Fiber prepreg impregnation device and method

Abstract

The present invention provides an impregnation device for fiber prepreg, comprising a membrane separation component, a hot pressing element and a heat barrier element. The hot pressing element is arranged below the membrane separation component. The heat barrier element is arranged between the membrane separation component and the hot pressing element. The present invention also provides an impregnation method for fiber prepreg. By setting the heat barrier element, it is prevented that the resin film is softened prematurely and adheres to the membrane layer due to receiving the hot air of the hot pressing element when the membrane separation component is in the membrane separation component, causing resin defects and poor fiber impregnation.

Description

Technical Field

[0001] The invention relates to an impregnation device and an impregnation method for fiber prepreg. Background Art

[0002] The fiber cloth forming is generally divided into two stages. The first is the resin coating stage, that is, coating the resin on the release layer. The next is the impregnation stage, which is mainly to heat press the resin layer and the fiber layer (it can be subjected to yarn spreading treatment before heat pressing) to form a fiber prepreg. The fabrics made by reprocessing the fiber prepreg have a wide range of applications. For example, the reinforced composite material prepared by the carbon fiber prepreg made of carbon fiber and resin has the characteristics of light weight and excellent strength and modulus, and is widely used in the structural parts of sports and entertainment products, the structure and interior parts of transportation vehicles, or civil engineering, etc.

[0003] However, in the existing impregnation device, in order to facilitate the continuous execution of the steps, the sending element of the resin layer and the separation element for separating the resin layer from the film layer are adjacent to the hot pressing element (for example, located above the hot pressing element). When the hot pressing element is heated, the heat radiation and hot air generated will cause the resin layer to be softened prematurely when it is located at the sending element and the separation element, so that when the film layer is subsequently separated, the resin adheres to the film layer, resulting in poor impregnation effect. Summary of the invention

[0004] Therefore, one aspect of the present invention is to provide a fiber prepreg impregnation device, comprising a membrane separation component, a hot pressing element vertically arranged below the membrane separation component, and a heat barrier element vertically arranged between the membrane separation component and the hot pressing element.

[0005] In some embodiments, the membrane separation assembly includes a first roller; a membrane folding element is disposed above the first roller; and a second roller is disposed between the membrane folding element and the first roller in a vertical direction, and the first roller in the direction of the membrane folding element and the intersection of the first roller in the direction of the second roller form a separation angle greater than 0 degrees.

[0006] In some embodiments, the position of the second roller is adjustable, and the separation angle is changed by changing the position of the second roller.

[0007] In some embodiments, the impregnation device further includes: a resin film sending element is arranged above the first roller, when vertically projected on the horizontal plane where the first roller is located, the resin film sending element and the membrane layer folding element are respectively located on opposite sides of the first roller, wherein the horizontal plane where the first roller is located is perpendicular to the vertical direction; and a fiber sending element is arranged below the membrane layer separation component.

[0008] In some embodiments, the surface of the heat-blocking element close to the heat-compression element is made of heat-reflective material.

[0009] In some embodiments, the thermal barrier element is arcuate in shape.

[0010] In some embodiments, when vertically projected onto a horizontal plane where the heat pressing element is located, the projection of the heat blocking element overlaps and is larger than the projection of the heat pressing element, wherein the horizontal plane where the heat pressing element is located is perpendicular to the vertical direction.

[0011] One aspect of the present invention is to provide a method for impregnating a fiber prepreg, comprising: providing an impregnation device comprising a membrane separation component, a hot pressing element arranged below the membrane separation component in a vertical direction, and a heat barrier element arranged between the membrane separation component and the hot pressing element in a vertical direction; providing a resin adhesive film, wherein the resin adhesive film comprises a release film, a resin layer is located on the release film, and a membrane layer is located on the resin layer; using the membrane separation component in the impregnation device to separate the membrane layer from the resin layer from the resin adhesive film to obtain a resin composite structure comprising a release film and a resin layer; providing a fiber layer; using the hot pressing element in the impregnation device to hot press the resin composite structure, the fiber layer, and the resin composite structure in order from top to bottom at a temperature above 90°C to obtain a fiber prepreg, wherein the resin layer in the fiber prepreg is in direct contact with the fiber layer.

[0012] In some embodiments, during the step of using the heat-pressing element in the impregnation device, a film layer separation component in the impregnation device is simultaneously used to separate the film layer from the resin layer from the resin adhesive film.

[0013] In some embodiments, when using a membrane separation component in an impregnation device, the step of separating the membrane layer from the resin layer from the resin film includes: if the tack of the resin layer is 500 grams to 2000 grams, adjusting the separation angle of the membrane layer and the resin layer in the membrane separation component to between 18 degrees and 45 degrees. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to make the above and other objects, features, advantages and embodiments of the present invention more clearly understood, the detailed description of the attached drawings is as follows:

[0015] Figure 1 A flow chart is shown of a method for impregnating a fiber prepreg according to some embodiments of the present invention.

[0016] Figure 2 A side view of an impregnation device for fiber prepreg according to some embodiments of the present invention is shown when performing an impregnation method.

[0017] Figure 3 A side view of an impregnation device for fiber prepreg according to some embodiments of the present invention is shown when performing an impregnation method.

[0018] FIG. 4A to FIG. 4D Various examples of thermal barrier elements in some embodiments of the present invention are shown. DETAILED DESCRIPTION

[0019] It is understood that the different implementations or embodiments provided below may implement different features of the objectives of the present invention. The embodiments of specific components and arrangements are used to simplify the present invention rather than to limit the present invention. Of course, these are only embodiments and are not intended to be limiting. For example, the description of the first feature formed on the second feature described below includes direct contact between the two, or other additional features are separated from the two without direct contact. In addition, the present invention may repeat reference numbers and / or symbols in multiple embodiments. Such repetition is for simplicity and clarity, and does not represent the relationship between the various embodiments and / or configurations discussed.

[0020] The terms used in this specification generally have common meanings in the art and in the context in which they are used. The embodiments used in this specification, including the examples of any term discussed herein, are merely illustrative and do not limit the scope and meaning of the present invention or any exemplary term. Likewise, the present invention is not limited to some embodiments provided in this specification.

[0021] In addition, spatially relative terms, such as "lower", "upper", etc., are used to conveniently describe the relative relationship of an element or feature to other elements or features in the drawings. These spatially relative terms are intended to encompass different orientations of the device when in use or operation in addition to the orientation shown in the drawings. The device may be otherwise oriented (e.g., rotated 90 degrees or in other orientations), and the spatially relative descriptions used herein may be interpreted accordingly.

[0022] In this document, unless the context specifically limits the article, "a", "an" and "the" may refer to one or more. It will be further understood that "comprising", "including", "having" and similar words used in this document specify the features, regions, integers, steps, operations, elements and / or components recorded therein, but do not exclude other features, regions, integers, steps, operations, elements, components, and / or groups thereof.

[0023] All references cited herein are treated as if each individual reference or patent application was specifically and individually incorporated by reference. If a definition or use of a term in a cited document is inconsistent or contrary to the definition of that term herein, the definition of that term herein shall apply.

[0024] Several embodiments are listed below to further illustrate the touch device of the present invention. However, they are only for illustration and are not intended to limit the present invention. The protection scope of the present invention shall be subject to the appended claims.

[0025] See also Figure 1 , Figure 1 A flow chart of a fiber prepreg impregnation method 100 according to some embodiments of the present invention is shown, comprising step S110, providing an impregnation device, comprising a membrane separation component, a hot pressing element, and a heat barrier element located between the membrane separation component and the hot pressing element; step S120, providing a resin adhesive film; step S130, using the membrane separation component in the impregnation device to separate the membrane layer and the resin layer from the resin adhesive film to obtain a resin composite structure including a release film and a resin layer; step S140, providing a fiber layer; and step S150, using the hot pressing element in the impregnation device to hot-press the fiber layer and the resin composite structure at a temperature higher than 90° C. to obtain a fiber prepreg.

[0026] In some embodiments, the impregnation device may be used only in some steps (such as step S130 and step S150). For example, the resin film and the fiber layer may be provided manually or by other machines. Figure 1 All steps in the impregnation method 100 shown can be performed by only a single fiber prepreg impregnation device. Figure 2 The impregnation device 200 is taken as an example to specifically illustrate the process of the fiber prepreg impregnation method 100, however, the implementation aspects of the present invention are not limited thereto.

[0027] Figure 2 A side view of a fiber prepreg impregnation device 200 according to some embodiments of the present invention is shown when performing an impregnation method.

[0028] like Figure 2 As shown, the impregnation device 200 includes a resin film sending element 210, a film separation component 220, a fiber sending element 230, a hot pressing element 240, and a heat blocking element 250. Unless otherwise specified below, the relative relationship between the elements "up" and "down" is mainly for the Z-axis direction (vertical direction). The resin film sending element 210 is adjacent to the film separation component 220, for example, it is located above the first roller 222 in the film separation component 220. When vertically projected on the horizontal plane where the first roller 222 is located (a plane on the X-axis that is perpendicular to the Z-axis), the resin film sending element 210 and the film folding element 224 are respectively located on opposite sides of the first roller 222. The hot pressing element 240 is arranged below the film separation component 220. The fiber sending element 230 is arranged below the film separation component 220, for example, it can be located between the roller R1 and the roller R2 in the hot pressing element 240 in the Z-axis direction. The heat blocking element 250 is disposed between the heat pressing element 240 and the membrane separation assembly 220 .

[0029] First, a resin film M0 is provided via a resin film transmitting element 210 , wherein the resin film M0 includes a release film L1 , a resin layer L2 located on the release film L1 , and a film layer L3 located on the resin layer L2 .

[0030] In some embodiments, the film layer L3 is a transparent film structure, which is used to prevent the resin layer L2 from contacting with suspended particles in the environment or pollutants from other sources, and keep the surface of the resin layer L2 clean. In some embodiments, the material of the film layer L3 may include, for example, a polymer (such as plastic).

[0031] In some embodiments, the material of the resin layer L2 may include a thermoplastic resin (eg, epoxy resin). In some embodiments, the melting point of the resin layer L2 is lower than 90°C, for example, the melting point of the resin layer L2 is 70°C, 80°C, 90°C, or any value in the aforementioned range.

[0032] Next, the resin film sending element 210 is used to transport the resin film M0 along a specific path to the film layer separation component 220. The film layer separation component 220 is configured to separate the film layer L3 from the resin layer L2 from the resin film M0 via a specific separation angle A, thereby obtaining a resin composite structure M1, wherein the resin composite structure M1 includes a release film L1 and a resin layer L2 located on the release film L1.

[0033] In some embodiments, the film layer separation assembly 220 includes a first roller 222, a film layer folding element 224, and a second roller 226. The first roller 222 is disposed below the resin film sending element 210 and is configured to receive the resin film M0. The film layer folding element 224 is disposed above the first roller 222 and is configured to fold the separated film layer L3 from the first roller 222 (for example, fold the film layer L3 in a roll). The second roller 226 is disposed between the film layer folding element 224 and the first roller 222 in the Z-axis direction, and is configured to separate the resin layer L2 and the release film L1 (i.e., the resin composite structure M1) from the resin film M0 through a separation angle A (greater than 0) sandwiched between the first roller 222 toward the film layer folding element 224 and the first roller 222 toward the second roller 226.

[0034] In some embodiments, the position of the second roller 226 is adjustable. By changing the position of the second roller 226, the separation angle A is changed. For example, the second roller 226 can be moved in the X-axis direction or the Z-axis direction according to the viscosity of the resin layer L2, thereby changing the separation angle A and achieving a better separation effect of the film layer L3.

[0035] For example, see Figure 3 , Figure 3It is also a side view of the fiber prepreg impregnation device 200 according to some embodiments of the present invention when performing the impregnation method, Figure 2 The difference is that Figure 3 The viscosity of the resin layer L2 is relatively high. To facilitate separation of the resin layer L2 and the film layer L3, the position of the second roller 226 moves downward along the direction D (Z-axis direction) to increase the separation angle A.

[0036] In some embodiments, when the viscosity of the resin layer L2 is less than 500 grams, the separation angle of the film layer L3 and the resin layer L2 can be adjusted to be less than 18 degrees. For example, when the viscosity of the resin layer L2 is between 100 grams and 500 grams, the separation angle of the film layer L3 and the resin layer L2 is adjusted to be between 13 degrees and 18 degrees (for example, 13 degrees, 14 degrees, 15 degrees, 16 degrees, 17 degrees, 18 degrees, or any value in the aforementioned range).

[0037] In some embodiments, when the viscosity of the resin layer L2 is between 500 grams and 2000 grams, the separation angle between the film layer L3 and the resin layer L2 is adjusted to be between 18 degrees and 45 degrees.

[0038] For example, when the viscosity of the resin layer L2 is 500 grams to 900 grams, the separation angle of the film layer L3 and the resin layer L2 is adjusted to be between 18 degrees and 25 degrees (for example, 18 degrees, 19 degrees, 20 degrees, 21 degrees, 22 degrees, 23 degrees, 24 degrees, 25 degrees, or values ​​in any of the aforementioned intervals). When the viscosity of the resin layer L2 is 900 grams to 1300 grams, the separation angle of the film layer L3 and the resin layer L2 is adjusted to be between 25 degrees and 33 degrees (for example, 25 degrees, 26 degrees, 27 degrees, 28 degrees, 29 degrees, 30 degrees, 31 degrees, 32 degrees, 33 degrees, or values ​​in any of the aforementioned intervals). If the viscosity of the resin layer L2 is between 1300 grams and 2000 grams, the separation angle of the film layer L3 and the resin layer L2 is adjusted to be between 33 degrees and 45 degrees (for example, 33 degrees, 34 degrees, 35 degrees, 36 degrees, 37 degrees, 38 degrees, 39 degrees, 40 degrees, 41 degrees, 42 degrees, 43 degrees, 44 degrees, 45 degrees or any value in the aforementioned range). If the viscosity of the resin layer L2 is above 2000 grams, the separation angle of the film layer L3 and the resin layer L2 is 45 degrees.

[0039] It is worth noting that if the separation angle A is not adjusted according to the viscosity of the resin layer L2, if the viscosity of the resin layer L2 is too high, the separation effect may be poor, and the resin of the resin layer L2 may remain on the surface of the film layer L3; if the viscosity of the resin layer L2 is too low, the separation stress provided by the separation angle A is too large, causing the film layer L3 to be separated from the resin film M0 prematurely, which may cause the film layer L3 to be displaced and difficult to effectively close, and increase the exposure time of the surface of the resin layer L2, indirectly increasing the risk of contamination molecules adhering to the resin surface.

[0040] See you later Figure 2 On the other hand, the fiber layer F is provided to the hot pressing element 240 via the fiber sending element 230. In some embodiments, the fiber layer F is, for example, carbon fiber or glass fiber. In some embodiments, a yarn spreading element 260 is provided between the fiber sending element 230 and the hot pressing element 240, configured to spread the fiber layer F and adjust the fiber arrangement and / or width of the fiber layer F.

[0041] Next, a hot pressing element 240 is used to receive the fiber layer F, and two resin composite structures M1 are simultaneously received from the upper and lower sides of the fiber layer F (in terms of the Z-axis direction) (for example, with the fiber layer F as the axis of symmetry, the elements on the lower side and the elements on the upper side are symmetrically distributed, which is not shown in the figure here).

[0042] Next, at a temperature higher than 90°C (for example, 90°C, 100°C, 110°C, 120°C or any value in the aforementioned range), the resin layers L2 in the two resin composite structures M1 are brought into direct contact with the fiber layer L, and are hot pressed in the order of resin composite structure M1, fiber layer F and resin composite structure M1 from top to bottom to obtain a fiber prepreg cloth C, wherein the upper surface and lower surface of the fiber layer F in the fiber prepreg cloth C are in direct contact with the resin layer L2.

[0043] It is worth emphasizing that the impregnation device 200 is a continuous device. When the hot pressing element 240 is used to heat press the fiber layer F and the resin composite structure M1, the membrane layer separation component 220 is used to separate the membrane layer L3 from the resin film M0. Therefore, if the heat blocking element 250 is not provided between the hot pressing element 240 and the membrane layer separation component 220 to block the hot air of the hot pressing element 240, even if the hot pressing element 240 is heat pressed at a temperature lower than 90°C (e.g., 70°C to 85°C), when the membrane layer separation component 220 separates the resin film M0, the resin may be softened by heat and adhere to the membrane layer L3 during separation, resulting in a defect in the resin layer L2 used for subsequent heat pressing, thereby reducing the impregnation effect of the fiber prepreg cloth C.

[0044] In some embodiments, the heat blocking element 250 is a heat insulating material, such as a porous material (such as foam or fiber) or a heat reflective material (such as aluminum foil or nickel).

[0045] In some embodiments, the heat blocking element 250 can completely shield the heat pressing element 240. For example, when vertically projected on the horizontal plane where the heat pressing element 240 is located (the plane on the X-axis that is perpendicular to the Z-axis), the projection of the heat blocking element 250 overlaps and is larger than the projection of the heat pressing element 240. By shielding the heat pressing element 240 over a large area, hot air is prevented from flowing to the membrane separation component 220 and the resin film sending component 210, thereby achieving a better heat blocking effect.

[0046] In some embodiments, the heat-blocking element 250 may use heat-reflecting material (such as metal (aluminum foil or nickel, etc.)) on the surface 252A close to the heat-pressing element 240 , or adjust the shape of the heat-blocking element 250 to enhance the heat-insulating effect.

[0047] For example, see FIG. 4A to FIG. 4D , illustrating different examples of the thermal barrier element 250 in some embodiments of the present invention.

[0048] Figure 4A as well as Figure 4B (Please also refer to Figure 2 ) is a double-layer structure, with a heat reflection layer 252 on one side close to the hot pressing element 240 and a porous layer 254 on the other side. Figure 4A as well as Figure 4B The difference is that Figure 4B The heat barrier element 250 is arc-shaped, and the arc-shaped concave shape design is combined with the heat reflection layer 252 disposed toward the heat pressing element 240 to converge the hot air to one side of the heat pressing element 240. Figure 4A Rectangular flat design. Figure 4B The arc shape achieves a better heat insulation effect, and can ensure that when the membrane layer L3 is separated, even if the hot pressing temperature is increased to 110°C, the resin layer L2 will not be overly softened and remain on the membrane layer L3.

[0049] Figure 4C as well as Figure 4D The heat barrier element 250 and Figure 4A as well as Figure 4B The difference of the thermal barrier element 250 is mainly that, Figure 4C as well as Figure 4D The heat barrier element 250 is a porous layer 254 covered with a heat reflective layer 252. That is, Figure 4C as well as Figure 4D In the heat barrier element 250, the heat reflection layer 252 is exposed to the outer surface, which can also achieve the heat barrier effect of reflecting heat energy. Figure 4C as well as Figure 4D The difference between Figure 4C is a rectangle, and Figure 4D For arc-shaped, this part of the discussion can be referred to Figure 4A as well as Figure 4B The description will not be repeated here.

[0050] Therefore, please return to Figure 2 By adjusting the position, shielding area, shape, material and structural design of the heat barrier element 250, the heat barrier effect of the heat barrier element 250 can be controlled, so that when the film layer L3 is separated, the allowable hot pressing temperature of the hot pressing element 240 is increased without leaving any resin in the film layer L3, thereby increasing the flexibility of selecting the type of resin in the resin layer L2. For example, a resin with a lower melting point (for example, below 90°C) can be included in the selection of the resin layer L2.

[0051] In some embodiments, according to the thickness requirement of the fiber layer F, a process for thickening the fiber layer F can be selectively added, including providing another fiber layer; removing the release film L1 of the fiber prepreg C to obtain the fiber prepreg to be processed; and hot pressing the other fiber layer and the fiber prepreg to be processed in a manner that the other fiber layer is in direct contact with the resin layer L2 to obtain a thickened fiber prepreg.

[0052] Some embodiments of the present invention provide an impregnation device and an impregnation method for fiber prepreg cloth. By setting a heat barrier element, it is prevented that the resin adhesive film receives heat from a hot pressing element during the membrane layer separation component, and prematurely softens and adheres to the membrane layer, causing resin defects and poor fiber impregnation.

[0053] Although the present invention has been disclosed as above with several specific embodiments, various modifications, changes and substitutions may be made to the aforementioned disclosure, and it should be understood that in some cases, certain features of the embodiments of the present invention will be adopted but other features will not be used accordingly without departing from the spirit and scope of the present invention. Therefore, the spirit and scope of the claims of the present invention should not be limited to the above exemplary embodiments.

[0054]

Explanation of symbols

[0055] 100:Impregnation method

[0056] 200: Impregnation device

[0057] 210: Resin film sending element

[0058] 220: Membrane separation component

[0059] 222: First roller

[0060] 224: Film layer folding element

[0061] 226: Second roller

[0062] 230: Fiber transmission element

[0063] 240:Hot pressing element

[0064] 250: Thermal barrier element

[0065] 252: Heat reflection layer

[0066] 252A: Surface

[0067] 254: porous layer

[0068] 260: Yarn spreading element

[0069] A: Separation Angle

[0070] C: Fiber prepreg

[0071] D: Direction

[0072] F: Fiber layer

[0073] M0: Resin film

[0074] M1: Resin composite structure

[0075] L1: Release film

[0076] L2: Resin layer

[0077] L3: Membrane layer

[0078] R1, R2: roller

[0079] S110, S120, S130, S140, S150: Steps

[0080] X: X-axis

[0081] Z: Z axis.

Claims

1. A fiber prepreg impregnation device, characterized in that: Include: Membrane separation components; A hot pressing element is disposed below the membrane separation assembly in a vertical direction; and The heat-blocking element is arranged between the membrane separation component and the hot pressing component in the vertical direction. The heat-blocking element completely shields the hot pressing component to prevent hot air from flowing to the membrane separation component.

2. The impregnation device according to claim 1, wherein the membrane separation component comprises: First roller; The film layer folding element is disposed above the first roller; and The second roller is disposed between the film layer folding element and the first roller in the vertical direction, and the intersection of the first roller toward the film layer folding element and the first roller toward the second roller presents a separation angle greater than 0 degrees. 3 . The impregnation device according to claim 2 , wherein the position of the second roller is adjustable, and the separation angle is changed by changing the position of the second roller.

4. The impregnation device according to claim 2, wherein: Also includes: The resin film sending element is disposed above the first roller. When vertically projected onto the horizontal plane where the first roller is located, the resin film sending element and the film layer folding element are respectively located on opposite sides of the first roller, wherein the horizontal plane where the first roller is located is perpendicular to the vertical direction; and The fiber sending element is arranged below the membrane layer separation component. 5 . The impregnation device according to claim 1 , wherein a surface of the heat-blocking element close to the hot-pressing element is made of a heat-reflecting material. The impregnation device according to claim 1 , wherein the heat blocking element is in an arc shape.

7. The impregnation device according to claim 1, wherein when vertically projected on the horizontal plane where the hot pressing element is located, the projection of the heat blocking element overlaps and is larger than the projection of the hot pressing element, wherein the horizontal plane where the hot pressing element is located is perpendicular to the vertical direction.

8. A method for impregnating a fiber prepreg, characterized in that: Include: Provide an impregnation device comprising a membrane separation component, a hot pressing element disposed below the membrane separation component in a vertical direction, and a heat blocking element disposed between the membrane separation component and the hot pressing element in the vertical direction, wherein the heat blocking element completely shields the hot pressing element to prevent hot air from flowing to the membrane separation component; Providing a resin adhesive film, wherein the resin adhesive film comprises a release film, a resin layer located on the release film, and a film layer located on the resin layer; Using the film layer separation component in the impregnation device, the film layer and the resin layer are separated from the resin adhesive film to obtain a resin composite structure including the release film and the resin layer; providing a fiber layer; as well as By using the hot pressing element in the impregnation device, the resin composite structure, the fiber layer and the resin composite structure are hot pressed in order from top to bottom at a temperature higher than 90°C to obtain a fiber prepreg cloth, wherein the resin layer in the fiber prepreg cloth is in direct contact with the fiber layer.

9. The impregnation method according to claim 8, wherein during the step of using the hot pressing element in the impregnation device, the film layer separation component in the impregnation device is simultaneously used to separate the film layer from the resin layer from the resin adhesive film.

10. The impregnation method according to claim 8, wherein the step of separating the membrane layer from the resin layer from the resin film using the membrane layer separation component in the impregnation device comprises: when the viscosity of the resin layer is 500 grams to 2000 grams, adjusting the separation angle of the membrane layer and the resin layer in the membrane layer separation component to between 18 degrees and 45 degrees.

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