the punching plate 7-PL, and the needle guide plate 7-GDP are not heated (i.e., are at room temperature).

[0460] Although the upper punching machine 7 has been described above with more reference to FIG. 9A, the configuration of the upper punching machine 7 may be equally applied to the lower punching machine 8 of FIG. 10, in which only the punching direction is reversed.

[0461] As is apparent from the above description, the present invention has the effect of making carding of a mixed raw material and shaping of nonwoven fabric more precise and increasing processing and production speed of the mixed raw material or a sole raw material (recycled carbon fiber), thereby improving processing efficiency and production efficiency.

[0462] Conventionally, it is not possible to manufacture 100% recycled carbon fiber nonwoven fabric, but a second embodiment of the present invention has the effect that it is possible to manufacture 100% recycled carbon fiber nonwoven fabric without mixing a resin by precise processing of only recycled carbon fiber using a recycled carbon fiber nonwoven fabric manufacturing system including a chute carding machine of the present invention.

[0463] Conventionally, two separate apparatuses, i.e., a carding machine and a horizontal shaping machine, are used, whereby processing is inefficient, but the present invention has the effect that a single chute carding machine performs the role (function) of the conventional carding machine and the conventional horizontal shaping machine with higher performance.

[0464] In addition, the present invention has the effect that the position of one first carding roller 50A-WKR is precisely adjusted by adjusting the position of a first die spring and then carding is performed, whereby it is possible to adjust the degree of carding of the mixed raw material or only recycled carbon fiber (RCF) and to card the mixed raw material or the recycled carbon fiber (RCF) with higher performance.

[0465] The present invention has the effect that the air under the mesh net is discharged out of a main chamber by a blower such that a web laminated on a mesh net and a web laminate WEBL, which is initial nonwoven fabric, are adsorbed on the top of the mesh net, and at the same time a drafter roller disposed above initial nonwoven fabric is rotated to press the initial nonwoven fabric such that the density and strength of the initial nonwoven fabric are very high, whereby it is possible to manufacture the initial nonwoven fabric with high efficiency.

[0466] The present invention has the effect that a second carding unit 50-3 is installed vertically under a first carding unit 50-2 such that the nonwoven fabric raw material (the mixed raw material or the sole raw material) which is primarily carded by the first carding unit 50-2 falls in a vertical direction by gravity and blowing force and is secondarily carded by the second carding unit, whereby it is possible to perform carding very efficiently.

[0467] In addition, the present invention has the effect that the carded nonwoven fabric raw material is transferred using gravity, whereby processing efficiency is improved, the primarily carded nonwoven fabric raw material falls in the vertical direction and is secondarily carded, and the secondarily carded web also falls in the vertical direction, is seated on the mesh net, and is processed, whereby it is possible to minimize processing energy consumption and to reduce manufacturing time.

[0468] As such, the present invention provides a system and method for efficiently manufacturing recycled carbon fiber nonwoven fabric with excellent quality and performance using the simplest method and the simplest process.

[0469] In particular, the present invention has the effect of creating and improving a highly efficient chute carding machine, enabling the production of high quality recycled carbon fiber nonwoven fabric.