Impregnation mold and production device and production method of continuous fiber composite material

Abstract

The present invention provides an impregnation mold and a production device and a production method for a continuous fiber composite material. The impregnation mold is provided with a resin melt flow channel (5) and a continuous fiber laying flow channel (10) which are interconnected. The invention is characterized in that a resin outlet pipeline (9) is provided on the impregnation mold, and the resin outlet pipeline (9) is connected to the resin melt flow channel (5) for recovering excess resin melt. The invention realizes melt impregnation of both sides of the fiber, thereby improving the surface impregnation degree of the continuous fiber by the thermoplastic resin. At the same time, the production process of the continuous fiber composite material prepreg tape and the recycling process of the thermoplastic resin are synchronously carried out, thereby solving the problem of mold leakage caused by excess resin melt in the production process.

Description

Technical Field

[0001] The invention belongs to the technical field of preparation and processing of continuous fiber composite materials, and specifically relates to an impregnation mold and a production device and a production method of the continuous fiber composite material. Background Art

[0002] With the normalization of environmental supervision and the increasing attention of the whole society to environmental issues, how to solve the technical problems of the industry such as volatile gases and dust, recycling of scraps and waste products in the production process of thermosetting composite materials has encountered unprecedented challenges. The market demand for products has gradually shrunk, and related companies are in urgent need of adjusting their product structure to achieve clean production and green development. Thermoplastic composite materials have benefited from the development of the green economy. Various types of thermoplastic composite materials, including engineering plastics, long fiber reinforced thermoplastic composite materials, and continuous fiber composite materials, have been increasingly widely used in the fields of lightweight automobiles, home appliances, and construction. The output of thermoplastic composite products in China has grown steadily.

[0003] Continuous fiber composite materials are high-strength, high-rigidity, and high-toughness composite materials that use continuous fibers as reinforcement materials and thermoplastic resins as the matrix. They are manufactured through a process of melt impregnation of thermoplastic resins. Available reinforcement materials include glass fiber, carbon fiber, aramid fiber, plant fiber, and basalt fiber; available resin matrices include PP, PE, PA6, PA66, PC, PET, PPS, PEEK, etc.; depending on product performance and molding requirements, the reinforcement material can be in the form of unidirectional or fabric. Due to its unique properties such as light weight, high strength, high impact resistance, and recyclability, it has always maintained rapid growth in the thermoplastic composite market. It has become the key development direction and preferred target for mergers and acquisitions by domestic and foreign industry giants, and will eventually replace the market dominance of short-fiber and long-fiber reinforced thermoplastic composites.

[0004] In the prior art, taking the patent application with application number CN201210202166.2 as an example, it discloses a high-strength thermoplastic composite material and its preparation method. The composite material is made of the following components in weight percentage: 70-80% thermoplastic resin and 20-30% continuous fiber. The preparation method is as follows: first, prepare a unidirectional fiber impregnated tape, then divide the unidirectional fiber impregnated tape into filaments, weave the impregnated strips after dividing into filaments, and finally hot press mold to obtain a thermoplastic composite material. In the production process of its continuous fiber composite material, the thermoplastic resin is often drawn out from the impregnation mold together with the continuous fiber, so in the actual production process, it is necessary to control the feeding of the thermoplastic resin and the continuous fiber more accurately. If the thermoplastic resin is fed less, the continuous fiber impregnation effect is likely to be poor. If the thermoplastic resin is fed less, the resin melt is likely to be excessive, resulting in leakage. Summary of the invention

[0005] In view of this, the present invention aims to propose an impregnation mold and a production device and a production method for continuous fiber composite materials, so as to solve the problems existing in the prior art such as poor continuous fiber impregnation effect and leakage caused by excessive resin melt, so as to improve the surface impregnation degree of the continuous fiber by the thermoplastic resin, and at the same time improve the utilization efficiency of the thermoplastic resin and reduce the production cost.

[0006] To achieve the above object, the technical solution of the present invention is achieved as follows:

[0007] A dipping mould is provided in which a resin melt flow channel and a continuous fiber laying flow channel which are interconnected are arranged. A resin outlet pipeline is arranged on the dipping mould. The resin outlet pipeline is connected with the resin melt flow channel and is used for recovering excess resin melt.

[0008] Furthermore, the resin melt flow channel includes a resin melt feed flow channel, a resin melt storage flow channel, and a resin melt discharge flow channel which are connected in sequence.

[0009] Furthermore, the impregnation mold is provided with a resin inlet pipeline, one end of the resin melt feed channel is connected to the resin inlet pipeline, and the other end of the resin melt feed channel is connected to the continuous fiber laying channel and the resin melt storage channel.

[0010] Furthermore, one end of the resin melt discharge flow channel is communicated with the resin outlet pipeline, and the other end of the resin melt discharge flow channel is communicated with the continuous fiber laying flow channel and the resin melt storage flow channel.

[0011] Furthermore, the resin melt flow channel includes at least one resin melt storage flow channel, and the discharge end and the feed end of any resin melt storage flow channel are both connected to the continuous fiber laying flow channel.

[0012] Furthermore, at least one resin melt storage cavity is provided on the resin melt storage flow channel.

[0013] Furthermore, at the connection point between the continuous fiber laying flow channel and the resin melt flow channel, the continuous fiber laying flow channel and the resin melt flow channel are cross-distributed at an angle of 0.

[0014] Furthermore, a regulating valve is arranged on the resin outlet pipeline.

[0015] Furthermore, the continuous fiber laying flow channel includes a continuous fiber yarn inlet and a tape outlet. A one-way check valve is arranged on the continuous fiber yarn inlet, and a stop valve is arranged on the tape outlet.

[0016] Furthermore, the impregnation mold includes a male mold plate and a female mold plate, and the male mold plate is detachably connected to the female mold plate; the resin melt flow channel and the continuous fiber laying flow channel are arranged in the female mold plate, and at least one pair of guide rollers is arranged in the continuous fiber laying flow channel.

[0017] Furthermore, the female template is provided with a guide roller assembly hole in the continuous fiber laying flow channel, one end of the guide roller is connected to the male template, and the other end of the guide roller is connected to the guide roller assembly hole in a detachable manner.

[0018] Furthermore, the guide roller assembly hole passes through the female template.

[0019] A production device for continuous fiber composite material comprises a thermoplastic resin processing system, a continuous fiber processing system and the impregnation mold; the thermoplastic resin processing system is connected to a resin melt flow channel, and the continuous fiber processing system is connected to a continuous fiber laying flow channel.

[0020] Furthermore, the continuous fiber processing system includes a first processing system and a second processing system, wherein the first processing system is connected to a continuous fiber yarn inlet of a continuous fiber laying channel, and the second processing system is connected to a strip outlet of the continuous fiber laying channel.

[0021] Furthermore, the first processing system includes a fiber yarn rack tensioning device, a yarn guiding and spreading device, a yarn dividing and spreading device, and a fiber preheating device connected in sequence, and the discharge port of the fiber preheating device is connected to the continuous fiber yarn inlet; the second processing system includes a strip cooling roller pressing device and a strip slitting and winding device connected in sequence, and the feed port of the strip cooling roller pressing device is connected to the strip outlet.

[0022] Furthermore, the yarn guiding and spreading device includes a yarn guiding plate, a yarn dividing comb, and a steel buckle; the yarn dividing and spreading device includes a curved surface dividing roller and a flat flattening tensioning roller; and the fiber preheating device includes an infrared heater and an electromagnetic heater.

[0023] Furthermore, the thermoplastic resin processing system includes a pre-processing system and a post-processing system, the pre-processing system is connected to a resin inlet pipeline, and the resin outlet pipeline is connected to the pre-processing system and / or the post-processing system.

[0024] Furthermore, the pre-treatment system comprises a resin extrusion plasticizing device and a resin melt pressurizing and conveying device which are connected in sequence, and the discharge port of the resin melt pressurizing and conveying device is connected to the resin inlet pipeline.

[0025] Furthermore, the resin outlet pipeline is connected to a feed port of a resin extrusion and plasticizing device.

[0026] Furthermore, the resin extrusion and plasticization device includes at least one of a planetary screw extruder, a single screw extruder and a twin screw extruder; and the resin melt pressurizing and conveying device includes a melt pump.

[0027] Furthermore, the post-processing system comprises a resin strip cooling device, a resin pelletizing and screening device and a resin particle drying and packaging device which are connected in sequence, and the feed port of the resin strip cooling device is connected to the resin outlet pipeline.

[0028] Furthermore, the resin strip cooling device includes a cooling water trough and a strip guide roller; the resin pelletizing and screening device includes a pelletizer and a vibrating screen; the resin particle drying and packaging device includes an air drier, a screw feeder, a high-mix mixer, a silo, a weighing scale, a bag sewing machine and a conveyor belt.

[0029] A method for producing a continuous fiber composite material, the method being applied to the production device, and comprising:

[0030] S1, yarn drawing: the continuous fiber is passed through the creel tensioning device, the yarn guide and yarn spreading device, the yarn splitting and spreading device, and the fiber preheating device in sequence, and the female template of the impregnation mold is taken, and the continuous fiber enters the continuous fiber laying flow channel through the continuous fiber yarn inlet, and then passes through the guide roller, the strip outlet, the strip cooling roller pressing device, and the strip slitting and winding device in sequence, and the yarn head of the continuous fiber is fixed on the strip slitting and winding device;

[0031] S2, mold closing: open the stop valve, close and connect the male mold plate and the female mold plate, close the regulating valve 8, and start the heating device to preheat the impregnation mold;

[0032] S3, impregnation: start the resin extrusion plasticizing device to plasticize the resin, and use the melt pressure conveying device to convey the plasticized excess or appropriate amount of resin melt from the resin inlet pipeline to the resin melt flow channel and the continuous fiber laying flow channel to achieve double-sided impregnation of the continuous fiber;

[0033] S4, cooling and winding: start the strip cooling roller pressing device and the strip slitting and winding device, use the strip cooling roller pressing device to cool and roll the impregnated continuous fibers to obtain a continuous fiber composite material strip, and then use the strip slitting and winding device to wind the cooled continuous fiber composite material strip to obtain the continuous fiber composite material.

[0034] Furthermore, in step S3, the continuous fibers are impregnated with excess resin melt.

[0035] Furthermore, the method comprises:

[0036] S5. Granulation: After the continuous fiber is evenly impregnated on the surface, start the resin granulation and screening device, then open the regulating valve to pull the excess resin into strips, and then granulate, screen, dry and package it after cooling for recycling.

[0037] Furthermore, the method comprises:

[0038] S6. Recycling of excess resin: After the continuous fibers are evenly impregnated on the surface, the regulating valve is opened to directly transport the excess resin to the resin extrusion plasticizing device through the resin outlet pipeline.

[0039] Compared with the prior art, the impregnation mold and the production device and method of the continuous fiber composite material described in the present invention have the following advantages:

[0040] The present invention discloses an impregnation mold and a production device and a production method for a continuous fiber composite material. Based on the impregnation mold, the impact force of a high-pressure steady-flow melt is used to realize melt impregnation of both sides of the continuous fiber, thereby improving the surface impregnation degree of the continuous fiber by the thermoplastic resin. At the same time, by setting a resin outlet pipeline, the resin melt is recovered, thereby realizing the synchronization of the production process of the continuous fiber composite material prepreg tape and the thermoplastic resin recovery and reuse process, so that during the entire impregnation process, there is no need to accurately control the feed amount of the thermoplastic resin, and it is only necessary to always keep the thermoplastic resin in excess. On the one hand, the precise control of the feed situation during the actual impregnation process is reduced, which is conducive to reducing the labor intensity of the operators. On the other hand, the excess thermoplastic resin can fully impregnate the continuous fiber, thereby improving the surface impregnation degree of the thermoplastic resin on the continuous fiber. This not only solves the mold leakage problem caused by the excess resin melt in the production process of the continuous fiber composite material tape, but also improves the impregnation effect of the continuous fiber, improves the utilization efficiency of the thermoplastic resin, and is conducive to reducing the production cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0042] Figure 1 It is a schematic diagram of the production process of the continuous fiber composite material of the present invention;

[0043] Figure 2 It is a schematic structural diagram of the melt impregnation mold of the present invention when the positive mold plate is omitted;

[0044] Figure 3 It is a schematic structural diagram of the female mold plate of the melt impregnation mold of the present invention.

[0045] Description of reference numerals:

[0046] Continuous fiber 1, resin inlet pipeline 2, continuous fiber yarn inlet 3, one-way check valve 4, resin melt flow channel 5, resin melt feeding flow channel 51, resin melt storage flow channel 52, resin melt discharge flow channel 53, resin melt storage cavity 6, guide roller 7, regulating valve 8, resin outlet pipeline 9, continuous fiber laying flow channel 10, stop valve 11, strip outlet 12, guide roller assembly hole 13. DETAILED DESCRIPTION

[0047] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0048] The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments.

[0049] As attached Figure 1-3 As shown, an impregnation mold and a production device for continuous fiber composite materials include a thermoplastic resin processing system, a continuous fiber processing system and an impregnation mold, wherein the impregnation mold is provided with a resin melt flow channel 5 and a continuous fiber laying flow channel 10 which are interconnected, the thermoplastic resin processing system is connected to the resin melt flow channel 5, and the continuous fiber processing system is connected to the continuous fiber laying flow channel 10.

[0050] Among them, the continuous fiber processing system processes the continuous fiber 1 and transports the continuous fiber 1 to the continuous fiber laying channel 10, and then the thermoplastic resin processing system processes the thermoplastic resin, injects the thermoplastic resin heated to a liquid state into the fat melt storage channel 5, and enters the continuous fiber laying channel 10; thereby, in the impregnation mold, the liquid thermoplastic resin contacts the continuous fiber for impregnation of the continuous fiber.

[0051] In addition, in the prior art, thermoplastic resin is often drawn out from the impregnation mold together with continuous fibers. Therefore, in the actual production process, it is necessary to control the feeding of thermoplastic resin and continuous fibers more accurately. If the thermoplastic resin feed is too little, the continuous fiber impregnation effect is likely to be poor. If the thermoplastic resin feed is too little, the resin melt is excessive, resulting in leakage.

[0052] In order to solve the related problems, the present invention also improves the impregnation mold, and a resin outlet pipeline 9 is provided on the impregnation mold, and the resin outlet pipeline 9 is connected to the resin melt flow channel 5 for recovering the resin melt; thus, by separately arranging the resin outlet pipeline 9 on the impregnation mold, it is not necessary to accurately control the feed amount of the thermoplastic resin during the entire impregnation process, and it is only necessary to always keep the thermoplastic resin in excess. On the one hand, the precise control of the feed situation during the actual impregnation process is reduced, which is conducive to reducing the labor intensity of the operator. On the other hand, the excess thermoplastic resin can fully impregnate the continuous fiber. The surface impregnation degree of the continuous fiber by the thermoplastic resin is improved; at the same time, the excess thermoplastic resin will be discharged from the impregnation mold through the resin outlet pipe 9, and can be transported to the thermoplastic resin processing system, on the one hand, it can be recycled back to the production device for reuse, on the other hand, the excess thermoplastic resin can also be granulated and recovered; thus, the excess thermoplastic resin will not cause leakage problems as the continuous fiber is drawn out, and the production process of the continuous fiber composite material prepreg tape and the melt granulation recovery and reuse process of the thermoplastic resin are realized simultaneously, thereby improving the utilization efficiency of the thermoplastic resin and helping to reduce production costs.

[0053] The resin melt flow channel 5 includes a resin melt feed flow channel 51, a resin melt storage flow channel 52, and a resin melt discharge flow channel 53 which are connected in sequence. Specifically:

[0054] The impregnation mold is provided with a resin inlet pipeline 2, one end of the resin melt feed channel 51 is connected to the resin inlet pipeline 2, and the other end of the resin melt feed channel 51 is connected to the continuous fiber laying channel 10 and the resin melt storage channel 52, thereby realizing the feeding process of the resin melt in the impregnation mold, so as to facilitate the subsequent impregnation of the continuous fiber with the resin melt.

[0055] One end of the resin melt discharge channel 53 is connected to the resin outlet pipeline 9, and the other end of the resin melt discharge channel 53 is connected to the continuous fiber laying channel 10 and the resin melt storage channel 52, so that after the resin melt completes the impregnation of the continuous fiber, the excess resin melt can be discharged from the impregnation mold through the resin melt discharge channel 53 and the resin outlet pipeline 9.

[0056] The resin melt flow channel 5 includes at least one resin melt storage flow channel 52, and the discharge end and the feed end of any resin melt storage flow channel 52 are both connected to the continuous fiber laying flow channel 10; thus, the resin melt enters the resin melt feed flow channel 51 through the resin inlet pipeline 2, a part of the resin melt flows into the continuous fiber laying flow channel 10, and impregnates one side of the continuous fiber, and the other part of the resin melt passes through the continuous fiber and flows into the resin melt storage flow channel 52, flows along the resin melt storage flow channel 52 and flows into the continuous fiber laying flow channel 10, and impregnates the other side of the continuous fiber, thereby realizing double-sided impregnation of the continuous fiber;

[0057] If the resin melt flow channel 5 only includes one resin melt storage flow channel 52, the excess resin melt will enter the resin outlet pipeline 9 and be discharged from the impregnation mold; if the resin melt flow channel 5 includes multiple resin melt storage flow channels 52, the excess resin melt will continue to flow into the next resin melt storage flow channel 52, continue to flow and impregnate the continuous fiber in the continuous fiber laying flow channel 10 until the final impregnation is completed. If there is still excess resin melt, it will pass through the resin outlet pipeline 9 and be discharged from the impregnation mold.

[0058] A regulating valve 8 is provided on the resin outlet pipeline 9 for regulating the process of excess resin melt being discharged from the impregnation mold; at least one resin melt storage cavity 6 is provided on the resin melt storage flow channel 52, so as to provide a certain storage space for excess resin melt inside the impregnation mold.

[0059] Preferably, at the connection point between the continuous fiber laying flow channel 10 and the resin melt flow channel 5, the continuous fiber laying flow channel 10 and the resin melt flow channel 5 are cross-distributed at 90 degrees.

[0060] The continuous fiber laying flow channel 10 includes a continuous fiber yarn inlet 3 and a strip outlet 12. A one-way check valve 4 is provided on the continuous fiber yarn inlet 3, and a stop valve 11 is provided on the strip outlet 12. Thus, by providing the one-way check valve 4 and the stop valve 11, it is possible to effectively prevent the resin solution from overflowing from the continuous fiber laying flow channel 10 after entering the continuous fiber laying flow channel 10, thereby preventing the occurrence of mold leakage problems.

[0061] The impregnation mold includes a male mold plate and a female mold plate. The male mold plate is detachably connected to the female mold plate, and the male mold plate and the female mold plate can be butt-jointed. Preferably, the male mold plate and the female mold plate are butt-jointed by sealing fasteners, such as bolts and other sealing fasteners.

[0062] The resin melt flow channel 5 and the continuous fiber laying flow channel 10 are arranged in the female mold plate, and at least one pair of guide rollers 7 are arranged in the continuous fiber laying flow channel 10. Figure 2 , 3 As shown, the continuous fiber laying channel 10 is a serpentine curved channel with multiple bends. The continuous fiber laying channel 10 is provided with a pair of guide rollers 7 at any bend, and the guide rollers 7 are driving adjustment rollers, and the guide rollers 7 are positioned on the same template at the same time;

[0063] Preferably, the female template is provided with a guide roller assembly hole 13 in the continuous fiber laying flow channel 10, one end of the guide roller 7 is connected to the male template, and the other end of the guide roller 7 is connected to the guide roller assembly hole 13 in a detachable manner; wherein, the guide roller assembly hole 13 passes through the female template; thus, in the actual production process, the male template and the female template are connected to each other, and the guide roller 7 serves as a driving adjustment roller to guide the continuous fiber to move in the continuous fiber laying flow channel 10; when the production device stops production, as the temperature decreases, the resin melt retained in the mold will solidify, at this time, the fasteners between the male template and the female template can be removed, and the male template and the female template can be pushed open from the guide roller assembly hole 13 by using a push rod, and the residual material in the flow channel inside the mold can be cleaned.

[0064] In order to facilitate actual production and processing, the impregnation mold is also provided with a heating device for preheating the materials in the resin melt flow channel 5 and the continuous fiber laying flow channel 10; preferably, the heating device is an electric heater.

[0065] The continuous fiber processing system includes a first processing system and a second processing system. The first processing system is connected to the continuous fiber yarn inlet 3 of the continuous fiber laying channel 10 , and the second processing system is connected to the tape outlet 12 of the continuous fiber laying channel 10 .

[0066] Specifically, the first processing system includes a fiber yarn rack tensioning device, a yarn guiding and spreading device, a yarn dividing and spreading device, and a fiber preheating device connected in sequence, and the discharge port of the fiber preheating device is connected to the continuous fiber yarn inlet 3; the second processing system includes a strip cooling roller pressing device and a strip slitting and winding device connected in sequence, and the feed port of the strip cooling roller pressing device is connected to the strip outlet 12.

[0067] Among them, the yarn guiding and spreading device includes a yarn guiding plate, a yarn dividing comb, and a steel buckle; the yarn dividing and spreading device includes a curved surface dividing roller and a flat flattening tensioning roller; and the fiber preheating device includes an infrared heater and an electromagnetic heater.

[0068] The thermoplastic resin processing system includes a pre-processing system and a post-processing system. The pre-processing system is connected to the resin inlet pipeline 2 of the resin melt flow channel 5, and the resin outlet pipeline 9 is connected to the pre-processing system and / or the post-processing system.

[0069] The pre-processing system includes a resin extrusion plasticizing device and a resin melt pressurizing and conveying device connected in sequence, and the discharge port of the resin melt pressurizing and conveying device is connected to the resin inlet pipeline 2; the post-processing system includes a resin strand cooling device, a resin pelletizing and screening device, and a resin pellet drying and packaging device connected in sequence;

[0070] When the resin outlet pipeline 9 is connected to the pretreatment system, excess resin melt in the impregnation mold can be circulated back to the pretreatment system from the resin outlet pipeline 9 for secondary utilization. Preferably, the resin outlet pipeline 9 is connected to the feed port of the resin extrusion plasticizing device.

[0071] When the resin outlet pipeline 9 is connected to the post-processing system, excess resin melt in the impregnation mold can enter the post-processing system through the resin outlet pipeline 9 for material recovery. Preferably, the feed port of the resin strip cooling device is connected to the resin outlet pipeline 9.

[0072] Specifically, the resin extrusion plasticizing device includes at least one of a planetary screw extruder, a single screw extruder and a twin screw extruder; the resin melt pressurizing and conveying device includes a melt pump; the resin drawing strip cooling device includes a cooling water trough and a strip guide roller; the resin pelletizing and screening device includes a pelletizer and a vibrating screen; the resin particle drying and packaging device includes an air drier, a screw feeder, a high-mix mixer, a silo, a metering scale, a bag sewing machine and a conveyor belt.

[0073] In addition, based on the above-mentioned continuous fiber composite material production device, the present invention also provides an impregnation mold and a production method of a continuous fiber composite material, which are applied to the production device; specifically, the production method includes:

[0074] S1, yarn drawing: the continuous fiber 1 is passed through the creel tensioning device, the yarn guiding and spreading device, the yarn spreading device, and the fiber preheating device in sequence, and the female template of the impregnation mold is taken, and the continuous fiber 1 enters the continuous fiber laying flow channel 10 through the continuous fiber yarn inlet 3, and then passes through the guide roller 7, the strip outlet 12, the strip cooling roller pressing device, and the strip slitting and winding device in sequence, and the yarn head of the continuous fiber 1 is fixed on the strip slitting and winding device;

[0075] S2, mold closing: open the stop valve 11, close and connect the male mold plate and the female mold plate, close the regulating valve 8, and start the heating device to preheat the impregnation mold;

[0076] S3, impregnation: start the resin extrusion plasticizing device to plasticize the resin, and use the melt pressure conveying device to convey the plasticized excess or appropriate amount of resin melt from the resin inlet pipeline 2 to the resin melt flow channel 5 and the continuous fiber laying flow channel 10 to achieve double-sided impregnation of the continuous fiber;

[0077] S4, cooling and winding: start the strip cooling roller pressing device and the strip slitting and winding device, use the strip cooling roller pressing device to cool and roll the impregnated continuous fibers to obtain a continuous fiber composite material strip, and then use the strip slitting and winding device to wind the cooled continuous fiber composite material strip to obtain the continuous fiber composite material.

[0078] In addition, in step S3, it is preferred to use an excess amount of resin melt to impregnate the continuous fibers to ensure that the continuous fibers are fully impregnated, which is beneficial to improving the impregnation effect of the continuous fibers.

[0079] On the basis of using excess resin melt, the production method further comprises:

[0080] S5, granulation: after the continuous fiber is evenly impregnated on the surface, the resin granulation and screening device is started, and then the regulating valve 8 is opened to pull the excess resin into strips, and then the resin is granulated, screened, dried and packaged after cooling for recycling.

[0081] Therefore, through step S5, the excess resin can be recycled, which is beneficial to saving materials.

[0082] In addition, for the excess resin melt, the granulation process of step S5 can be omitted, and step S6 can be performed: after the continuous fiber is evenly impregnated on the surface, the regulating valve 8 is opened to directly transport the excess resin through the resin outlet pipeline 9 to the resin extrusion plasticizing device, and re-participate in the impregnation process of the continuous fiber, thereby realizing the recycling of the excess resin melt.

[0083] For the production device, in addition to the production of the continuous fiber composite material, it is also possible not to inject resin melt into the resin melt flow channel 5, not to start the thermoplastic resin processing system, but only start the continuous fiber processing system, and lay continuous fibers in the continuous fiber processing system and the impregnation mold to produce continuous fiber strips; it is also possible not to start the continuous fiber processing system, but only start the thermoplastic resin processing system, and add thermoplastic resin into the production device, and then carry out the thermoplastic resin granulation process for producing thermoplastic resin particles.

[0084] In order to facilitate the understanding and implementation of the technical solution of the present invention, the present invention is further described below through specific embodiments, but it is not intended to limit the scope of the present invention.

[0085] Example 1

[0086] The purchased and qualified externally drawn continuous fiber yarn rolls are fixed on the creel in sequence, and a certain number of yarn heads are guided through the creel tensioning device and the yarn guide plate in sequence, and then enter the first pair of horizontally placed parallel mirror rollers, and then pass through three convex rollers with different curvatures (the curvature increases in sequence) and staggered three-dimensional distribution in sequence, enter the second pair of horizontally placed parallel mirror rollers, horizontally cross the interior of the cylindrical infrared heater, enter the third pair of horizontally placed parallel mirror rollers, vertically enter the continuous fiber yarn inlet 3 of the melt impregnation template with guide rollers, enter the continuous fiber laying flow channel 10, and then pass through three pairs of guide rollers 7 in sequence, enter the first pair of horizontally placed strip cooling parallel mirror rollers through the strip outlet 12, enter the second pair of horizontally placed strip cooling parallel mirror rollers, and then bypass three staggered three-dimensionally distributed flat extension rollers in sequence, and then be pulled and fixed to the double-station winder air expansion shaft to be started.

[0087] After confirming that the continuous glass fiber has been completely stretched and flattened, another melt impregnation template is molded and sealed with the melt impregnation template that has completed the yarn drawing by using connection and sealing devices such as bolts and gaskets, and the regulating valve 8 is closed.

[0088] The twin-screw extruder is turned on, and the plasticized resin melt is pressurized to 25 MPa through the melt pump, and enters the resin melt flow channel 5, the resin melt storage cavity 6 and the continuous fiber laying flow channel 10 through the resin inlet pipeline 2 to perform double-sided impregnation on the continuous fiber. At the same time, the double-station winder is started to wind the continuous fiber composite material strip.

[0089] When the surface of the continuous fiber to be wound can be evenly impregnated with the resin melt, start the resin pelletizing and screening device, open the regulating valve 8 to pull the strip (adjust the opening of the regulating valve 8 according to the resin impregnation degree of the continuous fiber surface and the thickness of the strip), and then pelletize, screen, dry and package it after cooling for recycling.

[0090] Example 2

[0091] After the purchased and qualified externally drawn continuous fiber yarn rolls are fixed on the creel in order, a certain number of yarn heads are guided through the creel tensioning device and the yarn guide plate according to the required continuous fiber content, and then enter the first pair of horizontally placed parallel mirror rollers, and then pass through 5 convex rollers with different curvatures (the curvature increases successively) and staggered three-dimensional distribution, and then enter the second pair of horizontally placed parallel mirror rollers, and then horizontally cross the interior of the cylindrical infrared heater and enter the third pair of horizontally placed parallel mirror rollers, and vertically enter the continuous fiber yarn inlet 3 of the melt impregnation template with guide rollers to enter the continuous fiber laying flow channel 10, and then successively pass through 5 pairs of guide rollers 7 and enter the first pair of horizontally placed strip cooling parallel mirror rollers through the strip outlet 12, and then enter the second and third pairs of horizontally placed strip cooling parallel mirror rollers in turn, and then bypass 5 planar extension rollers with staggered three-dimensional distribution in turn, and then be pulled and fixed to the double-station winder air expansion shaft to be started.

[0092] After confirming that the continuous glass fiber has been completely stretched and flattened, another melt impregnation template is molded and sealed with the melt impregnation template that has completed the yarn drawing by using connection and sealing devices such as bolts and gaskets, and the regulating valve 8 is closed.

[0093] The twin-screw extruder is turned on, and the plasticized resin melt is pressurized to 30 MPa by the melt pump and then enters the resin melt flow channel 5, the resin melt storage cavity 6 and the continuous fiber laying flow channel 10 through the resin inlet pipeline 2 to perform double-sided impregnation on the continuous fiber. At the same time, the double-station winder is started to wind the continuous fiber composite material strip.

[0094] When the surface of the continuous fiber to be wound is evenly impregnated with the resin melt, start the resin pelletizing and screening device, and open the regulating valve 8 to pull the strip (adjust the opening of the regulating valve 8 according to the resin impregnation degree of the continuous fiber surface and the thickness of the strip). After cooling, pelletizing, screening, drying and packaging are carried out for recycling.

[0095] Example 3

[0096] After the purchased and qualified external drawn continuous fiber yarn rolls are fixed on the creel in order, a certain number of yarn heads are guided through the creel tensioning device and the yarn guide plate according to the required continuous fiber content, and then enter the first pair of horizontally placed parallel mirror rollers, and then pass through three convex rollers with different curvatures (the curvatures increase successively) and staggered three-dimensional distribution, and then enter the second pair of horizontally placed parallel mirror rollers, and then horizontally cross the interior of the cylindrical infrared heater and enter the third pair of horizontally placed parallel mirror rollers, and vertically enter the continuous fiber yarn inlet 3 of the melt impregnation template with guide rollers to enter the continuous fiber laying flow channel 10, and then successively pass through 9 pairs of guide rollers 7 and enter the first pair of horizontally placed strip cooling parallel mirror rollers through the strip outlet 12, and then enter the second and third pairs of horizontally placed strip cooling parallel mirror rollers in turn, and then bypass two staggered three-dimensionally distributed flat extension rollers in turn, and then be pulled and fixed to the double-station winder air expansion shaft to be started.

[0097] After confirming that the continuous glass fiber has been completely stretched and flattened, another melt impregnation template is molded and sealed with the melt impregnation template that has completed the yarn drawing by using connection and sealing devices such as bolts and gaskets, and the regulating valve 8 is closed.

[0098] The twin-screw extruder is turned on, and the plasticized resin melt is pressurized to 35 MPa by the melt pump and then enters the resin melt flow channel 5, the resin melt storage cavity 6 and the continuous fiber laying flow channel 10 through the resin inlet pipeline 2 to perform double-sided impregnation on the continuous fiber. At the same time, the double-station winder is started to wind the continuous fiber composite material strip.

[0099] When the surface of the continuous fiber to be wound is evenly impregnated with the resin melt, start the resin pelletizing and screening device, and open the regulating valve 8 to pull the strip (adjust the opening of the regulating valve 8 according to the resin impregnation degree of the continuous fiber surface and the thickness of the strip). After cooling, pelletizing, screening, drying and packaging are carried out for recycling.

[0100] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An impregnation mold, wherein a resin melt flow channel (5) and a continuous fiber laying flow channel (10) are provided in the impregnation mold and are interconnected, wherein: The impregnation mold is provided with a resin outlet pipeline (9), and the resin outlet pipeline (9) is connected to the resin melt flow channel (5) and is used to recover excess resin melt; The resin melt flow channel (5) comprises a resin melt feed flow channel (51), a resin melt storage flow channel (52), and a resin melt discharge flow channel (53) which are connected in sequence; the discharge end of the resin melt feed flow channel (51) is respectively connected to the continuous fiber laying flow channel (10) and the resin melt storage flow channel (52); the discharge end and the feed end of the resin melt storage flow channel (52) are both connected to the continuous fiber laying flow channel (10); one end of the resin melt discharge flow channel (53) is connected to the resin outlet pipeline (9), and the other end of the resin melt discharge flow channel (53) is connected to the continuous fiber laying flow channel (10) and the resin melt storage flow channel (52); The resin melt enters the resin melt feeding channel (51), a portion of the resin melt flows into the continuous fiber laying channel (10) to impregnate one side of the continuous fiber, and another portion of the resin melt passes through the continuous fiber and flows into the resin melt storage channel (52), flows along the resin melt storage channel (52) and flows into the continuous fiber laying channel (10) to impregnate the other side of the continuous fiber, and the excess resin melt is discharged from the impregnation mold through the resin melt discharge channel (53) and the resin outlet pipeline (9).

2. A dipping mold according to claim 1, characterized in that: The impregnation mold is provided with a resin inlet pipeline (2), one end of the resin melt feed channel (51) is in communication with the resin inlet pipeline (2), and the other end of the resin melt feed channel (51) is in communication with the continuous fiber laying channel (10) and the resin melt storage channel (52).

3. The impregnation mold according to claim 1, characterized in that: The resin melt flow channel (5) comprises at least one resin melt storage flow channel (52), and the discharge end and the feed end of any resin melt storage flow channel (52) are both in communication with the continuous fiber laying flow channel (10).

4. The impregnation mold according to claim 1, characterized in that: At least one resin melt storage cavity (6) is provided on the resin melt storage flow channel (52).

5. The impregnation mold according to claim 1, characterized in that: At the connection point between the continuous fiber laying flow channel (10) and the resin melt flow channel (5), the continuous fiber laying flow channel (10) and the resin melt flow channel (5) are cross-distributed at 90 degrees.

6. The impregnation mold according to claim 1, characterized in that: A regulating valve (8) is provided on the resin outlet pipeline (9).

7. The impregnation mold according to claim 1, characterized in that: The continuous fiber laying flow channel (10) comprises a continuous fiber yarn inlet (3) and a strip material outlet (12); a one-way check valve (4) is provided on the continuous fiber yarn inlet (3), and a stop valve (11) is provided on the strip material outlet (12).

8. The impregnation mold according to claim 1, characterized in that: The impregnation mold comprises a male mold plate and a female mold plate, wherein the male mold plate is connected to the female mold plate in a detachable manner; the resin melt flow channel (5) and the continuous fiber laying flow channel (10) are arranged in the female mold plate, and at least one pair of guide rollers (7) is arranged in the continuous fiber laying flow channel (10).

9. The impregnation mold according to claim 8, characterized in that: The female template is provided with a guide roller assembly hole (13) in the continuous fiber laying flow channel (10); one end of the guide roller (7) is connected to the male template; and the other end of the guide roller (7) is connected to the guide roller assembly hole (13) in a detachable manner.

10. The impregnation mold according to claim 9, characterized in that: The guide roller assembly hole (13) passes through the female template.

11. A production device for continuous fiber composite materials, characterized in that: The production device comprises a thermoplastic resin processing system, a continuous fiber processing system and the impregnation mold according to any one of claims 1 to 10; the thermoplastic resin processing system is connected to a resin melt flow channel (5), and the continuous fiber processing system is connected to a continuous fiber laying flow channel (10).

12. The production device of a continuous fiber composite material according to claim 11, characterized in that: The continuous fiber processing system comprises a first processing system and a second processing system, wherein the first processing system is connected to a continuous fiber yarn inlet (3) of a continuous fiber laying channel (10), and the second processing system is connected to a strip outlet (12) of the continuous fiber laying channel (10).

13. The production device of a continuous fiber composite material according to claim 12, characterized in that: The first processing system comprises a fiber yarn rack tensioning device, a yarn guiding and spreading device, a yarn splitting and spreading device, and a fiber preheating device connected in sequence, wherein the discharge port of the fiber preheating device is connected to the continuous fiber yarn inlet (3); the second processing system comprises a strip cooling roller pressing device and a strip slitting and winding device connected in sequence, wherein the feed port of the strip cooling roller pressing device is connected to the strip outlet (12).

14. The production device of a continuous fiber composite material according to claim 13, characterized in that: The yarn guiding and spreading device comprises a yarn guiding plate, a yarn dividing comb and a steel buckle; the yarn dividing and spreading device comprises a curved surface yarn dividing roller and a flat flattening tensioning roller; and the fiber preheating device comprises an infrared heater and an electromagnetic heater.

15. The production device of a continuous fiber composite material according to claim 11, characterized in that: The thermoplastic resin processing system comprises a pre-processing system and a post-processing system, wherein the pre-processing system is connected to a resin inlet pipeline (2), and the resin outlet pipeline (9) is connected to the pre-processing system and / or the post-processing system.

16. The production device of a continuous fiber composite material according to claim 15, characterized in that: The pre-treatment system comprises a resin extrusion plasticizing device and a resin melt pressurizing and conveying device which are connected in sequence, and the discharge port of the resin melt pressurizing and conveying device is connected to a resin inlet pipeline (2).

17. The production device of a continuous fiber composite material according to claim 16, characterized in that: The resin outlet pipeline (9) is connected to the feed port of the resin extrusion plasticizing device.

18. The production device of a continuous fiber composite material according to claim 16, characterized in that: The resin extrusion plasticizing device comprises at least one of a planetary screw extruder, a single screw extruder and a twin screw extruder; the resin melt pressurizing and conveying device comprises a melt pump.

19. The production device of a continuous fiber composite material according to claim 15, characterized in that: The post-processing system comprises a resin strip cooling device, a resin pelletizing and screening device, and a resin pellet drying and packaging device which are connected in sequence, and the feed inlet of the resin strip cooling device is connected to a resin outlet pipeline (9).

20. The production device of a continuous fiber composite material according to claim 19, characterized in that: The resin strip cooling device includes a cooling water trough and a strip guide roller; the resin pelletizing and screening device includes a pelletizer and a vibrating screen; the resin particle drying and packaging device includes an air drier, a spiral feeder, a high-mix mixer, a silo, a metering scale, a bag sewing machine and a conveyor belt.

21. A method for producing a continuous fiber composite material, characterized in that: The production method is applied to the production device according to any one of claims 11 to 20, and the production method comprises: S1, yarn drawing: the continuous fiber (1) is passed through the yarn rack tensioning device, the yarn guide and yarn spreading device, the yarn spreading device, and the fiber preheating device in sequence, and then the continuous fiber (1) is taken out of the female mold plate of the impregnation mold, and enters the continuous fiber laying flow channel (10) through the continuous fiber yarn inlet (3), and then passes through the guide roller (7), the strip outlet (12), the strip cooling roller pressing device, and the strip slitting and winding device in sequence, and the yarn head of the continuous fiber (1) is fixed on the strip slitting and winding device; S2, mold closing: open the stop valve (11), close and connect the male mold plate and the female mold plate, close the regulating valve (8), and start the heating device to preheat the impregnation mold; S3, impregnation: the resin extrusion plasticizing device is turned on to plasticize the resin, and the melt pressure conveying device is used to convey the plasticized excess or appropriate amount of resin melt from the resin inlet pipeline (2) to the resin melt flow channel (5) and the continuous fiber laying flow channel (10), so as to achieve double-sided impregnation of the continuous fiber; S4, cooling and winding: start the strip cooling roller pressing device and the strip slitting and winding device, use the strip cooling roller pressing device to cool and roll the impregnated continuous fibers to obtain a continuous fiber composite material strip, and then use the strip slitting and winding device to wind the cooled continuous fiber composite material strip to obtain the continuous fiber composite material.

22. The method for producing a continuous fiber composite material according to claim 21, characterized in that: In step S3, the continuous fibers are impregnated with excess resin melt.

23. The method for producing a continuous fiber composite material according to claim 21, characterized in that: The method comprises: S5, granulation: after the continuous fibers are evenly impregnated on the surface, the resin granulation and screening device is started, and then the regulating valve (8) is opened to pull the excess resin into strips, and after cooling, the resin is granulated, screened, dried and packaged for recycling.

24. The method for producing a continuous fiber composite material according to claim 21, characterized in that: The method comprises: S6. Recycling of excess resin: After the surface of the continuous fibers is evenly impregnated, the regulating valve (8) is opened to directly transport the excess resin to the resin extrusion plasticizing device through the resin outlet pipeline (9).

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