A method of making a continuous fabric-reinforced thermoplastic composite

Abstract

The application discloses a kind of preparation methods of continuous fabric reinforced thermoplastic composite, which can regulate fiber content during preparation process, and realize full impregnation of fabric by intermittent wave pressing impregnation mold.The preparation method of continuous fabric reinforced thermoplastic composite uses a preparation device of continuous fabric reinforced thermoplastic composite, including the following steps:S1, realize the unwinding supply of fabric by unwinding device;S2, the fabric after unwinding passes through sizing roller group, infrared preheating device and coating mold in sequence to realize film coating;S3, realize resin impregnation by primary surface impregnation roller group;S4, the fabric realizes extrusion impregnation by multiple secondary impregnation components of secondary impregnation device;S5, the fabric passes through cooling roller group, flat pressing device and winding device in sequence to realize winding.The preparation method of continuous fabric reinforced thermoplastic composite can realize multiple impregnation of fabric prepreg;realize full impregnation of fabric;can meet the reference of different fields.

Description

Technical Field

[0001] This invention relates to the field of fabric composite material preparation, and in particular to a method for preparing a continuous fabric-reinforced thermoplastic composite material. Background Technology

[0002] Continuous fabric reinforced thermoplastic composites are composite materials composed of continuous fiber reinforcements and a thermoplastic resin matrix. Currently, the preparation technologies for continuous fabric reinforced thermoplastic composites include the following:

[0003] 1. Horizontal stretch forming: This method first involves pre-impregnating fibers into molten thermoplastic resin on a textile machine, then pressing the fiber and resin composite into a continuous strip shape using a series of rollers. Finally, the strip material is heated and cooled to cure the resin, yielding the desired reinforced thermoplastic composite material.

[0004] 2. Thermal spray molding: This method involves spraying molten thermoplastic resin powder or granules onto a textile, melting it under heating conditions, and using pressure to force the resin into the fiber gaps to form a composite structure. Finally, the material is cooled and cured to form a fabric-reinforced thermoplastic composite material.

[0005] 3. Nonwoven Prepreg Technology: This method involves prepregding continuous fibers with thermoplastic resin through an impregnation process, allowing the resin to penetrate into the fibers. The prepreg material is then subjected to hot pressing or thermosetting processes to tightly bond the fibers and resin, forming the desired continuous fabric-reinforced thermoplastic composite material.

[0006] For example, Chinese invention patent 202211719166.X discloses a continuous fiber-reinforced thermoplastic resin powder impregnation device, relating to the field of composite materials, to solve the technical problem of difficulty in controlling resin content in the preparation method of continuous carbon fiber prepreg. The impregnation device includes, in sequence, a yarn spreading device, a surface treatment device, a surface modification device, an electrostatic spraying device, and a hot pressing device for curing thermoplastic resin onto the fiber surface; the electrostatic spraying device includes an electrostatic spray gun, a second ultrasonic device, and a guiding device, the guiding device including a guide roller, which cooperates with the second ultrasonic device to open the surface tension of the solution in the fiber bundle and create gaps between the fibers; the surface modification device contains a silane coupling agent and nano-silica sol to improve the interfacial bonding between the fiber surface and the thermoplastic resin. This device can achieve uniform resin spraying and better control the resin content.

[0007] For example, Chinese Invention Patent No. 202222286740.9 discloses a fiber impregnation mold and a continuous fiber impregnation device. The fiber impregnation mold includes a box body and a feeding section disposed at one end of the box body. The box body has an impregnation channel for holding impregnation liquid, and the feeding end of the impregnation channel is connected to the fiber feeding channel in the feeding section. A first template and a second template for forming the fiber feeding channel are movably connected radially to adjust the size of the fiber feeding channel. Using the fiber impregnation mold provided in this application for continuous fiber impregnation, the fiber feeding channel can be enlarged by adjusting the distance between the first and second templates without disassembling the box body or removing the impregnation liquid from the impregnation channel. This allows the knotted fibers to be inserted into the box for impregnation, simplifying fiber replacement operations and reducing impregnation liquid waste.

[0008] Although the above-mentioned device can simplify fiber replacement operations and reduce the waste of impregnation solution, it cannot guarantee complete fiber impregnation or achieve control over fiber content. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to provide a method for preparing a continuous fabric-reinforced thermoplastic composite material in which the fiber content can be controlled during the preparation process, and the fabric can be fully impregnated by an intermittent wave-type pressing impregnation mold.

[0010] The technical solution adopted by the present invention to solve its technical problem is: a method for preparing a continuous fabric reinforced thermoplastic composite material, wherein the composite material is prepared by using a continuous fabric reinforced thermoplastic composite material preparation device;

[0011] The apparatus for preparing the continuous fabric-reinforced thermoplastic composite material includes, in sequence, an unwinding device, a web-correcting device, a sizing roller group, an infrared preheating device, a primary surface impregnation roller group, a secondary impregnation device, a cooling roller group, a flat pressing device, and a winding device.

[0012] A coating mold is provided between the infrared preheating device and the primary surface impregnation roller group; a film extruder is provided on the coating mold;

[0013] The secondary impregnation device includes a secondary impregnation assembly; the secondary impregnation assembly has at least two components; the secondary impregnation assembly includes an intermittent wave extrusion impregnation die and a re-leveling preheating device;

[0014] The intermittent wave extrusion impregnation mold includes a fixed concave mold and an upper convex mold that can move up and down; the fixed concave mold is provided with a wave groove; the wave groove is a three-part wave groove; that is, the wave crest, the wave trough, and the wave middle between the wave crest and the wave trough are divided into three equal parts; the upper convex mold is provided with a wave boss that matches the wave groove;

[0015] It also includes the following steps:

[0016] S1. The unwinding device is used to supply the fabric; during the unwinding process, the straightening device ensures that the fabric path is consistent.

[0017] S2. After unwinding, the fabric is guided and sized by the sizing roller group; then it is preheated by the infrared preheating device; the preheated fabric is coated by the coating mold.

[0018] S3. After the fabric passes through the coating mold, it is impregnated with resin through a surface impregnation roller group.

[0019] S4. The fabric is squeezed and impregnated through multiple secondary impregnation components of the secondary impregnation device;

[0020] The surface-impregnated prepreg enters the intermittent wave extrusion impregnation mold. By controlling the unwinding speed of the unwinding device and the winding speed of the winding device, the fibers move intermittently. This allows the fabric to remain stationary while being extruded and impregnated in the wave extrusion impregnation mold. After one extrusion impregnation is completed, the fabric gap is moved a certain distance by controlling the wave extrusion impregnation mold to perform the next extrusion impregnation.

[0021] After being squeezed and impregnated by the intermittent wave extrusion impregnation mold, the fabric enters the flattening and preheating device; the flattening and preheating device flattens and preheats the fabric; until the fabric passes through the last flattening and preheating device, the fabric undergoes multiple extrusion impregnations.

[0022] S5. The fabric, after being impregnated multiple times, is sequentially passed through a cooling roller assembly, a flat pressing device, and a winding device to achieve winding.

[0023] Cooling is achieved through a cooling roller assembly; the prepreg is impregnated in the subsequent stage through a flat pressing device, restoring the original structural state of the fabric; and the fabric is collected through a winding device.

[0024] Furthermore, in step S4, the intermittent wave extrusion impregnation mold includes a shell; the shell has an inner cavity; a fixed die device for forming a fixed die is provided in the inner cavity; an upper die device that can move up and down and forms an upper punch is provided above the fixed die device; a feed port is provided on one side of the shell; a discharge port is provided on the other side; transition rollers are provided below both the feed port and the discharge port; a lifting device and a guide sleeve are provided on the top of the shell.

[0025] The fixed die device includes a U-shaped fixing frame; at least two sprockets are provided inside the U-shaped fixing frame, one of which is a first driving sprocket and the other is a first driven sprocket;

[0026] A first chain is wound around the first drive sprocket and the first driven sprocket; a recessed module is provided on the outer surface of the first chain; when the first chain is in a straight state, the recessed module on the outer surface of the first chain can form multiple different extrusion dies;

[0027] The chain above the first drive sprocket and one of the first driven sprockets is in a horizontal state, and the concave modules on the chain are combined to form a fixed concave mold; the fixed concave mold extends into a U-shaped fixing frame;

[0028] A parallel chain is formed above and below the first drive sprocket and the first driven sprocket; a concave mold is formed on the outer surface of the chain; a fixing frame extends from the concave mold above the first drive sprocket and the first driven sprocket.

[0029] Both ends of the U-shaped fixing frame are provided with side supports; guide rollers are provided on the side supports; a first driving device for driving the first driving sprocket to rotate is provided on one side of the U-shaped fixing frame; the bottom of the U-shaped fixing frame is fixedly installed inside the housing.

[0030] The upper punch device includes an inverted U-shaped movable frame; at least two sprockets are arranged inside the inverted U-shaped movable frame, one of which is a second driving sprocket and the other is a second driven sprocket;

[0031] A second chain is wound around the second drive sprocket and the second driven sprocket; a protruding module is provided on the outer surface of the second chain; when the second chain is in a straight state, the protruding module on the outer surface of the second chain can form multiple different extrusion punches;

[0032] The chain below the second drive sprocket and one of the second driven sprockets is in a horizontal state, and the protrusions on the chain are combined to form an upper punch; the upper punch extends into an inverted U-shaped moving frame;

[0033] A second drive device for driving the second drive sprocket to rotate is provided on one side of the housing;

[0034] The top of the inverted U-shaped movable frame is equipped with a sliding column and a guide column; the sliding column is driven to move up and down by a lifting device; the guide column cooperates with a guide sleeve.

[0035] The extrusion die formed on the fixed die device matches the extrusion punch formed on the upper punch device.

[0036] Furthermore, the first chain is provided with a first die chain block and a second die chain block; there are multiple first die chain blocks and multiple second die chain blocks, and all the first die chain blocks are continuously distributed; and two adjacent first die chain blocks are hinged to form a first die chain.

[0037] All the second die chain blocks are continuously distributed; and two adjacent second die chain blocks are hinged together to form a second die chain.

[0038] The first die chain and the second die chain are hinged end to end to form an annular die chain; the annular die chain is wound around the first drive sprocket and the first driven sprocket; an extrusion die is formed on the outer surface of the chain above the first drive sprocket and the first driven sprocket; and a U-shaped fixing frame extends out;

[0039] The second chain is provided with a first punch chain block and a second punch chain block; there are multiple first punch chain blocks and multiple second punch chain blocks, and all the first punch chain blocks are continuously distributed; and two adjacent first punch chain blocks are hinged to form a first punch chain;

[0040] All the second punch chain blocks are continuously distributed; and two adjacent second punch chain blocks are hinged to form a second die chain.

[0041] The first punch chain and the second punch chain are hinged end to end to form an annular punch chain; the annular punch chain is wound around the second drive sprocket and the second driven sprocket; an extrusion punch is formed on the outer surface of the chain below the second drive sprocket and the second driven sprocket; and an inverted U-shaped moving frame extends out.

[0042] Furthermore, support transition wheels are provided on the inner sides of both the first and second chains.

[0043] Furthermore, the housing has an opening on one side, and an openable and closable transparent baffle is provided at the opening.

[0044] Furthermore, the waveform groove is a three-part waveform groove; that is, the wave crest, the wave trough, and the wave mid-section between the wave crest and the wave trough are divided into three equal segments.

[0045] Furthermore, in step S4, heating elements are provided in both the fixed concave die and the upper convex die of the intermittent wave extrusion impregnation mold.

[0046] Furthermore, the unwinding device described in step S1 is equipped with a tension controller.

[0047] Furthermore, the primary surface impregnation roller group mentioned in step S3 includes impregnation rollers; heating elements are provided inside the impregnation rollers, and the number of impregnation rollers is 2n, where n is a positive integer; two impregnation rollers form a squeezing roller group; the fabric is heated by the heating elements after passing through the primary surface impregnation roller group.

[0048] Furthermore, the flat pressing device in step S5 is equipped with a fixed base plate and a flat pressing plate; a heating element is provided on the fixed base plate; a compression device is provided on the flat pressing plate; the fabric is heated by the heating element through the flat pressing device and flattened by the flat pressing plate; the compression device adopts a hydraulic telescopic cylinder.

[0049] Furthermore, the fabric on the fabric roll on the unwinding device in step 1 is one of carbon fiber fabric, glass fiber fabric, aramid fiber fabric, and blended fabric; the resin matrix plasticized by the coating mold 6 and the film extruder 5 in step 2 includes one of PA, PC, PPS, PEEK, and PEKK.

[0050] The beneficial effects of the present invention are: the preparation method of continuous fabric reinforced thermoplastic composite material of the present invention, in step S3, the resin can be impregnated into the fabric surface by a single surface impregnation roller group, so as to ensure that the resin matrix is ​​evenly distributed on the fabric surface.

[0051] Secondly, in step S4, the fabric is fully impregnated through a secondary impregnation assembly. Specifically, the fabric is impregnated during the intermittent wave extrusion impregnation die pressing process. After being extruded and impregnated, the prepreg exhibits a wave shape. Then, the wave-shaped prepreg is restored to a flat state by a re-flattening and preheating device. Subsequently, the prepreg is repeatedly impregnated multiple times through the intermittent wave extrusion impregnation die and the re-flattening and preheating device to achieve full impregnation of the fabric.

[0052] Furthermore, the fiber content can be controlled by controlling the unwinding speed of the coated extruder and the unwinding device;

[0053] Furthermore, the intermittent wave extrusion impregnation mold described in this application is provided with a fixed die device for forming a fixed die and an upper punch device for forming an upper punch; different extrusion dies can be formed by the fixed die device and the upper punch device, which facilitates the extrusion impregnation of different fibers. Attached Figure Description

[0054] Figure 1 This is a flowchart of the preparation method of continuous fabric reinforced thermoplastic composite material in the embodiments of the present invention;

[0055] Figure 2 This is a schematic diagram of the layout of the preparation apparatus for continuous fabric-reinforced thermoplastic composite materials in an embodiment of the present invention;

[0056] Figure 3 This is a schematic diagram of the layout of the secondary impregnation component in an embodiment of the present invention;

[0057] Figure 4 This is a schematic diagram of the punch and die of the intermittent wave extrusion impregnation mold in an embodiment of the present invention;

[0058] Figure 5 This is a perspective view of the intermittent wave extrusion impregnation mold in an embodiment of the present invention;

[0059] Figure 6 This is a front view of the intermittent wave extrusion impregnation mold in an embodiment of the present invention;

[0060] Figure 7 This is a top view of the intermittent wave extrusion impregnation mold in an embodiment of the present invention;

[0061] Figure 8 This is the AA section view of Figure 6;

[0062] Figure 9 This is a schematic diagram of the structure of the intermittent wave extrusion impregnation die during extrusion in an embodiment of the present invention;

[0063] Figure 10 This is a schematic diagram of the internal structure of the intermittent wave extrusion impregnation mold after mold switching in an embodiment of the present invention;

[0064] Figure 11 This is the BB cross-sectional view of Figure 5;

[0065] The diagram shows: 1-unwinding device, 2-correction device, 3-sizing roller group, 4-infrared preheating device, 5-extruder, 6-coating die, 7-primary surface impregnation roller group, 8-secondary impregnation device; 81-intermittent corrugated extrusion impregnation die, 82-flattening preheating device.

[0066] 811-Housing shell; 812-Inlet; 813-Outlet; 814-Transition roller; 815-Fixed die device; 816-Upper punch device; 817-Guide sleeve; 819-Lifting device; 8110-Cavity; 8111-Second drive device; 8112-First drive device; 8113-Transparent baffle; 8114-Supporting transition wheel;

[0067] 8151-U-shaped fixing frame, 8152-first driven sprocket, 8153-first drive sprocket, 8154-first die chain block, 8155-second die chain block, 8156-side bracket, 8157-guide roller;

[0068] 8161-Inverted U-shaped fixing bracket, 8162-Second driven sprocket, 8163-Second drive sprocket, 8164-First punch chain block, 8165-Second punch chain block, 8166-Guide post, 8167-Sliding post;

[0069] 9-Cooling roller assembly, 10-Pressure pressing device, 11-Rewinding device. Detailed Implementation

[0070] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0071] like Figures 2 to 11 The apparatus for preparing a continuous fabric reinforced thermoplastic composite material, as shown in the present invention, includes an unwinding device 1, a web-correcting device 2, a sizing roller group 3, an infrared preheating device 4, a primary surface impregnation roller group 7, a secondary impregnation device 8, a cooling roller group 9, a flat pressing device 10, and a winding device 11 arranged in sequence.

[0072] A coating mold 6 is provided between the infrared preheating device 4 and the primary surface impregnation roller group 7; a film extruder 5 is provided on the coating mold 6;

[0073] The main function of the unwinding device 1 is to unwind the fabric, so as to provide a continuous supply of fabric.

[0074] The main function of the correction device 2 is to control the left and right movement of the unwinding device 1 so that the fabric follows a consistent path throughout the production process. The sizing roller group 3 guides the fabric path.

[0075] The infrared preheating device 4 is used to preheat the fabric, which facilitates the subsequent coating of the fabric by the coating mold 6.

[0076] After the fabric passes through the coating mold 6, the resin matrix remains on the fabric surface, still belonging to the upper and lower structural layers in space. Then, after passing through the surface impregnation roller group 7, the pressure between the impregnation roller and the fabric causes the resin to impregnate the fabric surface, while ensuring that the resin matrix is ​​evenly distributed on the fabric surface.

[0077] The secondary impregnation device 8 achieves complete impregnation of the fabric; specifically, the secondary impregnation device 8 includes a secondary impregnation assembly; the secondary impregnation assembly has at least two; the secondary impregnation assembly includes an intermittent wave extrusion impregnation mold 81 and a re-flattening preheating device 82.

[0078] The intermittent wave extrusion impregnation mold 81 includes a fixed concave mold and an upper punch that can move up and down; the fixed concave mold is provided with a wave groove; the wave groove is a three-part wave groove; that is, the wave crest, the wave trough, and the wave middle between the wave crest and the wave trough are divided into three equal parts; the upper punch is provided with a wave boss that matches the wave groove.

[0079] During the operation, after the fabric passes through the surface impregnation roller group 7 once, it is not fully impregnated, and dry yarn still exists inside the prepreg. Then, the surface-impregnated prepreg enters the intermittent wave extrusion impregnation mold 81. The fabric is impregnated during the pressing process of the mold. After being extruded and impregnated, the prepreg takes on a wave shape. Then, the wave-shaped prepreg fabric returns to a flat state after passing through the flattening and preheating device 82. Subsequently, the prepreg fabric is repeatedly impregnated multiple times by passing through the intermittent wave extrusion impregnation mold 81 and the flattening and preheating device 82.

[0080] The flat pressing device 10 enables the subsequent impregnation of the prepreg and restores the original structural state of the fabric. In addition, the inner surface of the flat pressing device 10 can be processed with various textures and printed on the surface of the prepreg fabric.

[0081] The secondary impregnation device 8 includes a fixed concave mold and an upper convex mold that can move up and down; the fixed concave mold has a corrugated groove; the upper convex mold has a corrugated boss that matches the corrugated groove. A fabric impregnation channel is formed between the corrugated groove and the corrugated boss. The path of the fabric impregnation channel has a strong influence on the impregnation effect of the fabric.

[0082] By setting the fabric impregnation channel as a three-part wave groove, it is easy to achieve three different impregnation segments—the peak, the trough, and the middle of the wave—within a single area, thereby improving the impregnation effect and ensuring complete impregnation.

[0083] like Figure 1 and Figure 2 As shown, a method for preparing a continuous fabric-reinforced thermoplastic composite material is described, which uses a continuous fabric-reinforced thermoplastic composite material preparation apparatus to prepare the composite material; the method includes the following steps:

[0084] 1. The unwinding device 1 enables continuous fabric supply; during the unwinding process, the correction device 2 ensures consistent fabric path; the specific unwinding speed can be set according to process requirements; and meets the corresponding fabric unwinding requirements.

[0085] 2. After unwinding, the fabric is guided and sized by the sizing roller group 3; then it is preheated by the infrared preheating device 4; after heating, the sizing agent on the surface of the fabric is removed, and the preheated fabric is coated by the coating mold 6; the fiber content is controlled by controlling the coating amount of the coating device; when the fabric passes through the coating mold 6, the coating mold 6 applies the coating extruded by the coating extruder 5 to the surface of the fabric.

[0086] 3. After the fabric passes through the coating mold 6, the resin matrix remains on the fabric surface. From the spatial perspective, it still belongs to the upper and lower structural layers. Then, after passing through the surface impregnation roller group 7, the pressure between the impregnation roller and the fabric causes the resin to impregnate the fabric surface layer, while ensuring that the resin matrix is ​​evenly distributed on the fabric surface.

[0087] 4. The fabric is squeezed and impregnated through multiple secondary impregnation components of the secondary impregnation device 8;

[0088] In the secondary impregnation device, the surface-impregnated prepreg enters the intermittent wave extrusion impregnation die 81. The fabric is impregnated during the pressing process of this die. After being extruded and impregnated, the prepreg takes on a wave shape. Specifically, during the passage through the intermittent wave extrusion impregnation die 81, the fibers can move intermittently by controlling the unwinding speed and the winding device. After the fibers are extruded and impregnated, they move a certain distance, and then the subsequent fibers are extruded, thus achieving intermittent extrusion impregnation. The wave-shaped prepreg then passes through the flattening and preheating device 82 to return to a flat state. Subsequently, the prepreg undergoes multiple impregnations through the intermittent wave extrusion impregnation die 81 and the flattening and preheating device 82.

[0089] 5. The fabric, after being impregnated multiple times, passes sequentially through the cooling roller group 9, the flat pressing device 10, and the winding device 11;

[0090] The flat pressing device 10 performs a subsequent impregnation of the prepreg and restores the original structural state of the fabric. Furthermore, the inner surface of the flat pressing device 10 can be processed with various textures to be printed onto the surface of the prepreg. The winding device 11 collects the impregnated fabric.

[0091] Specifically, in the preparation method of the continuous fabric-reinforced thermoplastic composite material of the present invention, the fabric on the unwinding device 1 in step 1 is one of carbon fiber fabric, glass fiber fabric, aramid fiber fabric and blended fabric; the resin plasticized in the coating mold 6 and the extruder 5 in step 2 includes one of PA, PC, PPS, PEEK and PEKK.

[0092] In one feasible embodiment, such as Figures 4 to 11 As shown; the intermittent wave extrusion impregnation mold 81 includes a housing 811;

[0093] The housing 811 can be made of stainless steel, and its main function is to achieve airtightness and prevent dust contamination.

[0094] The housing 811 has a feed inlet 812 on one side and a discharge outlet 813 on the other side; the feed inlet 812 and discharge outlet 813 facilitate the entry and exit of impregnated fibers.

[0095] A transition roller 814 is provided below the feed inlet 812 and the discharge outlet 813 to facilitate the guidance of the impregnated fibers.

[0096] The top of the housing 811 is provided with a lifting device 818 and a guide sleeve 817; the housing 811 has an inner cavity; a fixed die device 815 for forming a fixed die is provided in the inner cavity; an upper die device 816 that can move up and down and forms an upper punch is provided above the fixed die device 815.

[0097] like Figure 4 As shown, the fixed die device 815 includes a U-shaped fixing frame 8151; at least two sprockets are provided inside the U-shaped fixing frame 8151, one of which is a first driving sprocket 8153, and the other is a first driven sprocket 8152;

[0098] A first chain is wound on the first drive sprocket 8153 and the first driven sprocket 8152; a recessed module is provided on the outer surface of the first chain; when the first chain is in a straight state, the recessed module on the outer surface of the first chain can form multiple different extrusion dies;

[0099] The chain above the first drive sprocket 8153 and one of the first driven sprockets 8152 is in a horizontal state, and the concave modules on the chain are combined to form a fixed concave mold; the fixed concave mold extends out of a U-shaped fixing frame 8151;

[0100] A parallel chain is formed above and below the first drive sprocket 8153 and the first driven sprocket 8152; a concave mold is formed on the outer surface of the chain; a fixing frame 8151 extends from the concave mold above the first drive sprocket 8153 and the first driven sprocket 8152.

[0101] Both ends of the U-shaped fixing frame 8151 are provided with side brackets 8156; the side brackets 8156 are provided with guide rollers 8157; a first driving device 8112 for driving the first driving sprocket 8153 to rotate is provided on one side of the housing 811; the bottom of the U-shaped fixing frame 8151 is fixedly installed inside the housing 811.

[0102] Specifically, the U-shaped fixing bracket 8151 can be positioned at the bottom of the inner cavity of the housing 811 by setting a limiting boss 8158 at the bottom of the U-shaped fixing bracket 8151.

[0103] The upper punch device 816 includes an inverted U-shaped movable frame 8161; the inverted U-shaped movable frame 8161 is provided with at least two sprockets, one of which is a second drive sprocket 8163, and the other is a second driven sprocket 8162;

[0104] like Figure 3As shown, a second chain is wound on the second drive sprocket 8163 and the second driven sprocket 8162; a variety of protrusions are provided on the outer surface of the second chain; when the second chain is in a straight line, the protrusions on the outer surface of the second chain can form multiple different extrusion punches; that is, when the same type of protrusion on the second chain is located on the same straight line, a corresponding punch is formed.

[0105] The chain below the second drive sprocket 8163 and one of the second driven sprockets 8162 is in a horizontal state, and the protruding modules on the chain are combined to form an upper punch; the upper punch extends into an inverted U-shaped moving frame 8161;

[0106] A second drive device 8111 is provided on one side of the inverted U-shaped mobile frame 8161 to drive the second drive sprocket 8163 to rotate; specifically, a side wall cavity 8110 for accommodating the second drive device 8111 is provided inside the housing 811.

[0107] The top of the inverted U-shaped movable frame 8161 is provided with a sliding column 8167 and a guide column 8166; the sliding column 8167 is driven to move up and down by a lifting device 818; the guide column 8166 cooperates with the guide sleeve 817.

[0108] The extrusion die formed on the fixed die device 815 matches the extrusion punch formed on the upper punch device 816.

[0109] During the operation, the second chain is first driven to rotate by the second drive sprocket 8163 in the upper punch device 816 to form a pressing punch, and then the second drive sprocket 8163 is braked to stop rotating.

[0110] At the same time, the first chain is driven to rotate by the first drive sprocket 8153 in the fixed die device 815 to form a die matching the extrusion punch, and then the first drive sprocket 8153 is braked to stop rotating.

[0111] Specifically, the second drive sprocket 8163 is driven by the second drive device and the first drive sprocket 8153 is driven by the first drive device; both the second drive device and the first drive device can be stepper motors.

[0112] The fibers to be impregnated are passed between the upper punch device 816 and the fixed die device 815; then, the upper punch device 816 is moved downward by the lifting device 818 to achieve extrusion impregnation. During the downward movement of the upper punch device 816 to extrude the fibers, the fibers are in a stationary state. The intermittent movement of the fibers can be achieved by controlling the unwinding speed and the winding device; after the fibers are extruded, they move a certain distance, and then the subsequent fibers are extruded; thus achieving intermittent extrusion impregnation; the extrusion gap can be adjusted by controlling the lifting distance of the lifting device.

[0113] Secondly, the extrusion punch and extrusion die can be replaced by rotating the second drive sprocket 8163 and the first drive sprocket 8153, which is convenient for different impregnating fibers and improves the impregnation effect.

[0114] like Figures 5 to 11 As shown, in a feasible embodiment, both the fixed die device 815 and the upper punch device 816 are provided with two sprockets; and the chain blocks on the sprockets are two different types of chain blocks.

[0115] Specifically, the first chain is provided with a first die chain block 8154 and a second die chain block 8155; there are multiple first die chain blocks 8154 and second die chain blocks 8155, and all first die chain blocks 8154 are continuously distributed; and two adjacent first die chain blocks 8154 are hinged to form a first die chain.

[0116] All second die chain blocks 8155 are continuously distributed; and two adjacent second die chain blocks 8155 are hinged to form a second die chain.

[0117] The first die chain and the second die chain are hinged end to end to form an annular die chain; the annular die chain is wound around the first drive sprocket 8153 and the first driven sprocket 8152; an extrusion die is formed on the outer surface of the chain above the first drive sprocket 8153 and the first driven sprocket 8152; and a U-shaped fixing frame 8151 extends out.

[0118] The second chain is provided with a first punch chain block 8164 and a second punch chain block 8165; there are multiple first punch chain blocks 8164 and second punch chain blocks 8165, all first punch chain blocks 8164 are continuously distributed; and two adjacent first punch chain blocks 8164 are hinged to form a first punch chain.

[0119] All the second punch chain blocks 8165 are continuously distributed; and two adjacent second punch chain blocks 8165 are hinged to form a second die chain.

[0120] The first punch chain and the second punch chain are hinged end to end to form an annular punch chain; the annular punch chain is wound around the second drive sprocket 8163 and the second driven sprocket 8162; an extrusion punch is formed on the outer surface of the chain below the second drive sprocket 8163 and the second driven sprocket 8162; and an inverted U-shaped moving frame 8161 extends out.

[0121] To ensure structural stability and prevent chain deformation when the extrusion die and extrusion punch are subjected to pressure, in a feasible embodiment, support transition wheels 8114 are provided on the inner sides of both the first and second chains.

[0122] In order to facilitate observation of the extrusion impregnation process and the working status of the extrusion impregnation mold, in a feasible embodiment, the housing 811 has an opening on one side, and an openable and closable transparent baffle 8113 is provided at the opening.

[0123] In one feasible embodiment, to improve the impregnation effect and shorten the impregnation time, heating elements are provided in both the fixed concave die and the upper convex die of the intermittent wave extrusion impregnation die 81. The heating elements in both the fixed concave die and the upper convex die facilitate heating of the fabric and improve impregnation efficiency. The heating elements can be heating resistors.

[0124] To ensure consistent fabric tension during unwinding, in one feasible embodiment, the unwinding device 1 is equipped with a tension controller. The tension controller can be a spring tension controller, which is easy to control, has a simple structure, and is low in cost.

[0125] In one feasible embodiment, the primary surface impregnation roller group 7 described in step 3 includes impregnation rollers; each impregnation roller is equipped with a heating element, which is a resistance heating element. The number of impregnation rollers is 2n, where n is a positive integer; two impregnation rollers form a compression roller group. By selecting and setting different numbers of impregnation rollers, it can be ensured that the resin impregnates the fabric surface layer and the resin matrix is ​​evenly distributed on the fabric surface.

[0126] Specifically, each time the prepreg passes the front roller of the extrusion roller group, the resin matrix is ​​squeezed by the impregnation roller and the fabric, causing the resin to impregnate the fabric.

[0127] In one feasible embodiment, the flat pressing device 10 in the step is provided with a fixed base plate and a flat pressing plate; a heating element is provided on the fixed base plate; and a compression device is provided on the flat pressing plate. The compression device adopts a hydraulic telescopic cylinder. The compression device can be equipped with a high-pressure system; therefore, the device has the functions of heating raw materials and simultaneously configuring a high-pressure system to achieve the final impregnation of resin under high pressure, ultimately achieving full impregnation of the fabric.

Claims

1. A method for preparing a continuous fabric-reinforced thermoplastic composite material, characterized in that, Composite materials were prepared using a continuous fabric-reinforced thermoplastic composite material preparation apparatus; The apparatus for preparing the continuous fabric reinforced thermoplastic composite material includes an unwinding device (1), a web-correcting device (2), a sizing roller group (3), an infrared preheating device (4), a primary surface impregnation roller group (7), a secondary impregnation device (8), a cooling roller group (9), a flat pressing device (10), and a winding device (11) arranged in sequence. A coating mold (6) is provided between the infrared preheating device (4) and the primary surface impregnation roller group (7); a film extruder (5) is provided on the coating mold (6); The secondary impregnation device (8) includes a secondary impregnation assembly; the secondary impregnation assembly has at least two; the secondary impregnation assembly includes an intermittent wave extrusion impregnation die (81) and a re-flattening preheating device (82). The intermittent wave extrusion impregnation mold (81) includes a fixed concave mold and an upper convex mold that can move up and down; the fixed concave mold is provided with a wave groove; the wave groove is a three-part wave groove; that is, the wave crest, the wave trough, and the wave middle between the wave crest and the wave trough are divided into three equal parts; The upper punch is provided with a wave-shaped boss that matches the wave-shaped groove; a fabric impregnation channel is formed between the wave-shaped groove and the wave-shaped boss. It also includes the following steps: S1. The unwinding device (1) is used to supply the unwinding of the fabric; during the unwinding process, the correction device (2) is used to ensure that the path of the fabric is consistent. S2. After unwinding, the fabric is guided and sized by the sizing roller group (3); then it is preheated by the infrared preheating device (4); the preheated fabric is coated by the coating mold (6). S3. After the fabric passes through the coating mold (6), it is impregnated with resin through a surface impregnation roller group (7). S4. The fabric is squeezed and impregnated by multiple secondary impregnation components of the secondary impregnation device (8); The surface-impregnated prepreg enters the intermittent wave extrusion impregnation mold (81). By controlling the unwinding speed of the unwinding device (1) and the winding speed of the winding device (11), the fibers move intermittently. When the fabric is extruded and impregnated in the intermittent wave extrusion impregnation mold (81), the fabric is in a static state. After one extrusion impregnation is completed, the fabric gap is moved a certain distance by controlling the intermittent wave extrusion impregnation mold (81) to perform the next extrusion impregnation. After being squeezed and impregnated by the intermittent wave extrusion impregnation mold (81), the fabric enters the flattening and preheating device (82); the flattening and preheating device (82) is used to flatten and preheat the fabric; until the fabric passes through the last flattening and preheating device (82) to achieve multiple extrusion impregnations. S5. The fabric that has been impregnated multiple times passes through the cooling roller group (9), the flat pressing device (10), and the winding device (11) in sequence to achieve winding. Cooling is achieved by the cooling roller group (9); the prepreg is impregnated by the flat pressing device (10) and the original structure of the fabric is restored; the fabric is collected by the winding device (11).

2. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 1, characterized in that: The intermittent wave extrusion impregnation mold (81) in step S4 includes a shell (811); the shell (811) has an inner cavity; a fixed die device (815) for forming a fixed die is provided in the inner cavity; an upper die device (816) that can move up and down and forms an upper punch is provided above the fixed die device (815); a feed port (812) is provided on one side of the shell (811); a discharge port (813) is provided on the other side; a transition roller (814) is provided below both the feed port (812) and the discharge port (813); a lifting device (818) and a guide sleeve (817) are provided on the top of the shell (811). The fixed die device (815) includes a U-shaped fixing frame (8151); at least two sprockets are provided inside the U-shaped fixing frame (8151), one of which is a first driving sprocket (8153), and the others are first driven sprockets (8152); A first chain is wound around the first drive sprocket (8153) and the first driven sprocket (8152); a recessed module is provided on the outer surface of the first chain; when the first chain is in a straight state, the recessed module on the outer surface of the first chain forms a plurality of different extrusion dies; The chain above the first drive sprocket (8153) and one of the first driven sprockets (8152) is in a horizontal state, and the concave modules on the chain are combined to form a fixed concave mold; the fixed concave mold extends out of a U-shaped fixing frame (8151). A parallel chain is formed above and below the first drive sprocket (8153) and the first driven sprocket (8152); a concave mold is formed on the outer surface of the chain; a retaining frame (8151) extends from the concave mold above the first drive sprocket (8153) and the first driven sprocket (8152). Both ends of the U-shaped fixing frame (8151) are provided with side brackets (8156); guide rollers (8157) are provided on the side brackets (8156); a first driving device (8112) for driving the first driving sprocket (8153) to rotate is provided on one side of the U-shaped fixing frame (8151); the bottom of the U-shaped fixing frame (8151) is fixedly installed inside the housing (811); The upper punch device (816) includes an inverted U-shaped movable frame (8161); the inverted U-shaped movable frame (8161) is provided with at least two sprockets, one of which is a second drive sprocket (8163), and the others are second driven sprockets (8162); A second chain is wound around the second drive sprocket (8163) and the second driven sprocket (8162); a protruding module is provided on the outer surface of the second chain; when the second chain is in a straight state, the protruding module on the outer surface of the second chain forms a plurality of different extrusion punches; The chain below the second drive sprocket (8163) and one of the second driven sprockets (8162) is in a horizontal state, and the protrusions on the chain are combined to form an upper punch; the upper punch extends into an inverted U-shaped moving frame (8161). A second drive device (8111) for driving the second drive sprocket (8163) to rotate is provided on one side of the housing (811); The top of the inverted U-shaped movable frame (8161) is provided with a sliding column (8167) and a guide column (8166); the sliding column (8167) is driven to move up and down by a lifting device (818); the guide column (8166) cooperates with the guide sleeve (817); The extrusion die formed on the fixed die device (815) matches the extrusion punch formed on the upper punch device (816).

3. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 2, characterized in that: The first chain is provided with a first die chain block (8154) and a second die chain block (8155); there are multiple first die chain blocks (8154) and second die chain blocks (8155), and all first die chain blocks (8154) are continuously distributed; and two adjacent first die chain blocks (8154) are hinged to form a first die chain; All the second die chain blocks (8155) are continuously distributed; and two adjacent second die chain blocks (8155) are hinged to form a second die chain. The first die chain and the second die chain are hinged end to end to form an annular die chain; the annular die chain is wound around the first drive sprocket (8153) and the first driven sprocket (8152); an extrusion die is formed on the outer surface of the chain above the first drive sprocket (8153) and the first driven sprocket (8152); and a U-shaped fixing frame (8151) extends out. The second chain is provided with a first punch chain block (8164) and a second punch chain block (8165); there are multiple first punch chain blocks (8164) and second punch chain blocks (8165), and all first punch chain blocks (8164) are continuously distributed; and two adjacent first punch chain blocks (8164) are hinged to form a first punch chain; All the second punch chain blocks (8165) are continuously distributed; and two adjacent second punch chain blocks (8165) are hinged to form a second die chain; The first punch chain and the second punch chain are hinged end to end to form an annular punch chain; the annular punch chain is wound around the second drive sprocket (8163) and the second driven sprocket (8162); an extrusion punch is formed on the outer surface of the chain below the second drive sprocket (8163) and the second driven sprocket (8162); and an inverted U-shaped moving frame (8161) extends out.

4. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 2, characterized in that: Both the first chain and the second chain are provided with support transition wheels (8114) on their inner sides.

5. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 2, characterized in that: The housing (811) has an opening on one side, and a transparent baffle (8113) that can be opened and closed is provided at the opening.

6. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 1, characterized in that: Heating elements are provided in both the fixed cavity and the upper punch of the intermittent wave extrusion impregnation mold (81) described in step S4.

7. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 1, characterized in that: The unwinding device (1) in step S1 is equipped with a tension controller, which controls the tension during the unwinding process of the fabric.

8. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 1, characterized in that: The primary surface impregnation roller group (7) mentioned in step S3 has an impregnation roller; a heating element is provided inside the impregnation roller, and the number of impregnation rollers is 2n, where n is a positive integer; two impregnation rollers form a squeezing roller group; the fabric is heated by the heating element after passing through the primary surface impregnation roller group (7).

9. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 1, characterized in that: The flat pressing device (10) in step S5 is equipped with a fixed base plate and a flat pressing plate; a heating element is provided on the fixed base plate; a compression device is provided on the flat pressing plate; the fabric is heated by the heating element through the flat pressing device (10) and flattened by the flat pressing plate; the compression device adopts a hydraulic telescopic cylinder.

10. The method for preparing the continuous fabric-reinforced thermoplastic composite material as described in claim 1, characterized in that: The fabric on the fabric roll on the unwinding device (1) in step 1 is one of carbon fiber fabric, glass fiber fabric, aramid fiber fabric and blended fabric; the resin matrix plasticized by the coating mold (6) and the film extruder (5) in step 2 is one of PA, PC, PPS, PEEK and PEKK.

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