Die with Flow Diffusing Gate Passage and Method for Impregnating Same Fiber Rovings

• US 20150044377A1
• Filed: 04/26/2012
• Published: 02/12/2015
• Est. Priority Date: 04/29/2011
• Status: Active Grant

• Current Assignee: Ticona LLC (Celanese Corporation)
• Original Assignee: Ticona LLC (Celanese Corporation)
• Inventors: Tibor, Timothy L., Regan, Timothy A., Johnson, Aaron H.
• Granted Patent: US 9,623,437 B2
• Time in Patent Office: Days
• US Class Current: 427/358
• CPC Class Codes: B05C 11/021 Apparatus for spreading or distributing liquids or other fluent materials already applied to the surface of an elongated body, e.g. a wire, a tube
• CPC Class Codes: B05C 5/0241 for applying liquid or other fluent material to elongated work, e.g. wires, cables, tubes
• CPC Class Codes: B05C 5/0245 for applying liquid or other fluent material to a moving work of indefinite length, e.g. to a moving web B05C5/0241, B05C5/0254, B05C5/027, B05C5/0283 take precedence
• CPC Class Codes: B05C 5/027 Coating heads with several outlets, e.g. aligned transversally to the moving direction of a web to be coated B05C5/0254 takes precedence
• CPC Class Codes: B05D 1/265 Extrusion coatings
• CPC Class Codes: B29B 15/122 with a matrix in liquid form, e.g. as melt, solution or latex
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 48/305 having a wide opening, e.g. for forming sheets
• CPC Class Codes: B29C 48/34 Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated
• CPC Class Codes: B29C 48/35 with rollers
• CPC Class Codes: B29C 48/705 in the die zone, e.g. to create flow homogeneity
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

Abstract

A die and a method for impregnating fiber rovings with a polymer resin are disclosed. The die includes a manifold assembly (220), an impregnation zone (250), and a gate passage (270). The manifold assembly (220) flows the resin therethrough, and includes a channel (222). The impregnation zone (250) is in fluid communication with the manifold assembly (220), and is configured to impregnate the roving with the resin. The gate passage (270) is between the manifold assembly (220) and the impregnation zone (250), and flows the resin from the manifold assembly (220) such that the resin coats the roving. The gate passage (270) includes a projection (300). The projection (300) is configured to diffuse resin flowing through the gate passage (270).

Claims

1. A die for impregnating at least one fiber roving with a polymer resin, the die comprising:

a manifold assembly for flowing the resin therethrough, the manifold assembly comprising a channel;

an impregnation zone in fluid communication with the manifold assembly, the impregnation zone configured to impregnate the roving with the resin; and

a gate passage between the manifold assembly and the impregnation zone for flowing the resin from the manifold assembly such that the resin coats the roving, the gate passage comprising a projection configured to diffuse resin flowing through the gate passage.

2. The die of claim 1, further comprising a plurality of projections.

3. The die of claim 2, wherein the plurality of projections are spaced apart to define a plurality of passages therebetween.

4. The die of claim 1, wherein the projection has a tapered cross-sectional profile in a flow direction of the resin through the gate passage.

5. The die of claim 1, wherein the projection includes an outer surface and at least one side surface, the at least one side surface extending between the outer surface and an inner wall of the gate passage, and wherein the at least one side surface is tapered towards the outer surface.

6. The die of claim 1, wherein the manifold assembly further comprises a plurality of channels.

7. The die of claim 6, further comprising a plurality of projections, and wherein each of the plurality of projections corresponds to one of the plurality of channels.

8. The die of claim 6, wherein the plurality of channels are a plurality of branched runners.

9. The die of claim 8, wherein the plurality of branched runners have a symmetrical orientation along a central axis.

10. The die of claim 1, wherein at least a portion of the channel is curvilinear.

11. The die of claim 1, wherein the manifold assembly defines an outlet region, and wherein at least a portion of the channel disposed in the outlet region has an increasing area in a flow direction of the resin.

12. The die of claim 1, wherein the manifold assembly defines an outlet region, and wherein at least a portion of the channel disposed in the outlet region has a curvilinear cross-sectional profile.

13. The die of claim 1, wherein the gate passage extends vertically between the manifold assembly and the impregnation zone.

14. The die of claim 1, wherein at least a portion of the gate passage has a decreasing cross-sectional profile in a flow direction of the resin.

15. The die of claim 1, wherein the resin is a thermoplastic resin.

16. The die of claim 1, wherein the resin is a thermoset resin.

17. A method for impregnating at least one fiber roving with a polymer resin, the method comprising:

flowing a polymer resin through a manifold assembly, the manifold assembly comprising a channel;

flowing the polymer resin from the manifold assembly into a gate passage;

diffusing the polymer resin within the gate passage;

coating at least one fiber roving with the resin; and

traversing the coated roving through an impregnation zone to impregnate the roving with the resin.

18. The method of claim 17, wherein flowing the resin through the manifold assembly comprises flowing the resin through an outlet region of the manifold assembly, and wherein at least a portion of the channel disposed in the outlet region has an increasing area in a flow direction of the resin.

19. The method of claim 17, wherein at least a portion of the gate passage has a decreasing cross-sectional profile in a flow direction of the resin.

20. The method of claim 17, further comprising coating a plurality of ravings with the resin and traversing the coated ravings through the impregnation zone.