Method and equipment for manufacturing continuous fiber reinforced structural member

Abstract

The invention relates to the technical field of structural part injection molding, in particular to a manufacturing method and equipment for a continuous fiber reinforced structural part, and aims to solve the problem that a structural part manufactured in the prior art cannot meet the requirements for light weight and high strength at the same time. Comprising the following steps: heating a thermoplastic composite material sheet and putting the thermoplastic composite material sheet into a mold; designing an original material formula, preparing materials according to the formula, and mixing the materials into a uniform melt; conveying and injection molding of melt materials are controlled through a reversing valve; the manufacturing data is associated with the product. The equipment comprises an extruding and mixing mechanism for melting, plasticizing and mixing each material in an original material formula, an injection molding mechanism for realizing the injection of a melt material, an injection molding machine mold locking unit for completing molding and curing, a control system for coordinating the whole process and an information tracing mechanism for ensuring the traceability of a product. The scheme is suitable for manufacturing functional parts with extremely high requirements on performance and safety in aerospace and automobile industries.

Description

Technical Field

[0001] The present application relates to the technical field of injection molding of structural parts, and in particular to a method and equipment for manufacturing continuous fiber reinforced structural parts. Background Art

[0002] With the rapid development of the low-altitude economy, it has become an important part of the country's strategic emerging industries. The low-altitude economy covers many fields such as low-altitude manufacturing, low-altitude flight, low-altitude support and comprehensive services. Among them, low-altitude manufacturing is particularly critical, which includes the research and development and production of aircraft and their parts. In this field, unprecedented stringent requirements are put forward for the lightweight, stability and traceability of parts, especially for new aircraft such as electric vertical take-off and landing aircraft (eVTOL) and unmanned flying cars, and the demand for lightweight, strength and reliability of parts is growing.

[0003] The structural parts of low-altitude aircraft bear the important task of supporting and connecting other components. These structural parts must have sufficient strength and rigidity, and at the same time meet the requirements of lightweight to improve the overall performance and endurance of the aircraft. Although traditional metal materials have high strength, they are difficult to meet the requirements of lightweight due to their heavy weight. Therefore, composite materials and high-performance plastics have gradually become the preferred materials for manufacturing low-altitude aircraft structural parts.

[0004] Compounding injection molding technology is mainly capable of formula design and processing high-performance, high-filling materials. It uses a twin-screw extrusion compounding system to melt and mix multiple materials to form a uniform melt, and introduces thermoplastic composite sheet processing units and processes, combined with injection molding technology to prepare the required parts. This technology can ensure that the material has consistent performance while being locally strengthened, which is crucial for manufacturing high-performance plastic parts.

[0005] However, the existing compounding and injection molding technology may not be able to fully take into account the dual requirements of lightweight and high strength when applied to the manufacture of low-altitude aircraft structural parts. The quality of aircraft structural parts cannot be guaranteed during the production process, which limits its application in the manufacture of high-performance aircraft parts. In addition, the existing technology also has shortcomings in the thermal history control of material processing, the introduction and retention of continuous fibers, automation control, and product traceability. Summary of the invention

[0006] Low-altitude aircraft, such as electric vertical take-off and landing aircraft (eVTOL) and unmanned flying cars, have extremely high requirements for the lightweight, high strength, temperature resistance, corrosion resistance and impact resistance of structural parts. The first aspect of the present application provides a method for manufacturing a continuous fiber reinforced structural part. The structural part prepared by this method can not only effectively take into account the lightweight and high strength requirements of the structural part, but also significantly improve the temperature resistance, corrosion resistance and impact resistance of the material, thereby ensuring that the structural part exhibits excellent performance in a complex working environment. The method specifically includes the following steps: preheating the thermoplastic composite sheet; Designing a raw material formula, feeding each component in the raw material formula into an extruder according to a proportion for mixing to obtain a melt material; Combining the preheated thermoplastic composite material sheet with the melt material through injection molding to obtain a structural part; The control system collects manufacturing data of the structural component and associates the manufacturing data with the structural component; Among them, the original material formula includes fibers, and the fibers are fed into the extruder by a continuous fiber conveying device. The control system includes a preset proportion of the fibers in the original material formula, and the control system interacts with the continuous fiber conveying device to adjust the real-time proportion of the fibers so that the real-time proportion of the fibers remains consistent with the preset proportion.

[0007] Preferably, the inlet position of the fiber into the extruder is at or after the middle position of the extruder along the material flow direction in the extruder.

[0008] Preferably, the control system interacts with the continuous fiber delivery device to adjust the real-time ratio of the fibers so that the real-time ratio of the fibers is consistent with the preset ratio, including: The continuous fiber delivery device detects the number of strands and the linear speed of the fiber and transmits them to the control system; The control system includes the Tex value of the fiber and the real-time delivery amount of each component in the original material formula. The control system calculates the fiber mass input into the extruder per unit time according to the following formula: The actual fiber mass input into the extruder per unit time = number of fiber strands × linear speed × Tex value; The control system calculates the real-time ratio of the fibers according to the actual fiber mass input into the extruder per unit time and the real-time delivery amount of each component in the original material formula, and compares it with the preset ratio of the fibers; If there is a deviation in the comparison result, at least one of the following methods shall be adopted to make adjustments to eliminate the deviation: The fiber strand count was adjusted and the extruder screw speed was adjusted to a minimum of 1 revolution per second.

[0009] Preferably, the preheated thermoplastic composite material sheet is combined with the melt material by injection molding to obtain a structural part, which includes: a material storage stage and an injection pressure holding stage. The material storage stage includes: conveying the molten material in the extruder to the injection device, and in the case where the melt buffer device contains the molten material, conveying the molten material in the melt buffer device to the injection device; The injection and pressure holding stage includes: injecting the molten material in the injection device into the mold cavity where the thermoplastic composite material sheet is located, so that the thermoplastic composite material sheet and the molten material are combined to obtain a structural part; at the same time, the extruder is connected to the melt buffer device, and the molten material in the extruder enters the melt buffer device.

[0010] Preferably, during the material storage stage, the temperature in the injection device is 210° C. to 400° C., the back pressure is 10 bar to 200 bar, and the maximum material storage position is 5 times the diameter of the injection piston; Preferably, during the injection pressure holding stage, the injection speed of the injection device is from 20 mm / s to the upper limit of the injection speed of the injection device, preferably from 20 mm / s to 150 mm / s, and the pressure is held at 50 bar to 800 bar during the injection process, and the time is from 0 s to 1000 s, preferably from 2.5 s to 3.5 s; Preferably, during the injection pressure holding stage, the temperature of the melt buffer device is 210° C. to 400° C.; Preferably, the material storage stage and the injection pressure holding stage can be performed cyclically to achieve continuous production of structural parts.

[0011] Preferably, the original material formula is designed, and each component in the original material formula is fed into an extruder in proportion for mixing to obtain a melt material comprising: The resin matrix, mineral powder and fiber are fed into an extruder in a ratio of (50-60): (1-10): (30-60) for mixing to obtain a molten material; Preferably, the ratio of resin matrix, mineral powder and fiber is 55:5:40; Preferably, the resin matrix is ​​made of polypropylene resin; Preferably, the fiber is a continuous fiber, and the Tex value of the continuous fiber is set to 2300 g / km to 2500 g / km; Preferably, the extruder is a twin-screw extruder, the internal temperature of the extruder is 210° C. to 400° C., the output is 110 kg / h to 120 kg / h, and the screw speed is 180 rpm to 200 rpm.

[0012] Preferably, preheating the thermoplastic composite sheet comprises: The thermoplastic composite sheet is heated and placed in a mold, and the heating temperature is 210° C. to 230° C.; Preferably, the thermoplastic composite sheet is made of a fiber-reinforced resin material, preferably one of 30% to 60% continuous fiber-reinforced polypropylene resin material, carbon fiber-reinforced polypropylene, and nylon.

[0013] Preferably, collecting the manufacturing data of the structural component and associating the manufacturing data with the structural component comprises: collecting manufacturing data of the structural component, packaging the received manufacturing data into an information code, and setting the information code on the structural component; Preferably, the manufacturing data includes at least one of the heating temperature of the thermoplastic composite sheet, material mixing parameters, molding parameters, and processor information.

[0014] The second aspect of the present application provides a manufacturing device for a continuous fiber reinforced structural member, which is used to implement the above method, and the device includes: The extrusion mixing mechanism comprises an extruder, a weight-loss metering feeding device and a continuous fiber conveying device, wherein the weight-loss metering feeding device is connected to the extruder and used to add raw materials and measure the amount of raw materials added; the continuous fiber conveying device is connected to the extruder and used to convey fibers and collect fiber conveying amount data in real time and feed it back to the control system; Preferably, the fiber inlet position into the extruder is at or after the middle position of the extruder along the material flow direction in the extruder; An injection molding mechanism comprises an injection device, a melt buffer device, a reversing valve and a locking nozzle, wherein the extruder, the injection device, the melt buffer device and the locking nozzle are connected via the reversing valve; An injection molding machine clamping unit, connected to the injection molding mechanism and used for molding the structural part; A control system connected to the extrusion mixing mechanism, the injection molding mechanism and the injection molding machine clamping unit, for realizing automatic control and coordination of the structural component manufacturing process and collecting manufacturing data of the structural component; and The information tracing mechanism is connected to the control system and is used to receive the manufacturing data collected by the control system and associate the manufacturing data with the structural component.

[0015] Preferably, the continuous fiber delivery device comprises a continuous fiber delivery frame, a continuous fiber delivery roller sensor and a continuous fiber delivery tube, the continuous fiber delivery roller sensor and the fiber entry end of the continuous fiber delivery tube are both arranged on the continuous fiber delivery frame, a fiber roll is placed on the continuous fiber delivery frame, the fiber passes through the continuous fiber delivery roller sensor and enters the continuous fiber delivery tube, and the fiber output end of the continuous fiber delivery tube is connected to the extruder; Preferably, the injection molding machine clamping unit comprises an equipment bed, a mold, a manipulator and a temperature control device, wherein the mold, the manipulator and the temperature control device are all arranged on the equipment bed, and the mold is connected to the locking nozzle.

[0016] Preferably, the information traceability mechanism includes a data storage unit, an information packaging unit and an information code generating device. The data storage unit is connected to the control system to receive and store the structural component manufacturing data that needs to be associated; the information packaging unit is connected to the data storage unit and is used to convert the structural component manufacturing data into an information code suitable for printing or display; the information code generating device is connected to the information packaging unit and is a device for generating a physical two-dimensional code label.

[0017] The above one or more solutions of the present application have at least the following beneficial effects: First of all, the technical solution of this application not only takes into account the dual goals of mechanical properties and lightweight of low-altitude aircraft structural parts by using continuous fiber reinforced resin materials for injection molding, but also improves the temperature resistance, corrosion resistance, and especially impact resistance of the material. This enables the product to exhibit excellent performance in a complex working environment. In addition, the application delivers continuous fibers to the twin-screw extruder through a continuous fiber conveying device, and through the interaction between the continuous fiber conveying roller sensor and the control system, the fiber delivery amount can be adjusted in time to control it at the optimal ratio, further improving the quality of the final product. In addition, the continuously switching reversing valve and the extruder-injection device integrated design realize continuous production, reduce the production cycle, and improve production efficiency. Strictly control the key parameters in the mixing, injection and molding processes, such as temperature, pressure, time, etc., to ensure that each step is in the best working state, thereby improving the molding accuracy and consistency. This method is particularly suitable for the manufacture of aerospace or automotive industry parts that require high mechanical strength, lightweight and processing stability and consistency.

[0018] Secondly, this technical solution integrates an efficient extrusion and mixing mechanism, a precise injection molding mechanism, a stable injection molding machine clamping unit, and an advanced information traceability system. Continuous glass fiber is added to the downstream opening of the twin-screw extruder, and the threaded element design completes the processing and dispersion of the fiber under low shear force, and completely melts and mixes with other material components, ensuring that the continuous fiber effectively retains its length and improves the overall performance of the composite material. At the same time, by using thermoplastic organic sheets, effective local reinforcement of the product is achieved to meet the strict requirements of structural parts for mechanical properties. This integrated design allows the entire manufacturing process to be completed in one step through injection molding, greatly improving the product's design freedom and the ability to realize complex shapes.

[0019] Thirdly, the information traceability mechanism included in this technical solution enhances the transparency of the product and provides strong support for maintenance and quality assurance. The control system collects key data in the manufacturing process in real time, including the heating temperature of the thermoplastic composite sheet, material mixing parameters, molding parameters, etc., and encapsulates this information into an information code (such as a QR code) and attaches it to each finished product. Scanning the information code allows you to view detailed production process records to ensure the controllability and traceability of product quality. This approach avoids product quality issues and also facilitates later tracking and management.

[0020] In addition, the equipment can flexibly configure the working parameters of each component according to specific production requirements to meet the processing requirements of different material formulas and meet the diverse product manufacturing needs, especially for low-altitude aircraft structural parts that require high strength and lightweight properties. Overall, this technical solution has greatly improved production efficiency and product quality, reduced energy consumption and costs, and provided a new solution for the manufacturing of high-performance aircraft parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings are used to provide a further understanding of the present application and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation of the present application. In the accompanying drawings: Figure 1 is a schematic diagram of the steps of a method for manufacturing a continuous fiber reinforced structural member provided in an embodiment of the present application; Figure 2 is a schematic structural diagram of a manufacturing device for a continuous fiber reinforced structural member provided in an embodiment of the present application; Figure 3 It is a structural schematic diagram of the extrusion mixing mechanism and the injection molding mechanism of the manufacturing equipment of the continuous fiber reinforced structural member provided in the embodiment of the present application; Figure 4 It is a structural schematic diagram of the connection between the extrusion mixing mechanism and the injection molding mechanism of the manufacturing equipment for the continuous fiber reinforced structural member provided in the embodiment of the present application; Figure 5 It is a schematic structural diagram of the connection between a continuous fiber delivery pipe and an extruder of a manufacturing device for a continuous fiber reinforced structural member provided in an embodiment of the present application; Figure 6 is a schematic structural diagram of a continuous fiber conveying device of a continuous fiber reinforced structural member manufacturing device provided in an embodiment of the present application; Figure 7 is a schematic structural diagram of a continuous fiber conveying roller sensor of a continuous fiber reinforced structural component manufacturing device provided in an embodiment of the present application; Figure 8 It is a schematic diagram of a report generated by an information tracing mechanism of a continuous fiber reinforced structural component manufacturing device according to an embodiment of the present application for product information tracing.

[0022] Reference numerals: 1. Extrusion mixing mechanism; 11. Extruder; 12. Loss-in-weight metering feeding device; 13. Continuous fiber conveying device; 131. Continuous fiber conveying rack; 132. Continuous fiber conveying roller sensor; 133. Continuous fiber conveying tube; 2. Injection molding mechanism; 21. Injection device; 22. Melt buffer device; 23. Reversing valve; 24. Locking nozzle; 3. Injection molding machine clamping unit; 31. Equipment bed; 32. Mold; 33. Manipulator; 34. Temperature control device; 4. Information tracing organization; 41. Information code generating equipment. DETAILED DESCRIPTION

[0023] Embodiments of the present application will be described in detail below, examples of which are shown in the accompanying drawings, and the components of the embodiments of the present application generally described and shown in the accompanying drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the application claimed for protection, but merely represents selected embodiments of the present application.

[0024] Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative work shall fall within the scope of protection of this application.

[0025] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0026] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0027] With the booming development of the low-altitude economy, the research and development and production of new low-altitude aircraft such as electric vertical take-off and landing aircraft and unmanned flying cars have become key. The structural parts of these aircraft must not only have sufficient strength and rigidity to ensure flight safety, but also meet the requirements of lightweight to improve overall performance and endurance. Traditional metal materials are difficult to meet the lightweight requirements due to their heavy weight, and composite materials and high-performance plastics have gradually become the first choice for manufacturing low-altitude aircraft structural parts. However, the existing compounding injection molding technology has many shortcomings when applied to the manufacture of low-altitude aircraft structural parts. On the one hand, it is difficult to fully take into account the dual requirements of lightweight and high strength, resulting in unstable product quality; on the other hand, there are also obvious defects in the thermal history control of material processing, the introduction and retention of continuous fibers, automatic control, and product traceability, which limits its application in the manufacture of high-performance aircraft parts. Therefore, it is particularly urgent to develop an injection molding method and equipment that can meet the high-performance requirements of low-altitude aircraft structural parts.

[0028] In view of the shortcomings of the prior art in the manufacture of low-altitude aircraft structural parts, the present application provides a method and equipment for manufacturing continuous fiber reinforced structural parts, aiming to solve the problems that the prior art is difficult to take into account both lightweight and high-strength requirements, inaccurate production process control, and poor product traceability. The present application adopts continuous fiber reinforced resin materials for injection molding, which not only effectively improves the mechanical properties of the structural parts, but also achieves the lightweight goal and meets the high performance requirements of low-altitude aircraft for structural parts. At the same time, the equipment of the present application integrates an efficient extrusion mixing mechanism, a precise injection molding mechanism, a stable injection molding machine clamping unit, and an advanced information tracing system, which can realize the automatic control of the production process and the real-time collection of key data, ensuring the stability and traceability of product quality. In addition, by strictly controlling the key parameters in the mixing, injection and molding processes, such as temperature, pressure, time, etc., the present application further improves the molding accuracy and product consistency, and provides a reliable solution for the efficient and high-quality production of low-altitude aircraft structural parts.

[0029] The following will be combined Figure 1 and Figure 8 The technical solution of the present application is described clearly and completely. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments.

[0030] Figure 1 It is a schematic diagram of the steps of a method for manufacturing a continuous fiber reinforced structural member provided in an embodiment of the present application.

[0031] See also Figure 1 In a first aspect, the present application provides a method for manufacturing a continuous fiber reinforced structural member, comprising the following steps: S100, preheating the thermoplastic composite material sheet.

[0032] Before starting injection molding, the thermoplastic composite sheet must first be preheated to ensure that it meets the molding requirements and improves the molding effect and the performance of the final product. The specific operations are: After the thermoplastic composite sheet is heated to a certain temperature, it is placed in the injection mold for the next molding step.

[0033] In some specific examples, the heating process can be performed using an infrared heating station, a heating furnace, or other temperature control device.

[0034] In some specific examples, the temperature of the heated thermoplastic composite sheet is 180°C to 400°C, for example, 180°C, 190°C, 200°C, 210°C, 220°C, 230°C, 240°C, 250°C, 300°C, 350°C, 400°C, etc. The preheating treatment by heating enables the thermoplastic composite sheet to be better injected with the subsequently injected melt material for the injection molding process, thereby improving the bonding strength of the final product.

[0035] In some specific examples, the material of the thermoplastic composite sheet can be any resin reinforced with any fiber, such as continuous fiber reinforced polypropylene resin material, carbon fiber reinforced polypropylene, nylon, etc., preferably 30% to 60% continuous fiber reinforced polypropylene resin material, such as 30%, 40%, 45%, 50%, 60%, etc., preferably 45%. This material has excellent mechanical properties, improved temperature resistance and impact resistance, and is suitable for manufacturing components with high performance requirements such as low-altitude aircraft.

[0036] S200, designing an original material formula, and feeding each component in the original material formula into an extruder in proportion for mixing to obtain a molten material.

[0037] In this step, the raw materials of different components are transported to the extruder for mixing and melting to prepare the melt material to ensure that the final structural parts have the required properties during the molding process. This step specifically includes: Designing the original material formula means preparing the original material according to a certain ratio of resin matrix, mineral powder and fiber. The specific ratio can be adjusted according to different products. The preferred ratio of resin matrix, mineral powder and fiber is (50-60): (1-10): (30-60). For example, the ratio of resin matrix, mineral powder and fiber is (50, 52, 54, 56, 58, 60): (1, 2, 4, 6, 8, 10): (30, 32, 35, 37, 39, 41, 43, 45, 50, 55, 60). Preferably, the original material is prepared according to the ratio of resin matrix mass accounting for 55% of the original material mass, mineral powder accounting for 5% of the original material mass, and continuous fiber accounting for 40% of the original material mass. The resin matrix and mineral powder are stored separately in separate hoppers. The addition of mineral powder can improve the rigidity and wear resistance of the material; the addition of continuous fiber can improve the tensile strength, rigidity, fatigue resistance, impact resistance, etc. of the structural parts.

[0038] The resin matrix and mineral powder are accurately fed into the extruder for mixing through the weightless metering feeding device. At the same time, the continuous fiber is fed into the extruder through the continuous fiber conveying device to ensure that the continuous fiber is fully mixed with the resin matrix and mineral powder. The input amount of the continuous fiber can be calculated in real time, and the input amount of the continuous fiber to the material ratio can be made within the set range by fine-tuning the extruder screw speed or adjusting the fiber quantity.

[0039] The fiber entrance position of the extruder is at the middle position of the extruder and after the middle position along the material flow direction in the extruder. Strong shearing force will be generated at the front screw of the extruder, which can easily cause excessive shearing and damage of the fiber. Setting the fiber entrance at the middle position and after the middle position can avoid the fiber from being subjected to high-intensity shearing force when entering the extruder, thereby maintaining the integrity and length of the fiber, and further improving the mechanical properties of the composite material, such as tensile strength, rigidity and fatigue resistance.

[0040] In some specific examples, the continuous fiber can be continuous glass fiber, continuous carbon fiber, continuous aramid fiber, etc.

[0041] Finally, the extruder processes the above raw materials to obtain a uniform melt material, which enters the next molding process.

[0042] In this step, the final product is formed directly by using a specially designed formula, omitting the procurement of commercial plastic particles. This not only simplifies the production process, but also effectively reduces the manufacturing cost of the product. The introduction of continuous fibers significantly increases the effective retention length of the fibers in the resin matrix. Compared with the use of chopped fibers, continuous fibers can form a more complete network structure and skeleton support in the resin matrix, thereby greatly improving the ability of the reinforced material to absorb energy and significantly enhancing the overall strength of the material. This step can ensure that the final structural parts have better mechanical properties and higher reliability when subjected to external forces.

[0043] In some specific examples, the resin matrix is ​​usually made of polypropylene resin, which has good corrosion resistance, thermal stability and molding performance.

[0044] In some specific examples, the continuous fiber is selected from continuous fibers with a Tex value of 1200 g / km to 2500 g / km, such as 1200 g / km, 1500 g / km, 1800 g / km, 2000 g / km, 2100 g / km, 2200 g / km, 2300 g / km, 2400 g / km, 2500 g / km, etc., preferably 1200 g / km or 2400 g / km. "Tex value" is a unit used in the textile industry to indicate the thickness of yarn or fiber, defined as the weight of fiber in grams per 1000 meters in length. Using continuous fibers with higher Tex values ​​can help achieve better mechanical properties while reducing the risk of fiber breakage, thereby ensuring the quality and reliability of the finished product.

[0045] In some specific examples, the extruder can be a twin-screw extruder. The twin-screw extrusion mixing system is responsible for efficiently melt-mixing and dispersing the raw materials (such as resin matrix, mineral powder and continuous fiber) to ensure uniform distribution of each component. In this process, the melt is directly transported to the piston of the subsequent injection device. Compared with the traditional method of injection molding using commercial plastic particles, this method significantly reduces the thermal history of material processing. By reducing the number of heat treatments, the performance degradation of the material during the processing process is effectively reduced, and the original properties of the material are maintained.

[0046] In some specific examples, the temperature of the twin-screw extruder is set to 210°C to 400°C, for example, 210°C, 220°C, 250°C, 280°C, 300°C, 320°C, 340°C, 380°C, 400°C, etc., preferably 240°C, to ensure that the resin matrix, mineral powder and continuous fiber can be fully melted and evenly mixed during the extrusion process.

[0047] In some specific examples, the output of the twin-screw extruder is set to 110kg / h to 120kg / h, for example, 110kg / h, 111kg / h, 112kg / h, 113kg / h, 114kg / h, 115kg / h, 116kg / h, 117kg / h, 118kg / h, 119kg / h, 120kg / h, etc., preferably 114kg / h, and the screw speed is set to 180rpm to 200rpm, for example, 180rpm, 185rpm, 188rpm, 189rpm, 190rpm, 195rpm, 200rpm, etc., preferably 189rpm, to meet the needs of large-scale production and maintain a stable mixing effect.

[0048] S300, combining the preheated thermoplastic composite material sheet with the melt material through injection molding to obtain a structural part.

[0049] The melt material is transported to the injection mold where the preheated thermoplastic composite material sheet is located, and the molding operation is performed to produce the target structural part. The specific operations of this step include: S310, adjusting the reversing valve to the first state and entering the material storage stage.

[0050] The material storage stage is to transport the molten material in the extruder to the injection device. In the case where the melt buffer device contains molten material, the molten material in the melt buffer device is also transported to the injection device.

[0051] The reversing valve in the first state enables the extruder and the melt buffer device to be connected to the injection device but not to the injection mold.

[0052] In some specific examples, the extruder specifically uses a twin-screw extruder, which can efficiently melt the molten material completely and evenly mix it, and therefore the screw used for plasticization in the injection device can be replaced by a piston. This design not only simplifies the structure of the injection unit equipment and reduces unnecessary parts, but also greatly increases its effective utilization rate compared to traditional screw injection units. It also significantly reduces the effect of the melt being sheared by the screw again, thereby avoiding the loss of material properties. More importantly, it effectively protects the retained length of the continuous fiber, prevents it from being shortened due to additional shear force, and ensures the mechanical strength of the composite material.

[0053] In some specific examples, the temperature in the injection device is set to 210°C to 400°C, for example, 210°C, 220°C, 250°C, 280°C, 300°C, 320°C, 340°C, 380°C, 400°C, etc., preferably 245°C. This temperature can ensure the fluidity of the molten material during the injection process.

[0054] In some specific examples, the back pressure of the injection device is set to 10 bar to 200 bar, for example, 10 bar, 20 bar, 30 bar, 40 bar, 50 bar, 100 bar, 150 bar, 200 bar, etc., preferably 45 bar, and the back pressure is the backward pressure borne by the piston or screw in the injection device. The function of the back pressure is to ensure that the melt can be fully compacted, remove air bubbles, increase the melt density, and ensure uniform mixing of the materials.

[0055] In some specific examples, the storage position of the injection device is set to 5 times the diameter of the injection piston. The preferred storage position is 250mm to 300mm, for example 250mm, 260mm, 270mm, 280mm, 290mm, 300mm, etc., more preferably 280mm. This is the position setting of the piston or screw in the injection device, that is, in the storage stage, the piston or screw in the injection device retreats to a distance of 250mm to 300mm from the injection end of the injection device.

[0056] In some specific examples, if injection holding has been performed before this stage, this stage is performed simultaneously with the cooling stage in the mold.

[0057] S320, adjusting the reversing valve to the second state and entering the injection pressure maintaining stage.

[0058] During the injection and holding pressure stage, the injection device is connected to the locked nozzle, so that the molten material is injected from the injection device into the injection mold and combined with the thermoplastic composite material sheet through injection molding, and then the pressure is held; at the same time, the injection device is disconnected from the extruder and the melt buffer device, while the extruder is connected to the melt buffer device, the molten material in the extruder enters the melt buffer device, and the piston of the melt buffer moves upward to prepare for the injection stage.

[0059] In some specific examples, the injection device injects the molten material into the injection mold where the preheated thermoplastic composite sheet is located through a locked nozzle at a speed of 20mm / s-150mm / s. For example, the injection speed can be 20mm / s, 30mm / s, 50mm / s, 80mm / s, 100mm / s, 120mm / s, 150mm / s, etc., and the preferred injection speed is 65mm / s. In this way, it can be ensured that the molten material can quickly and evenly fill the entire mold cavity and tightly combine with the preheated thermoplastic composite sheet. The selection of injection speed is crucial to ensure that the melt can quickly and evenly fill the entire mold cavity. If the injection speed is too slow, the melt may cool too quickly and fail to completely fill the mold cavity; if it is too fast, it may generate too much shear heat or cause the gas in the mold cavity to be unable to be discharged in time, forming defects such as bubbles or shrinkage holes.

[0060] In some specific examples, during the injection of the molten material, a pressure holding procedure is carried out simultaneously, and the pressure holding pressure can be adjusted according to the actual products produced, and may be above 50-1000 bar. The pressure holding time can also be adjusted according to the actual products, and may be above 0s-1000s, preferably in the range of 50bar to 800bar, for example, 50bar, 100bar, 150bar, 200bar, 300bar, 400bar, 500bar, 600bar, 700bar, 800bar, etc., more preferably in the range of 280bar to 320bar, and the injection time can be determined according to product requirements, and may be 0s-1000s, for example, 1s, 100s, 500s, 1000s, etc., preferably 2.5s to 3.5s, for example, 2.5s, 2.6s, 2.7s, 2.8s, 2.9s, 3.0s, 3.1s, 3.2s, 3.3s, 3.4s, 3.5s, etc. When producing medium and large products, the melt can be injected at a pressure of 500 bar for 5 seconds. The main purpose of holding pressure is to ensure the density and flatness of the melt in the mold cavity and prevent product defects caused by cooling shrinkage. Appropriate holding pressure can improve the quality and dimensional accuracy of the finished product, which is especially important for large or complex parts.

[0061] In some specific examples, the melt buffer device is maintained at 210°C to 400°C during the whole process, for example, 210°C, 220°C, 250°C, 280°C, 300°C, 320°C, 340°C, 380°C, 400°C, etc., preferably 240°C. The temperature of the melt buffer device is similar to or the same as the temperature of the extruder to ensure that the melt material will not solidify due to the temperature drop during the buffering period. At the same time, it receives fresh melt material from the extruder to prepare for the next injection.

[0062] The control reversing valve alternates between the first state and the second state, repeatedly storing materials and injecting and holding pressure, thus realizing the continuous and efficient preparation of structural parts. This dynamic switching mechanism ensures that a series of operations such as melt material delivery, injection, holding pressure and cooling can be completed accurately in each cycle.

[0063] This continuous production mode not only improves production efficiency, but also reduces equipment downtime, energy consumption and costs.

[0064] The above steps realize the integrated operation of melt mixing and injection of material formula, greatly shorten the thermal history of material processing, and maximize the original performance of the material, which not only improves production efficiency but also ensures the stability and reliability of product quality.

[0065] S400: Collect manufacturing data of the structural component and associate it with the structural component.

[0066] In order to ensure product quality and facilitate traceability, an information management system is used to monitor the production process and associate relevant data with structural parts. The specific operations are as follows: The control system collects key data in the manufacturing process in real time, including the heating temperature of thermoplastic composite sheets, material mixing parameters, molding parameters, processor information, etc.; the collected data will be transmitted to the information traceability agency, which will package the data and generate an information code (such as a QR code).

[0067] The information code will be attached or engraved on each structural part as the unique identification of the product. Through the information code, the production batch, manufacturing process and related parameters of the product can be traced back to ensure the controllability and traceability of product quality.

[0068] The manufacturing method of the continuous fiber reinforced structural parts provided in the above-mentioned embodiments of the present application, by using continuous fiber reinforced resin materials for injection molding, not only improves the mechanical properties of low-altitude aircraft structural parts, but also increases the high temperature resistance, corrosion resistance and impact resistance of the material, and can show excellent performance in a complex working environment. By adopting a continuously switched reversing valve and an integrated design of an extruder-injection device, the present method can achieve continuous production, reduce the production cycle, and improve production efficiency. Through strict manufacturing process control and real-time data acquisition, the present method can ensure that the products of each production batch meet the quality standards and have high traceability, avoiding product quality problems. Accurately control key parameters in the mixing, injection and molding processes, such as temperature, pressure, time, etc., to ensure that each step is in the best working state, thereby improving molding accuracy and consistency.

[0069] When manufacturing low-altitude aircraft structural parts, the manufacturing method of continuous fiber reinforced structural parts provided in the above embodiments of the present application uses a combination of a twin-screw extrusion mixing system and an injection molding system to not only improve the overall performance of the material, but also achieves local effective strengthening of the product by using a thermoplastic organic sheet. This method can provide additional strength support at key locations, thereby meeting the strict requirements of the structural parts for mechanical properties. In addition, this integrated design allows the entire manufacturing process to be completed in one step through injection molding, greatly improving the design freedom of the product and the ability to realize complex shapes. This is an effective means of manufacturing plastic parts with extreme lightweight performance and high mechanical strength requirements. For example, when manufacturing the cabin ceiling shell of an electric vertical take-off and landing aircraft (eVTOL), this method can ensure that the 45% continuous fiber reinforced polypropylene resin material used maintains optimal performance during the molding process, thereby providing the required high strength and lightweight properties.

[0070] This method is particularly useful for applications that require high strength, high temperature resistance and good toughness, such as in the aerospace or automotive industries. It ensures that continuous fibers and other additives are evenly distributed throughout the product, resulting in excellent mechanical properties and reliability.

[0071] The following, combined Figures 2 to 7 The manufacturing device of the continuous fiber reinforced structural member provided by the present application is described in detail. It should be understood that the device is used to implement each step in the above method embodiment, that is, the description of the device embodiment corresponds to the description of the method embodiment, so the parts not described in detail in the two types of embodiments can refer to each other.

[0072] Figure 2 is a schematic structural diagram of a manufacturing device for a continuous fiber reinforced structural member provided according to an embodiment of the present application, Figure 3is a schematic structural diagram of an extrusion mixing mechanism and an injection molding mechanism of a manufacturing device for a continuous fiber reinforced structural member provided according to an embodiment of the present application, Figure 4 It is a structural schematic diagram of the connection between the extrusion mixing mechanism and the injection molding mechanism of the manufacturing equipment of the continuous fiber reinforced structural member provided according to one embodiment of the present application; Figure 5 This is a schematic structural diagram of the connection between a continuous fiber delivery pipe and an extruder of a manufacturing device for a continuous fiber reinforced structural member provided according to an embodiment of the present application; Figure 6 is a schematic structural diagram of a continuous fiber conveying device of a continuous fiber reinforced structural member manufacturing device provided according to an embodiment of the present application; Figure 7 It is a schematic structural diagram of a continuous fiber conveying roller sensor of a continuous fiber reinforced structural component manufacturing device provided according to an embodiment of the present application.

[0073] See also Figures 2 to 7 In the second aspect of the present application, there is provided a manufacturing device for continuous fiber reinforced structural parts, which integrates extrusion mixing, injection molding, molding and information tracing functions, aiming to achieve efficient and high-quality production of composite material structural parts, and specifically includes: an extrusion mixing mechanism 1, an injection molding mechanism 2, an injection molding machine clamping unit 3, a control system and an information tracing mechanism 4.

[0074] The extrusion mixing mechanism 1 includes an extruder 11, a weight-loss metering feeding device 12 and a continuous fiber conveying device 13. The weight-loss metering feeding device 12 is connected to the extruder 11 and is used to add raw materials and measure the amount of raw materials added; the continuous fiber conveying device 13 is connected to the extruder 11 and is used to input continuous fibers and measure. The inlet position of the fiber entering the extruder is at the middle position of the extruder and after the middle position along the material flow direction in the extruder. Preferably, the inlet position of the fiber entering the extruder is between 1 / 2 and 1 / 3 of the length of the extruder along the material flow direction.

[0075] The extruder 11 is responsible for melting and mixing the raw materials (such as polypropylene resin matrix and mineral powder) with the continuous fibers to form a uniform melt material.

[0076] In some specific examples, the extruder 11 uses a twin-screw extruder, and continuous glass fiber is added at the downstream opening of the twin-screw extruder. The threaded element design completes the processing and dispersion of the fiber under lower shear force, and completely melts and mixes with other material components, ensuring that the continuous fiber effectively retains its length and improving the overall performance of the composite material.

[0077] The weight-loss metering feeding device 12 is arranged on the extruder 11, and is used to accurately add and meter the amount of raw materials. For example, in a specific embodiment, after the original material formula is designed, the weight-loss metering feeding device 12 can set the input amount of each component according to the proportion of each component in the original material formula, so as to feed each component in the original material formula into the extruder in proportion for mixing. Such a setting can ensure that the formula ratio is accurate and avoid product defects caused by inaccurate raw material ratio or uneven dispersion.

[0078] The continuous fiber conveying device 13 is also connected to the extruder 11 and is responsible for inputting and metering the continuous fiber. The device can cooperate with the control system and the extruder to realize the closed-loop control of the continuous fiber input amount, that is, automatically adjust the continuous fiber input rate according to the set parameters to ensure the uniform distribution of the continuous fiber in the melt. For example, for 40% of the continuous fiber, its input speed can be monitored in real time by a sensor and kept stable by a closed-loop control system.

[0079] The injection molding mechanism 2 includes an injection device 21 , a melt buffer device 22 , a reversing valve 23 and a locking nozzle 24 . The melt buffer device 22 and the injection device 21 are interconnected via the reversing valve 23 .

[0080] The injection device 21 can receive the melt material from the extruder 11 and the melt buffer device 22, and inject it into the mold of the injection molding machine clamping unit 3 at a specific speed and pressure. The injection device 21 is equipped with a precise control unit that can adjust the injection speed (e.g., 65 mm / s) and the holding pressure (e.g., 300 bar, 3 seconds) to ensure the quality and repeatability of the melt filling the mold cavity.

[0081] The melt buffer device 22 is located between the extruder 11 and the injection device 21, and is used to receive the molten material in the extruder 11 during the injection and pressure holding stage and to transport the material inside to the injection device 21 during the material storage stage. That is, it plays a role in balancing the continuous operation of the extruder and the intermittent injection operation rhythm of the injection device, reducing fluctuations caused by asynchrony, and enabling the extruder 11 and the injection device 21 to work in coordination.

[0082] The reversing valve 23 is a key component connecting the extruder 11, the injection device 21 and the locking nozzle 24. The reversing valve 23 can be switched between a first state and a second state, thereby realizing the storage and injection transmission of the molten material.

[0083] In the first state, i.e. the material storage stage, the reversing valve 23 is adjusted so that the extruder 11 and the melt buffer device 22 are connected to the injection device 21 , while the injection device 21 cannot be connected to the mold of the clamping unit 3 of the injection molding machine through the locking nozzle 24 .

[0084] In the second state, i.e. the injection pressure holding stage, the reversing valve 23 is adjusted so that the extruder 11 is connected to the melt buffer device 22 but not to the injection device 21; and the injection device 21 is connected to the mold of the clamping unit 3 of the injection molding machine through the locking nozzle.

[0085] The locking nozzle 24 is installed at the front end of the injection device 21, directly contacts the mold 32, and is responsible for introducing the melt into the mold cavity of the mold of the injection molding machine clamping unit 3 to perform injection molding of the structural parts. The design of the locking nozzle 24 needs to consider factors such as sealing, high temperature resistance and easy cleaning to ensure long-term stable operation.

[0086] The injection molding machine clamping unit 3 is connected to the injection molding mechanism 2 and is used for molding structural parts.

[0087] The control system (not shown in the figure) is electrically connected to the extrusion mixing mechanism 1, the injection molding mechanism 2 and the injection molding machine clamping unit 3, respectively, to achieve a high degree of automation of the entire manufacturing process. It not only monitors the working status of each component, but also automatically adjusts some parameters according to the preset program to ensure that each step is executed under the optimal conditions.

[0088] The control system is responsible for collecting key manufacturing data, such as the heating temperature of the thermoplastic composite sheet, material mixing parameters, molding conditions, etc., and transmitting this information to the information traceability organization 4 for subsequent product quality tracking and management.

[0089] like Figure 8 As shown, the information traceability mechanism 4 is connected to the control system, receives and processes the manufacturing data, and then encapsulates it into an information code. Each finished product will be accompanied by a unique information code, which can be scanned to view detailed production process records, including but not limited to organic sheet heating information, injection molding parameters, processor information, etc. This approach not only enhances product transparency, but also provides strong support for maintenance and quality assurance.

[0090] In some embodiments, see Figure 3 and Figure 6 The continuous fiber conveying device 13 includes a continuous fiber conveying frame 131, a continuous fiber conveying roller sensor 132 and a continuous fiber conveying tube 133. The fiber entry ends of the continuous fiber conveying roller sensor 132 and the continuous fiber conveying tube 133 are arranged on the continuous fiber conveying frame 131. A continuous fiber roll is placed on the continuous fiber conveying frame 131. The continuous fiber passes through the continuous fiber conveying roller sensor 132, enters the continuous fiber conveying tube 133, and enters the middle section or the rear section of the twin-screw extruder through the fiber output end of the continuous fiber conveying tube 133, thereby avoiding the front plasticizing section of the twin-screw extruder and threaded structures such as kneading blocks or mixing blocks, so as to prevent the continuous fiber from being excessively crushed.

[0091] The continuous fiber conveying roller sensor 132 monitors the number of continuous fibers, line speed (km / h) and tension passing through the conveying pipe in real time, and provides accurate data feedback to the control system. The control system pre-sets the percentage of the continuous aramid fiber mass required per unit time to the total material, that is, the preset ratio of the continuous fiber, and the Tex value of the continuous fiber (such as 2400g / km), and then according to the formula: the fiber mass input into the twin-screw extruder per unit time = the number of fiber bundles × the fiber input line speed × the Tex value, the control system can calculate the real-time input amount of continuous fibers into the twin-screw extruder per unit time, and the control system can monitor the real-time delivery amount of each component in the original material formula per unit time in real time, and then divide the real-time input fiber mass by the real-time material delivery total amount to obtain the real-time ratio of continuous fiber delivery, and compare it with the preset ratio. If there is a deviation, the continuous fiber mass input into the twin-screw extruder per unit time will be controlled by fine-tuning the twin-screw extruder screw speed (the minimum screw speed change per second is 1 turn) or increasing or decreasing the number of continuous fibers, so that it is kept consistent with the set percentage value as much as possible.

[0092] In some specific examples, the control system also includes information such as the current equipment output rate (how many kilograms per hour).

[0093] The fiber output end of the continuous fiber conveying tube 133 is connected to the middle and rear section of the extruder 11 to form a closed continuous fiber transmission channel, which ensures that the continuous fiber is not affected by the external environment during the process from the conveyor to the extruder, avoids the interference of pollutants such as dust and moisture, and also prevents the continuous fiber from knotting or entanglement.

[0094] The three components in this embodiment together form a closed-loop control system (the closed-loop control function can be activated or deactivated) to ensure the precise input of continuous fibers. By optimizing the design and layout of each component, the entire conveying system can operate efficiently while minimizing shear force and retaining the original length of the continuous fibers to the maximum extent, which is particularly important for enhancing the mechanical properties of composite materials. Accurate continuous fiber metering and stable conveying process not only improve product quality, but also reduce the scrap rate caused by uneven continuous fiber input, and improve overall production efficiency and consistency.

[0095] In some specific examples, the number of continuous fibers should be about 8 strands. If the number of fibers (strands) is small or excessive when the required continuous fiber feed amount is certain, it is necessary to increase or decrease the continuous fiber linear speed, that is, to significantly increase or decrease the screw machine speed. When the screw machine speed is significantly changed, other problems will arise. Therefore, by controlling the number of continuous fiber strands to about 8 strands, the continuous fiber delivery amount can be more accurately controlled, thereby preparing better quality structural parts.

[0096] In some specific examples, the number of continuous fibers is 8 strands, the continuous fiber conveying roller sensor 132 measures the continuous fiber linear speed to be 2.38 km / h, and the Tex value of the continuous fiber is 2400 g / km. At this time, the fiber mass input into the twin-screw extruder per unit time = fiber number × fiber input linear speed × Tex value = 8 × 2.38 km / h × 2400 g / km = 45700 g / h = 45.7 kg / h. The control system will compare this value with the pre-set required value. At this time, the screw speed of the twin-screw extruder is 195 / min. If there is a deviation in the comparison, the control center will further fine-tune the screw speed of the twin-screw extruder to make it as close to the set value as possible.

[0097] In some embodiments, see Figure 2 The injection molding machine clamping unit 3 includes an equipment bed 31, a mold 32, a manipulator 33, a temperature control device 34, a fixed mold plate, a movable mold plate, etc.

[0098] The equipment bed 31 serves as a supporting platform, carrying the mold 32, the manipulator 33 and the temperature control device 34, and providing a stable installation foundation.

[0099] The mold 32 is installed on the equipment bed 31 and directly connected to the locking nozzle 24. It carries the preheated thermoplastic composite sheet and receives the molten material from the injection molding mechanism. The mold is a key component that determines the shape and size of the final product. It has precise chambers and channels inside, which can accurately control the flow path of the melt to ensure that every detail meets the design requirements.

[0100] The mold 32 is usually made of high-strength alloy steel with good thermal conductivity and wear resistance. In order to improve production efficiency, the mold is also equipped with a quick change interface to facilitate rapid switching between different batches. In addition, a heating element is integrated inside the mold. The manipulator 33 can be installed on the equipment bed 31 and near the mold according to actual production needs. The manipulator 33 is responsible for automated operations, including placing the cut sheets into the infrared heating station for preheating, hanging the preheated sheets into the mold 32, and taking out the finished products. The design of the manipulator needs to consider flexibility, accuracy and speed to ensure that each action can be performed accurately.

[0101] The temperature control device 34 can be arranged on the equipment bed 31 or on the fixed platen according to actual production needs, and arranged around the mold 32. The temperature control device 34 can preheat the thermoplastic composite sheet as needed to promote good bonding between the melt and the thermoplastic composite sheet and avoid product defects caused by temperature differences.

[0102] In some specific examples, the temperature control device 34 is usually in the form of an infrared heating station, an electric heating plate or an induction heater, etc., which has the characteristics of rapid heating, uniform heating and easy control.

[0103] In some embodiments, the information tracing mechanism 4 includes a data storage unit (not shown in the figure), an information packaging unit (not shown in the figure) and an information code generating device 41. The data storage unit is connected to the control system to receive and store the structural component manufacturing data that needs to be associated; the information packaging unit is connected to the data storage unit to convert the structural component manufacturing data into an information code suitable for printing or display; the information code generating device 41 is connected to the information packaging unit to generate information codes such as Figure 8 Device with physical QR code label shown.

[0104] The workflow of the injection molding equipment for manufacturing low-altitude aircraft structural parts provided in the second aspect of the present application is as follows: (1) Preheating of thermoplastic composite sheets: The thermoplastic composite sheet is preheated by a temperature control device 34 and then placed into a mold 32 by a robot 33 to prepare for subsequent molding steps.

[0105] (2) Material mixing: The resin matrix and mineral powder in proportion are fed into the extruder 11 through the weight loss metering feeding device 12; at the same time, the continuous fiber in proportion is fed into the extruder 11 through the continuous fiber conveying device 13.

[0106] The extruder 11 melts and mixes the above ingredients at a certain temperature and rotation speed to obtain a uniform melt material.

[0107] (3) Storage and injection of melt materials: The reversing valve 23 is adjusted to the first state, so that the melt material in the extruder 11 is transported to the injection device 21 .

[0108] After the material storage is completed, the reversing valve 23 is adjusted to the second state, so that the injection device 21 injects the molten material into the mold 32 where the preheated thermoplastic composite material sheet is located through the locking nozzle 24 at a certain injection speed, and maintains the pressure to ensure that the molten material is tightly combined with the thermoplastic composite material sheet and fills the entire mold cavity.

[0109] During this process, the melt buffer device 22 maintains the same temperature as the injection device 21 (the temperature is set to be the same) and receives fresh melt material from the extruder to prepare for the next material storage stage.

[0110] After the injection is completed, the reversing valve 23 is adjusted to the first state again, the melt material in the extruder 11 and the melt buffer device 22 is transported to the injection device 21, and then the reversing valve is switched again, so that the preparation of the structural parts is continuously repeated.

[0111] (4) Structural parts forming: After the injection is completed, during the material storage stage, the molten material is cooled and solidified in the mold 32 to form the final structural part. After the mold is opened, it is taken away by the robot 33, and then a new preheated thermoplastic composite material sheet is placed in it, waiting for the next injection.

[0112] (5) Data collection and information tracing: The control system collects key data of the entire manufacturing process, such as heating temperature of thermoplastic composite sheets, material mixing parameters, molding parameters, etc.

[0113] These data are transmitted to the information tracing agency 4, which encapsulates the data into Figure 8 The information code (such as a QR code) shown in the figure is attached to each finished product to achieve product traceability.

[0114] The second aspect of the present application provides a continuous fiber reinforced structural part manufacturing device, which realizes continuous and efficient preparation of structural parts by quickly switching between the first state and the second state through the reversing valve, reduces the equipment downtime, and greatly improves the overall work efficiency. The manipulator and the intelligent control system work together to realize the automation of the entire process from preheating treatment of thermoplastic composite sheets to removal of finished products, reducing manual intervention, reducing human errors, and improving production stability.

[0115] The equipment can strictly control key process parameters such as injection speed, holding pressure parameters, melt buffer device temperature, etc., ensuring that each production step can be executed under optimal conditions, thereby significantly improving the quality of the finished product. The use of a twin-screw extruder for material mixing reduces the risk of the melt being sheared again, protects the length of continuous fibers, and improves the mechanical strength and durability of the composite material. The equipment collects and transmits manufacturing data through the control system, and the information traceability mechanism generates a QR code containing detailed manufacturing information, which is attached or engraved on each finished product. This approach not only enhances the transparency of the product, but also provides strong support for maintenance and quality assurance, facilitating later tracking and management.

[0116] In addition, the equipment can flexibly configure the working parameters of each component according to specific production requirements to meet diverse product manufacturing needs, especially for low-altitude aircraft structural parts that require high strength and lightweight properties.

[0117] It should be noted that the technical solutions in the various embodiments of the present application can be combined with each other, but the basis for the mutual combination is that it can be implemented by ordinary technicians in the field; when the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist, that is, it does not belong to the scope of protection of this application.

[0118] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit it. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for manufacturing a continuous fiber reinforced structural member, characterized in that: The steps include: preheating the thermoplastic composite sheet; Designing a raw material formula, feeding each component in the raw material formula into an extruder according to a proportion for mixing to obtain a melt material; Combining the preheated thermoplastic composite material sheet with the melt material through injection molding to obtain a structural part; The control system collects manufacturing data of the structural component and associates the manufacturing data with the structural component; Among them, the original material formula includes fibers, and the fibers are fed into the extruder by a continuous fiber conveying device. The control system includes a preset proportion of the fibers in the original material formula, and the control system interacts with the continuous fiber conveying device to adjust the real-time proportion of the fibers so that the real-time proportion of the fibers remains consistent with the preset proportion.

2. The method for manufacturing a continuous fiber reinforced structural member according to claim 1, characterized in that: The fiber inlet position entering the extruder is at the middle position of the extruder and after the middle position along the material flow direction in the extruder.

3. The method for manufacturing a continuous fiber reinforced structural member according to claim 1, characterized in that: The control system interacts with the continuous fiber delivery device to adjust the real-time ratio of the fibers so that the real-time ratio of the fibers is consistent with the preset ratio, including: The continuous fiber delivery device detects the number of strands and the linear speed of the fiber and transmits them to the control system; The control system includes the Tex value of the fiber and the real-time delivery amount of each component in the original material formula. The control system calculates the fiber mass input into the extruder per unit time according to the following formula: The actual fiber mass input into the extruder per unit time = number of fiber strands × linear speed × Tex value; The control system calculates the real-time ratio of the fibers according to the actual fiber mass input into the extruder per unit time and the real-time delivery amount of each component in the original material formula, and compares it with the preset ratio of the fibers; If there is a deviation in the comparison result, at least one of the following methods shall be adopted to make adjustments to eliminate the deviation: The fiber strand count was adjusted and the extruder screw speed was adjusted to a minimum of 1 revolution per second.

4. The method for manufacturing a continuous fiber reinforced structural member according to claim 1, characterized in that: The preheated thermoplastic composite material sheet is combined with the melt material by injection molding to obtain a structural part, including: a material storage stage and an injection pressure holding stage, The material storage stage includes: conveying the molten material in the extruder to the injection device, and in the case where the melt buffer device contains the molten material, conveying the molten material in the melt buffer device to the injection device; The injection and pressure holding stage includes: injecting the molten material in the injection device into the mold cavity where the thermoplastic composite material sheet is located, so that the thermoplastic composite material sheet and the molten material are combined to obtain a structural part; at the same time, the extruder is connected to the melt buffer device, and the molten material in the extruder enters the melt buffer device.

5. The method for manufacturing a continuous fiber reinforced structural member according to claim 4, characterized in that: During the material storage stage, the temperature in the injection device is 210° C. to 400° C., the back pressure is 10 bar to 200 bar, and the maximum material storage position is 5 times the diameter of the injection piston.

6. The method for manufacturing a continuous fiber reinforced structural member according to claim 4, characterized in that: During the injection pressure holding stage, the injection speed of the injection device is from 20 mm / s to the upper limit of the injection speed of the injection device, and the pressure is held at 50 bar to 800 bar during the injection process for a time of 0 s to 1000 s.

7. The method for manufacturing a continuous fiber reinforced structural member according to claim 4, characterized in that: The injection speed of the injection device is 20 mm / s to 150 mm / s.

8. The method for manufacturing a continuous fiber reinforced structural member according to claim 4, characterized in that: The injection process takes 2.5s to 3.5s.

9. The method for manufacturing a continuous fiber reinforced structural member according to claim 4, characterized in that: During the injection and pressure holding stage, the temperature of the melt buffer device is 210°C to 400°C.

10. The method for manufacturing a continuous fiber reinforced structural member according to claim 4, characterized in that: The material storage stage and the injection pressure holding stage can be performed cyclically to achieve continuous production of structural parts.

11. The method for manufacturing a continuous fiber reinforced structural member according to claim 1, characterized in that: Designing an original material formula, feeding each component in the original material formula into an extruder in proportion for mixing to obtain a melt material comprising: The resin matrix, mineral powder and fiber are fed into an extruder in a ratio of (50-60): (1-10): (30-60) for mixing to obtain a molten material.

12. The method for manufacturing a continuous fiber reinforced structural member according to claim 11, characterized in that: The ratio of resin matrix, mineral powder and fiber is 55:5:

40.

13. The method for manufacturing a continuous fiber reinforced structural member according to claim 11, characterized in that: The resin matrix is ​​made of polypropylene resin.

14. The method for manufacturing a continuous fiber reinforced structural member according to claim 11, characterized in that: The fiber is a continuous fiber, and the Tex value of the continuous fiber is set to be 2300 g / km to 2500 g / km.

15. The method for manufacturing a continuous fiber reinforced structural member according to claim 11, characterized in that: The extruder is specifically a twin-screw extruder, the internal temperature of the extruder is 210° C. to 400° C., the output is 110 kg / h to 120 kg / h, and the screw speed is 180 rpm to 200 rpm.

16. The method for manufacturing a continuous fiber reinforced structural member according to claim 1, characterized in that: The preheating of the thermoplastic composite sheet includes: The thermoplastic composite sheet is heated and then placed into a mold, and the heating temperature is 210°C to 230°C.

17. The method for manufacturing a continuous fiber reinforced structural member according to claim 16, characterized in that: The thermoplastic composite material sheet adopts a fiber-reinforced resin material.

18. The method for manufacturing a continuous fiber reinforced structural member according to claim 17, characterized in that: The fiber-reinforced resin material used in the thermoplastic composite sheet is one of 30% to 60% continuous fiber-reinforced polypropylene resin material, carbon fiber-reinforced polypropylene, and nylon.

19. The method for manufacturing a continuous fiber reinforced structural member according to claim 1, characterized in that: Collecting the manufacturing data of the structural component and associating it with the structural component includes: The manufacturing data of the structural component is collected, the received manufacturing data is packaged into an information code, and the information code is set on the structural component.

20. The method for manufacturing a continuous fiber reinforced structural member according to claim 19, characterized in that: The manufacturing data includes at least one of the heating temperature of the thermoplastic composite sheet, material mixing parameters, molding parameters, and processor information.

21. A manufacturing device for continuous fiber reinforced structural parts, characterized in that: include: The extrusion mixing mechanism comprises an extruder, a weight-loss metering feeding device and a continuous fiber conveying device, wherein the weight-loss metering feeding device is connected to the extruder and used to add raw materials and measure the amount of raw materials added; the continuous fiber conveying device is connected to the extruder and used to convey fibers and collect fiber conveying amount data in real time and feed it back to the control system; An injection molding mechanism comprises an injection device, a melt buffer device, a reversing valve and a locking nozzle, wherein the extruder, the injection device, the melt buffer device and the locking nozzle are connected via the reversing valve; An injection molding machine clamping unit, connected to the injection molding mechanism, for molding the structural parts; A control system connected to the extrusion mixing mechanism, the injection molding mechanism and the injection molding machine clamping unit, for realizing automatic control and coordination of the structural component manufacturing process and collecting manufacturing data of the structural component; and The information tracing mechanism is connected to the control system and is used to receive the manufacturing data collected by the control system and associate the manufacturing data with the structural component.

22. The manufacturing equipment for continuous fiber reinforced structural parts according to claim 21, characterized in that: The fiber inlet position entering the extruder is at the middle position of the extruder and after the middle position along the material flow direction in the extruder.

23. The manufacturing equipment for continuous fiber reinforced structural parts according to claim 21, characterized in that: The continuous fiber conveying device includes a continuous fiber conveying frame, a continuous fiber conveying roller sensor and a continuous fiber conveying tube. The continuous fiber conveying roller sensor and the fiber entry end of the continuous fiber conveying tube are both arranged on the continuous fiber conveying frame. A fiber roll is placed on the continuous fiber conveying frame. The fiber enters the continuous fiber conveying tube through the continuous fiber conveying roller sensor. The fiber output end of the continuous fiber conveying tube is connected to the extruder.

24. The manufacturing equipment for continuous fiber reinforced structural parts according to claim 21, characterized in that: The injection molding machine clamping unit comprises an equipment bed, a mold, a manipulator and a temperature control device. The mold, the manipulator and the temperature control device are all arranged on the equipment bed, and the mold is connected to the locking nozzle.

25. The manufacturing equipment for continuous fiber reinforced structural parts according to claim 21, characterized in that: The information tracing mechanism includes a data storage unit, an information packaging unit and an information code generating device. The data storage unit is connected to the control system to receive and store the structural component manufacturing data that needs to be associated; the information packaging unit is connected to the data storage unit and is used to convert the structural component manufacturing data into an information code suitable for printing or display; the information code generating device is connected to the information packaging unit and is a device for generating a physical two-dimensional code label.

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