A thermoplastic prepreg fabric continuous melt infiltration composite device and process

Abstract

This invention discloses a continuous melt-infiltration lamination device and process for thermoplastic prepreg fabrics, relating to the field of thermoplastic fiber prepreg processing technology. A resin film unwinding device is used to wind a thermoplastic resin film; a pre-forming device is used to simultaneously pressurize and pre-form the fiber planar fabric and the thermoplastic resin film under set pre-forming heating temperature and pressure conditions; the reverse lamination roller of the continuous melt-infiltration lamination device rotates in the opposite direction to the traction direction of the fiber planar fabric pre-laminated with the thermoplastic resin film; the pre-formed fiber / resin film laminate structure is applied to the surface of the reverse lamination roller with an S-shaped wrap angle; a hot-pressing melt-lamination lamination zone is formed between the contact surfaces of the reverse lamination roller and the half-roller hot-pressing assembly; a traction device is used for traction and winding of the melt-infiltrated thermoplastic resin prepreg. This invention can improve the hot-melt effect between the fiber fabric and the film thermoplastic resin, facilitate the expulsion of gas from the fiber filaments, and effectively improve the overall density of the prepreg fabric.

Description

Technical Field

[0001] The invention relates to the technical field of thermoplastic fiber prepreg processing, in particular to a thermoplastic prepreg fabric continuous melt-infiltration composite device and process. Background Art

[0002] At present, thermoplastic prepreg, as a key intermediate product of thermoplastic composite materials, is difficult to prepare and has relatively high production costs. There are currently various fiber and thermoplastic resin infusion composite preparation technology research methods, such as powder method, melt extrusion method, in-situ polymerization method and thin film melt infiltration composite method.

[0003] The thin film composite method uses thermoplastic film resin and high-performance fiber to laminate, and then melts the resin film laminated on the fiber surface by heating, so as to achieve effective composite with the fiber reinforcement to prepare thermoplastic fiber prepreg. The continuous filament bundle fabric thermoplastic prepreg is prepared by heating and melting the film resin matrix and fiber fabric. The production efficiency is high, but the melting pressure of the film resin inside the fiber fabric monofilament is insufficient, resulting in low melting efficiency. At the same time, during the melting process of the resin film inside the fiber bundle, the gas inside the monofilament fiber is not easy to be discharged, which directly affects the density and interlayer bonding performance of the final prepreg. Summary of the invention

[0004] In view of the deficiencies in the prior art, the purpose of the present invention is to provide a continuous melt-infiltration composite device and process for thermoplastic preimpregnated fabrics, which can improve the hot melting effect of fiber fabrics and film thermoplastic resins, and facilitate the discharge of gas inside the fiber monofilaments, thereby effectively improving the overall densification effect of the preimpregnated fabrics.

[0005] In order to achieve the above object, the present invention is implemented through the following technical solutions:

[0006] In a first aspect, an embodiment of the present invention provides a thermoplastic prepreg fabric continuous melt infiltration composite device, comprising:

[0007] A resin film unwinding device, used for winding a thermoplastic resin film;

[0008] The pre-setting device comprises a pair of pre-setting rollers, which are used to pressurize and laminate the fiber plane fabric and the thermoplastic resin film synchronously for pre-setting under the conditions of set pre-setting heating temperature and pressure;

[0009] A continuous melt infiltration composite device comprises a reverse composite roller and a half-roll hot pressing assembly, wherein the reverse composite roller adopts a steering direction opposite to the pulling direction of the fiber plane fabric pre-laminated with the thermoplastic resin film; the pre-shaped fiber / resin film laminate structure is applied to the surface of the reverse composite roller with an S-shaped wrap angle; a hot pressing melt composite zone is formed between the contact surfaces of the reverse composite roller and the half-roll hot pressing assembly, which is used to complete the melt infiltration composite of the pre-shaped fiber / resin film laminate;

[0010] The traction device comprises a pair of traction rollers, which are used for traction and winding of the thermoplastic resin prepreg after melt infiltration and compounding.

[0011] As a further implementation, the bonding surface between the fiber / resin film laminate structure and the reverse composite roller is not less than the semi-cylindrical area of ​​the reverse composite roller.

[0012] As a further implementation, the two reverse composite rollers rotate in opposite directions, and the half-roller hot pressing assemblies corresponding to the two reverse composite rollers are located on different sides.

[0013] As a further implementation method, the half-roller hot pressing assembly adopts an arc-shaped cylindrical structure and adopts electric heating or oil heating.

[0014] As a further implementation method, a hydraulic drive system is used to form a hot pressing and melting composite zone between the arc cylindrical inner surface of the half-roll hot pressing assembly and the corner contact surface of the reverse composite roller.

[0015] As a further implementation method, the pre-molding temperature is controlled within a range of 30-50° C. lower than the thermal deformation temperature of the resin film, and the pre-molding line pressure is ≤500 KN / m.

[0016] In a second aspect, an embodiment of the present invention further provides a thermoplastic prepreg fabric continuous melt infiltration composite process, comprising:

[0017] Winding a thermoplastic resin film of a set width onto a resin film unwinding device;

[0018] Under the conditions of the set predetermined heating temperature and pressure, the fiber plane fabric and the thermoplastic resin film drawn out of the resin film unwinding device are synchronously passed through the predetermined rollers for pressurization and lamination to be predetermined;

[0019] The pre-shaped fiber / resin film laminate structure is applied to the surface of the reverse composite roller at an S-shaped wrap angle, and then pressurized by a half-roll hot-pressing assembly to form a hot-pressed melt composite zone between the contact surfaces of the reverse composite roller and the half-roll hot-pressing assembly;

[0020] The thermoplastic resin prepreg after melt infiltration and compounding is pulled and subsequently rolled up by a pulling device.

[0021] As a further implementation method, the reverse composite roller adopts a steering direction opposite to the traction direction of the fiber plane fabric pre-laminated with the thermoplastic resin film; the laminating surface between the fiber / resin film laminate structure and the reverse composite roller is not less than the semi-cylindrical area of ​​the reverse composite roller.

[0022] As a further implementation, the width of the thermoplastic resin film is between 300-1600 mm; the fiber plane fabric adopts a unidirectional fiber arrangement or a two-dimensional plane weaving method.

[0023] As a further implementation method, the pre-forming temperature is controlled within the range of 30-50°C lower than the thermal deformation temperature of the resin film, and the pre-forming line pressure is ≤500KN / m; the maximum working temperature of the pre-forming roller is 400°C; the maximum working temperature of the reverse composite roller and the half-roller hot pressing assembly is 500°C.

[0024] The beneficial effects of the present invention are as follows:

[0025] The present invention adopts a prepreg preparation method of melt infiltration and compounding after laminating and bonding a membrane resin matrix with a fiber flat fabric, wherein: a pre-forming device is used to realize the plane positioning and bonding of the continuous fiber flat fabric and the membrane resin matrix, and the resin matrix can be evenly distributed in a large plane; a two-stage continuous melt infiltration compounding device is designed to construct a uniform melt infiltration compounding area of ​​the membrane resin matrix and the continuous fiber flat fabric lamination structure, to ensure the temperature uniformity and pressure driving effect of the resin melt penetration, and to achieve efficient impregnation and compounding of the resin and the fiber; the reverse compounding roller of the continuous melt infiltration compounding device adopts a rotation mode opposite to the traction of the fiber fabric, to effectively ensure the fiber resin melt impregnation time, and to improve the compounding uniformity effect of the membrane resin. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The accompanying drawings in the specification, which constitute 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 improper limitations on the present invention.

[0027] Figure 1 It is a schematic diagram of the device structure according to one or more embodiments of the present invention.

[0028] Among them, 1. resin film unwinding device, 2. pre-forming device, 3. continuous melt infiltration composite device, 4. traction device, 5. reverse composite roller, 6. half-roller hot pressing assembly. DETAILED DESCRIPTION

[0029] Embodiment 1:

[0030] This embodiment provides a thermoplastic prepreg fabric continuous melt infiltration composite device, such as Figure 1As shown, it includes a resin film unwinding device 1, a pre-forming device 2, a continuous melt infiltration and compounding device 3 and a traction device 4 which are arranged in sequence.

[0031] Specifically, the resin film unwinding device 1 is used to wind thermoplastic resin films of various widths, and the resin film unwinding device 1 uses rollers to wind the thermoplastic resin film. The width of the thermoplastic resin film can be between 300-1600 mm, and a suitable film-shaped resin raw material can be matched according to the specification requirements of the final thermoplastic prepreg. The thickness of the film can be flexibly adjusted between 0.01-0.2 mm, and the thickness can be selected according to the resin content requirements of the final prepreg.

[0032] Thermoplastic resin films can also be selected from different types, such as polyethylene, polypropylene, polyether ketone, polyether ether ketone, polyphenylene sulfide, polycarbonate, polyoxymethylene, polyamide, polyurethane, etc. Any one of the film-like resin raw materials can be selected. The weight of the resin film can be flexibly adjusted according to the requirements of the prepreg product, and the basic weight is 40-120g / m 2 Select within range.

[0033] The pre-forming device 2 of this embodiment adopts a pair of rollers driving mode, that is, it includes two pre-forming rollers, and the two pre-forming rollers constitute a pair of pre-forming rollers. Under certain pre-forming heating temperature and pressure conditions, the fiber plane fabric and the film-like resin matrix drawn out of the resin film unwinding device are synchronously pressed and bonded through the pre-forming rollers for pre-forming, and the pre-forming temperature is controlled within the range of 30-50°C lower than the thermal deformation temperature of the resin film, which can effectively avoid the resin flowing during the pre-forming process due to excessive fluidity after the resin is melted; the pre-forming line pressure is ≤500KN / m.

[0034] Furthermore, the pre-shaped roller can be made of forged alloy steel such as 38CrMoA l, 40CrMoA l, 42CrMo, 40Cr, 9Cr2Mo, etc., and the alloy material is subjected to medium frequency quenching treatment on the roller surface to improve its surface hardness.

[0035] The diameter of the pre-setting roller is controlled within the range of 100-500mm, and the length of the roller is controlled within the range of 500-2000mm. The maximum working temperature of the pre-setting roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy of the pre-setting roller is ≤0.005mm@RT, and the speed of the roller is controlled within 5-50m / min.

[0036] The fiber plane fabric introduced by the pre-forming device 2 can adopt a unidirectional fiber arrangement or a two-dimensional plane weaving method, wherein the fiber type can be selected from any one of glass fiber, carbon fiber, aramid fiber, basalt fiber, etc. and is not limited to the above types, and the fiber plane weaving method can adopt any two-dimensional weaving structure of plain weave, twill or satin weave.

[0037] The plain, twill or satin fabric of glass fiber, carbon fiber, aramid fiber or basalt fiber and the film-like resin matrix drawn out from the resin film unwinding device are synchronously pressed and laminated through a predetermined forming roller for predetermined forming. The predetermined forming temperature is 220°C and the predetermined forming line pressure is ≤500KN / m.

[0038] The continuous melt infiltration composite device 3 consists of two parts: a reverse composite roller 5 and a half-roll hot pressing assembly 6. Two reverse composite rollers 5 are arranged at intervals and rotate in opposite directions. The center line of the two reverse composite rollers 5 is perpendicular to the traction direction of the thermoplastic resin film.

[0039] In this embodiment, the reverse composite roller 5 adopts a steering direction opposite to the traction direction of the fiber plane fabric pre-bonded with the thermoplastic resin film, and the predetermined fiber / resin film laminate structure is applied to the surface of the reverse composite roller with a large S wrap angle, and the bonding surface is not less than the semi-cylindrical area of ​​the reverse composite roller (wrapping angle ≥ 180°). After that, pressurization is applied through the half-roll hot pressing assembly 6 to form a hot pressing and melting composite zone between the contact surfaces of the reverse composite roller 5 and the half-roll hot pressing assembly 6, and the melt infiltration and composite of the predetermined fiber / resin film laminate is completed in the cavity.

[0040] The reverse composite roller 5 can be made of forged alloy steel such as 38CrMoA l, 40CrMoA l, 42CrMo, 40Cr, 9Cr2Mo, etc. The alloy material is subjected to medium frequency quenching treatment on the roller surface to improve its surface hardness. At the same time, the surface of the reverse composite roller is plated with hard chrome and sprayed with Teflon coating for surface anti-sticking roller treatment.

[0041] The roller diameter of the reverse composite roller 5 is controlled within the range of 300-500mm, and the roller length is controlled within the range of 500-2000mm. The maximum working temperature of the reverse composite roller is 500℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy of the reverse composite roller is ≤0.002mm@RT, and the speed of the reverse composite roller is controlled within the range of 5-50m / min, and its rotation is opposite to the traction direction of the fiber plane fabric.

[0042] Furthermore, the half-roller hot pressing component 6 adopts an arc-shaped cylindrical design. The half-roller hot pressing component 6 can be made of forged alloy steel such as 38CrMoAl, 40CrMoA l, 42CrMo, 40Cr, 9Cr2Mo, etc., and adopts electric heating or oil heating. The maximum working temperature is 500°C, and the temperature control accuracy is ≤±1°C.

[0043] A hydraulic drive system is used to form a melt impregnation zone for heating and pressurizing a predetermined fiber / resin film laminate structure between the arc cylindrical inner surface of the half-roll hot pressing assembly and the angle contact surface of the reverse composite roller. The composite temperature is flexibly designed according to the hot melt flow temperature characteristics of the thermoplastic resin film. The composite melt pressure is controlled within the range of 0.5-5MPa and can be flexibly adjusted according to the melt infiltration requirements.

[0044] The continuous melt infiltration composite device 3 completes the impregnation and melt infiltration of resin and fiber fabric through the cooperation of the reverse composite roller 5 and the half-roll hot pressing assembly 6. It is set up as two systems. A single system can be configured with different heating and pressurizing temperature ranges to form a two-level temperature and pressure gradient, effectively completing the multi-level melt infiltration composite of thermoplastic resin and fiber fabric.

[0045] The traction device 4 uses a roller pressurizing method to complete the traction and subsequent winding of the thermoplastic resin prepreg after melt infiltration and compounding; that is, the traction device 4 includes two traction rollers, and the traction rollers are made of metal material. For example, the traction rollers can be made of forged alloy steel such as 38CrMoA l, 40CrMoA l, 42CrMo, 40Cr, 9Cr2Mo, etc. The roller diameter is controlled within the range of 300-500mm, the roller length is controlled within the range of 500-2000mm, and the roller speed is controlled within the range of 5-50m / min.

[0046] The pre-forming device 2 of this embodiment can realize the planar positioning and bonding of the continuous fiber flat fabric and the membrane-like resin matrix, and can effectively realize the uniform distribution of the resin matrix in a large plane range; through the design of a two-stage continuous melt infiltration composite device, a uniform melt infiltration composite area of ​​the membrane-like resin matrix and the continuous fiber flat fabric laminated structure is constructed to ensure the temperature uniformity and pressure driving effect of the resin melt penetration, and realize efficient impregnation and composite of resin and fiber; the reverse composite roller 5 of the continuous melt infiltration composite device 3 adopts a rotation method opposite to the traction of the fiber fabric, which effectively ensures the fiber resin melt impregnation time and improves the uniform composite effect of the membrane resin.

[0047] Embodiment 2:

[0048] This embodiment provides a continuous melt-infiltration composite process for thermoplastic prepreg fabrics, using the device described in the first embodiment, including:

[0049] Winding a thermoplastic resin film of a set width onto a resin film unwinding device;

[0050] Under the conditions of the set predetermined heating temperature and pressure, the fiber plane fabric and the thermoplastic resin film drawn out of the resin film unwinding device are synchronously passed through the predetermined rollers for pressurization and lamination to be predetermined;

[0051] The pre-shaped fiber / resin film laminate structure is applied to the surface of the reverse composite roller at an S-shaped wrap angle, and then pressurized by a half-roll hot-pressing assembly to form a hot-pressed melt composite zone between the contact surfaces of the reverse composite roller and the half-roll hot-pressing assembly;

[0052] The thermoplastic resin prepreg after melt infiltration and compounding is pulled and subsequently rolled up by a pulling device.

[0053] This embodiment adopts a prepreg preparation method of laminating and bonding a membrane resin matrix and a fiber flat fabric (unidirectional or two-dimensional weaving) and then melt-infiltration compounding, which can effectively achieve uniform distribution of the resin matrix within a large plane; ensure the temperature uniformity and pressure driving effect of resin melt penetration, achieve efficient impregnation compounding of resin and fiber; and improve the uniform compounding effect of the membrane resin.

[0054] Embodiment three:

[0055] This embodiment provides a continuous melt infiltration composite process for thermoplastic prepreg fabrics. The device described in the first embodiment is used. The resin unwinding device is equipped with a 40g / m2 resin with a width of 300mm and a thickness of 0.01mm. 2 Polyethylene film. After the resin film unwinding device, the roller of the pre-setting device with a diameter of 100mm and a length of 500mm is prepared by using 38CrMoAl forged alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy of the roller is ≤0.005mm@RT, and the speed of the roller is controlled at 5m / min. After pre-setting, it enters the continuous continuous infiltration composite device composed of the reverse composite roller and the half-roll hot pressing assembly. The reverse composite roller with a diameter of 500mm and a length of 600mm is prepared by using 40CrMoAl alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy is ≤0.002mm@RT, and the speed of the reverse composite roller is controlled at 10m / min. The semi-roller hot pressing component is made of 40CrMoAl forged alloy steel and is designed in an arc-shaped cylindrical shape. The semi-roller hot pressing component adopts electric heating, with a maximum operating temperature of 400℃ and a temperature control accuracy of ≤±1℃.

[0056] The reverse composite roller and the fiber plane fabric with pre-laminated thermoplastic resin film are pulled in opposite directions. The pre-formed fiber / resin film laminated structure is applied to the surface of the reverse composite roller at a wrap angle of 200°, and then pressurized by the half-roll hot pressing assembly to form a hot pressing and melting composite zone between the contact surface of the reverse composite roller and the half-roll hot pressing assembly, and the melt infiltration and composite of the pre-formed fiber / resin film laminated material is completed in the cavity. A hydraulic drive is used to form a melt impregnation zone between the arc cylindrical inner surface of the half-roll hot pressing assembly and the wrap angle contact surface of the reverse composite roller. The continuous melt infiltration and composite device is set as two systems, and the composite temperature is controlled in two temperature gradient zones of 130 and 150°C, and the composite melt pressure is set at two pressure gradients of 0.6MPa and 2MPa. The metal roller pressurization method is used to complete the traction and subsequent winding of the thermoplastic resin prepreg after melt infiltration and compounding. The traction uses a 9Cr2Mo forged alloy steel metal roller with a diameter of 300mm and a length of 1000mm. The roller speed is 20m / min.

[0057] Embodiment 4:

[0058] This embodiment provides a continuous melt infiltration composite process for thermoplastic prepreg fabrics. The device described in the first embodiment is used. The resin unwinding device is equipped with 110 g / m2 of 700 mm width and 0.1 mm thickness. 2 Polypropylene film. After the resin film unwinding device, the roller of the pre-setting device with a diameter of 300mm and a length of 1000mm is prepared by using 42CrMo forged alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 500℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy of the roller is ≤0.005mm@RT, and the speed of the roller is controlled at 30m / min. After pre-setting, it enters the continuous continuous infiltration composite device composed of reverse composite roller and half-roll hot pressing assembly. 40Cr alloy steel treated by medium frequency quenching is used to prepare the reverse composite roller with a diameter of 400mm and a length of 1000mm. The maximum working temperature of the roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy is ≤0.002mm@RT, and the speed of the reverse composite roller is controlled at 20m / min. The semi-roller hot pressing assembly is made of 9Cr2Mo forged alloy steel and is designed in an arc-shaped cylindrical shape. The semi-roller hot pressing assembly adopts oil heating, with a maximum operating temperature of 400℃ and a temperature control accuracy of ≤±1℃.

[0059] The reverse composite roller and the fiber plane fabric with pre-laminated thermoplastic resin film are pulled in opposite directions. The pre-formed fiber / resin film laminated structure is applied to the surface of the reverse composite roller at a wrap angle of 180°, and then pressurized by the half-roll hot pressing assembly to form a hot pressing and melting composite zone between the contact surface of the reverse composite roller and the half-roll hot pressing assembly, and the melt infiltration and composite of the pre-formed fiber / resin film laminated material is completed in the cavity. A hydraulic drive is used to form a melt impregnation zone between the inner surface of the arc cylinder of the half-roll hot pressing assembly and the wrap angle contact surface of the reverse composite roller. The continuous melt infiltration and composite device is set as two systems, and the composite temperature is controlled in two temperature gradient zones of 180 and 220°C, and the composite melting pressure is set in two pressure gradients of 1MPa and 2MPa. The metal roller pressurization method is used to complete the traction and subsequent winding of the thermoplastic resin prepreg after melt infiltration and compounding. The traction uses a 38CrMoAl forged alloy steel metal roller with a diameter of 4500mm and a length of 1000mm. The roller speed is 45m / min.

[0060] Embodiment five:

[0061] This embodiment provides a continuous melt infiltration composite process for thermoplastic prepreg fabrics. The device described in the first embodiment is used. The resin unwinding device is equipped with 80g / m2 of 1200mm width and 0.09mm thickness. 2Polycarbonate film. After the resin film unwinding device, the roller of the pre-setting device with a diameter of 300mm and a length of 500-2000mm is prepared by using 40CrMoAl forged alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy of the roller is ≤0.005mm@RT, and the speed of the roller is controlled at 5-50m / min. After pre-setting, it enters the continuous continuous infiltration composite device composed of the reverse composite roller and the half-roll hot pressing assembly. The reverse composite roller with a diameter of 500mm and a length of 1100mm is prepared by using 40CrMoAl alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy is ≤0.002mm@RT, and the speed of the reverse composite roller is controlled at 45m / min. The semi-roller hot pressing assembly is made of 9Cr2Mo forged alloy steel and is designed in an arc-shaped cylindrical shape. The semi-roller hot pressing assembly adopts electric heating, with a maximum operating temperature of 500℃ and a temperature control accuracy of ≤±1℃.

[0062] The reverse composite roller and the fiber plane fabric with pre-laminated thermoplastic resin film are pulled in opposite directions. The pre-formed fiber / resin film laminated structure is applied to the surface of the reverse composite roller at a wrap angle of 190°, and then pressurized by the half-roll hot pressing assembly to form a hot pressing and melting composite zone between the contact surface of the reverse composite roller and the half-roll hot pressing assembly, and the melt infiltration and composite of the pre-formed fiber / resin film laminated material is completed in the cavity. A hydraulic drive is used to form a melt impregnation zone between the inner surface of the arc cylinder of the half-roll hot pressing assembly and the wrap angle contact surface of the reverse composite roller. The continuous melt infiltration and composite device is set as two systems, and the composite temperature is controlled in two temperature gradient zones of 210 and 230°C, and the composite melt pressure is set at two pressure gradients of 0.8MPa and 2MPa. The metal roller pressurization method is used to complete the traction and subsequent winding of the thermoplastic resin prepreg after melt infiltration and compounding. The traction uses a 38CrMoAl forged alloy steel metal roller with a diameter of 4500mm and a length of 1000mm. The roller speed is 40m / min.

[0063] Embodiment six:

[0064] This embodiment provides a continuous melt infiltration composite process for thermoplastic prepreg fabrics. The device described in the first embodiment is used. The resin unwinding device is equipped with a 70g / m2 resin with a width of 1000mm and a thickness of 0.08mm. 2Polyurethane film. After the resin film unwinding device, the roller of the pre-setting device with a diameter of 400mm and a length of 1000mm is prepared by using 42CrMo forged alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 400℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy of the roller is ≤0.005mm@RT, and the speed of the roller is controlled at 30m / min. After pre-setting, it enters the continuous continuous infiltration composite device composed of the reverse composite roller and the half-roll hot pressing assembly. The reverse composite roller with a diameter of 400mm and a length of 1000mm is prepared by using 38CrMoAl alloy steel treated by medium frequency quenching. The maximum working temperature of the roller is 500℃, the temperature control accuracy is ≤±1℃, the mechanical accuracy is ≤0.002mm@RT, and the speed of the reverse composite roller is controlled at 20m / min. The semi-roller hot pressing component is made of 40CrMoAl forged alloy steel and is designed in an arc-shaped cylindrical shape. The semi-roller hot pressing component adopts electric heating, with a maximum operating temperature of 300℃ and a temperature control accuracy of ≤±1℃.

[0065] The reverse composite roller and the fiber plane fabric with pre-laminated thermoplastic resin film are pulled in opposite directions. The pre-formed fiber / resin film laminated structure is applied to the surface of the reverse composite roller at a wrap angle of 180°, and then pressurized by the half-roll hot pressing assembly to form a hot pressing and melting composite zone between the contact surface of the reverse composite roller and the half-roll hot pressing assembly, and the melt infiltration and composite of the pre-formed fiber / resin film laminated material is completed in the cavity. A hydraulic drive is used to form a melt impregnation zone between the arc cylindrical inner surface of the half-roll hot pressing assembly and the wrap angle contact surface of the reverse composite roller. The continuous melt infiltration and composite device is set as two systems, and the composite temperature is controlled in two temperature gradient zones of 150 and 230°C, and the composite melting pressure is set at two pressure gradients of 1.5MPa and 1MPa. The metal roller pressurization method is used to complete the traction and subsequent winding of the thermoplastic resin prepreg after melt infiltration and compounding. The traction uses a 9Cr2Mo forged alloy steel metal roller with a diameter of 500mm and a length of 1000mm. The roller speed is 40m / min.

[0066] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A thermoplastic prepreg fabric continuous melt infiltration composite device, characterized in that: include: A resin film unwinding device, used for winding a thermoplastic resin film; The pre-setting device comprises a pair of pre-setting rollers, which are used to pressurize and laminate the fiber plane fabric and the thermoplastic resin film synchronously for pre-setting under the conditions of set pre-setting heating temperature and pressure; A continuous melt infiltration composite device comprises a reverse composite roller and a half-roll hot pressing assembly, wherein the reverse composite roller adopts a steering direction opposite to the pulling direction of the fiber plane fabric pre-laminated with the thermoplastic resin film; the pre-shaped fiber / resin film laminate structure is applied to the surface of the reverse composite roller with an S-shaped wrap angle; a hot pressing melt composite zone is formed between the contact surfaces of the reverse composite roller and the half-roll hot pressing assembly, which is used to complete the melt infiltration composite of the pre-shaped fiber / resin film laminate; A traction device, including a pair of traction rollers, used for traction and winding of the thermoplastic resin prepreg after melt infiltration and compounding; The contact surface between the fiber / resin film laminate structure and the reverse composite roller is not less than the semi-cylindrical area of ​​the reverse composite roller; The two reverse composite rollers rotate in opposite directions, and the half-roller hot pressing components corresponding to the two reverse composite rollers are located on different sides. The surface of the reverse composite roller is plated with hard chrome and sprayed with Teflon coating for surface anti-sticking roller treatment; The half-roller hot pressing assembly adopts an arc-shaped cylindrical structure and adopts an electric heating or oil heating method.

2. A thermoplastic prepreg fabric continuous melt infiltration composite device according to claim 1, characterized in that: A hydraulic drive system is used to form a hot pressing and melting composite zone between the arc cylindrical inner surface of the half-roll hot pressing component and the wrap angle contact surface of the reverse composite roller.

3. A thermoplastic prepreg fabric continuous melt infiltration composite device according to claim 1, characterized in that: The pre-molding temperature is controlled within the range of 30-50°C lower than the thermal deformation temperature of the resin film, and the pre-molding line pressure is ≤500KN / m.

4. A continuous melt infiltration composite process for thermoplastic prepreg fabrics using a continuous melt infiltration composite device for thermoplastic prepreg fabrics as claimed in any one of claims 1 to 3, characterized in that: Winding a thermoplastic resin film of a set width onto a resin film unwinding device; Under the conditions of the set predetermined heating temperature and pressure, the fiber plane fabric and the thermoplastic resin film drawn out of the resin film unwinding device are synchronously passed through the predetermined rollers for pressurization and lamination to be predetermined; The pre-shaped fiber / resin film laminate structure is applied to the surface of the reverse composite roller at an S-shaped wrap angle, and then pressurized by a half-roll hot-pressing assembly to form a hot-pressed melt composite zone between the contact surfaces of the reverse composite roller and the half-roll hot-pressing assembly; The thermoplastic resin prepreg after melt infiltration and compounding is pulled and subsequently rolled up by a pulling device.

5. A thermoplastic prepreg fabric continuous melt infiltration composite process according to claim 4, characterized in that: The reverse composite roller adopts a steering direction opposite to the pulling direction of the fiber plane fabric pre-laminated with the thermoplastic resin film; the laminating surface between the fiber / resin film laminated structure and the reverse composite roller is not less than the semi-cylindrical area of ​​the reverse composite roller.

6. A thermoplastic prepreg fabric continuous melt infiltration composite process according to claim 4 or 5, characterized in that: The width of the thermoplastic resin film is between 300-1600 mm; the fiber plane fabric adopts a unidirectional fiber arrangement or a two-dimensional plane weaving method.

7. A thermoplastic prepreg fabric continuous melt infiltration composite process according to claim 6, characterized in that: The pre-forming temperature is controlled within the range of 30-50℃ lower than the thermal deformation temperature of the resin film, and the pre-forming line pressure is ≤500KN / m; the maximum working temperature of the pre-forming roller is 400℃; the maximum working temperature of the reverse composite roller and the half-roller hot pressing assembly is 500℃.

Images