Method of manufacturing fiber substrate and method of manufacturing resin rotator

Patent metadata

Field	Value
Publication number	US-9962887-B2
Application number	US-201414335983-A
Country	US
Kind code	B2
Filing date	Jul 21, 2014
Priority date	Jul 21, 2014
Publication date	May 8, 2018
Grant date	May 8, 2018

Abstract

There is little fluctuation in amount of short fibers among individual products of fiber substrate. No damage is caused to a mold for the fiber substrate. Continuous production of the fiber substrates is possible. A method of manufacturing a fiber substrate includes the steps of: preparing slurry by dispersing short fibers in a dispersion medium; pouring the slurry into a cylindrical mold from above the cylindrical mold, the slurry being directed to a slurry diffusion member disposed in the center of the cylindrical mold and having an upward pointing conical or pyramidal shape; pouring the dispersion medium or water onto the slurry diffusion member from above the slurry diffusion member to cause the short fibers adhering to the slurry diffusion member to fall down, after the step of pouring the slurry; and discharging the dispersion medium from the cylindrical mold to accumulate the short fibers in the cylindrical mold to obtain a fiber aggregate.

First claim

What is claimed is:

1. A method of manufacturing a fiber substrate comprising the steps of:
preparing slurry by dispersing short fibers in a dispersion medium; pouring the slurry into a cylindrical mold from above the cylindrical mold, the slurry being directed to a slurry diffusion member disposed at the center of the cylindrical mold and having an upward pointing conical or pyramidal shape;
pouring the dispersion medium that is the same as the dispersion medium used to prepare the slurry, the dispersion medium consisting essentially of organic solvent, onto the slurry diffusion member from above the slurry diffusion member to cause the short fibers adhering to the slurry diffusion member to fall down, after the step of pouring the slurry; and
discharging the dispersion medium from the cylindrical mold to accumulate the short fibers in the cylindrical mold to obtain a fiber aggregate.

2. The method of manufacturing a fiber substrate according to claim 1 , further comprising the step of:
compressing the fiber aggregate during or after the step of discharging the dispersion medium.

3. The method of manufacturing a fiber substrate according to claim 1 , wherein
in the step of discharging, the discharging of the dispersion medium is performed under a reduced-pressure atmosphere.

4. The method of manufacturing a fiber substrate according to claim 2 , wherein
in the step of discharging, the discharging of the dispersion medium is performed under a reduced-pressure atmosphere.

5. The method of manufacturing a fiber substrate according to claim 2 , wherein
in the step of compressing, the compression of the fiber aggregate is performed while applying heat.

6. The method of manufacturing a fiber substrate according to claim 1 , wherein
the fiber aggregate is shaped like a gear in the cylindrical mold.

7. The method of manufacturing a fiber substrate according to claim 2 , wherein
the fiber aggregate is shaped like a gear in the cylindrical mold.

8. The method of manufacturing a fiber substrate according to claim 3 , wherein
the fiber aggregate is shaped like a gear in the cylindrical mold.

9. The method of manufacturing a fiber substrate according to claim 4 , wherein
the fiber aggregate is shaped like a gear in the cylindrical mold.

10. The method of manufacturing a fiber substrate according to claim 5 , wherein
the fiber aggregate is shaped like a gear in the cylindrical mold.

11. A method of manufacturing a resin rotator, comprising the step of:
impregnating the fiber substrate manufactured by the method according to claim 1 with a resin and curing the resin.

12. The method of manufacturing a resin rotator according to claim 11 , further comprising the step of:
performing tooth cutting on an outer peripheral portion of the fiber substrate after the step of impregnating and curing.

13. A method of manufacturing a resin rotator, comprising the step of:
impregnating the fiber substrate manufactured by the method according to claim 2 with a resin and curing the resin.

14. The method of manufacturing a resin rotator according to claim 13 , further comprising the step of:
performing tooth cutting on an outer peripheral portion of the fiber substrate after the step of impregnating and curing.

15. A method of manufacturing a resin rotator, comprising the step of:
impregnating the fiber substrate manufactured by the method according to claim 3 with a resin and curing the resin.

16. The method of manufacturing a resin rotator according to claim 15 , further comprising the step of:
performing tooth cutting on an outer peripheral portion of the fiber substrate after the step of impregnating and curing.

17. A method of manufacturing a resin rotator, comprising the step of:
impregnating the fiber substrate manufactured by the method according to claim 5 with a resin and curing the resin.

18. The method of manufacturing a resin rotator according to claim 17 , further comprising the step of:
performing tooth cutting on an outer peripheral portion of the fiber substrate after the step of impregnating and curing.

19. A method of manufacturing a resin rotator, comprising the step of:
impregnating the fiber substrate manufactured by the method according to claim 6 with a resin and curing the resin.

20. The method of manufacturing a resin rotator according to claim 19 , further comprising the step of:
performing tooth cutting on an outer peripheral portion of the fiber substrate after the step of impregnating and curing.

Assignees

• Shin Kobe Electric Machinery Co Ltd
• Hitachi Chemical Co Ltd

Inventors

• Ozawa Masaya
• Sugiyama Masao

Classifications

• B29C43/56

  Compression moulding under special conditions, e.g. vacuum · CPC title

• B29K2705/12

  Iron · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title

• B29K2105/12

  of short lengths, e.g. chopped filaments, staple fibres or bristles · CPC title

• B29C2043/029

  using axial compression along a longitudinal axis · CPC title