An automated placement molding method and automated placement molding apparatus for a composite material

Abstract

The application discloses an automatic placement forming method and automatic placement forming equipment of a composite material, and the method comprises the following steps: compounding fiber yarn and a resin film to obtain a prepreg; inputting the prepreg into a pressing mechanism and heating the prepreg through a heating mechanism; setting the mold temperature to be 20-150 DEG C, the placement temperature to be 130-420 DEG C, the pressure of the pressing roller to be 1-20 MPa, and the placement speed to be 10-500 mm / s, so as to perform composite material placement forming on the prepreg. The application can avoid the use of high-priced materials such as prepreg tapes or prepreg filaments, the quality of the formed parts is good, and technical reference is provided for the industrial production of low-cost, high-quality and high-efficiency composite materials.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material forming, in particular to an automatic placement forming method and automatic placement forming equipment for composite materials. BACKGROUND

[0002] In recent years, the automatic placement forming technology of continuous fiber reinforced composite materials has attracted widespread attention, especially in the field of civil aviation. It has become a trend to manufacture large structural components using the automatic placement forming technology. The quality of the structural components is largely dependent on the raw materials, process, equipment, etc., among which the raw materials play a crucial role as the starting point.

[0003] At present, the raw materials used in automatic placement forming are pre-impregnated tapes or pre-impregnated filaments of continuous fiber reinforced thermoplastic or thermosetting resins. However, in the prior art, the interfacial adhesion and affinity between continuous reinforcing fibers such as glass fibers and carbon fibers and the matrix resin are very low. Therefore, there are many void defects in the interface region between the fibers and the resin, resulting in poor mechanical properties of the composite materials. SUMMARY

[0004] The purpose of the present application is to provide an automatic placement forming method and automatic placement forming equipment for composite materials, which aims to solve the problem of poor mechanical properties of composite materials formed by traditional methods.

[0005] In a first aspect, the present application provides an automatic placement forming method for composite materials, which comprises:

[0006] compositing the fiber yarns and the resin film to obtain a pre-impregnated material;

[0007] inputting the pre-impregnated material into a pressing mechanism and heating the pre-impregnated material by a heating mechanism, setting the mold temperature to 20-150℃, the placement temperature to 130-420℃, the roller pressure to 1-20MPa, and the placement speed to 10-500mm / s, to perform composite material placement forming on the pre-impregnated material.

[0008] Preferably, the step of compositing the fiber yarns and the resin film to obtain a pre-impregnated material comprises:

[0009] fixing the yarn roll of the continuous fiber material on a creel mechanism, and making the yarns of the yarn roll pass through a yarn collecting mechanism and then a yarn spreading mechanism in the same horizontal plane, to obtain a fiber thin layer;

[0010] feeding an upper resin film and a lower resin film, and making the upper resin film and the lower resin film respectively composite with the upper surface and the lower surface of the fiber thin layer at an impregnation mechanism to obtain a pre-impregnated material.

[0011] Preferably, in the step of fixing the yarn roll of the continuous fiber material on the creel mechanism:

[0012] The continuous fiber material is at least one of carbon fiber, glass fiber, aramid fiber, polyimide fiber, boron fiber, ultra-high molecular weight polyethylene fiber, polypropylene fiber, polyamide fiber, hemp fiber, alumina fiber, and silicon carbide fiber.

[0013] The thickness of the fiber sheet is 0.01-0.5mm.

[0014] Preferably, in the step of transporting the upper resin film and the lower resin film and allowing the upper resin film and the lower resin film to be respectively compounded with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain the prepreg:

[0015] The upper resin film and the lower resin film are one of thermoplastic resin film or thermosetting resin film, the thermoplastic resin film is one of polyethylene, polypropylene, polyamide, polycarbonate, thermoplastic polyurethane, thermoplastic polyimide, polyphenylene sulfide, and poly (aryl ether ketone), and the grammage of the thermoplastic resin film is 9-70g / m 2 .

[0016] Preferably, in the step of transporting the upper resin film and the lower resin film and allowing the upper resin film and the lower resin film to be respectively compounded with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain the prepreg:

[0017] The thermosetting resin film is one of epoxy resin, phenolic resin, bismaleimide resin, benzoxazine resin, polyurethane resin, and polyimide resin, and the grammage of the thermosetting resin film is 10-65g / m 2 .

[0018] Preferably, in the step of transporting the upper resin film and the lower resin film and allowing the upper resin film and the lower resin film to be respectively compounded with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain the prepreg:

[0019] The temperature of the impregnation mechanism is 70-450℃, the pressure of the impregnation mechanism is 1-20MPa, and the gap of the impregnation mechanism is 0.05-0.3mm.

[0020] The resin content in the prepreg is 20wt%-50wt%.

[0021] Preferably, the step of transporting the upper resin film and the lower resin film and allowing the upper resin film and the lower resin film to be respectively compounded with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain the prepreg further comprises:

[0022] In the pre-impregnation process, the combination area of the resin film and the fiber sheet is ultrasonically treated at a frequency of 5-40 kHz.

[0023] Preferably, in the step of inputting the prepreg into the pressing mechanism and heating the prepreg by the heating mechanism:

[0024] The heating mechanism is any one of a hot gas heater, an infrared heater, and a laser heater, and the heating temperature of the heating mechanism is 70-450 DEG C.

[0025] In summary, the application proposes a composite material laying forming method to adapt to the designed automatic laying forming equipment, thereby realizing efficient and low-cost preparation of the composite material while ensuring excellent mechanical properties of the composite material.

[0026] In the second aspect, the application also provides an automatic laying forming equipment for realizing the composite material laying forming method, which comprises a creel mechanism, a yarn collecting mechanism, a yarn spreading mechanism, a pre-impregnation mechanism, and a pressing mechanism.

[0027] The creel mechanism is used for placing yarn rolls, the yarn spreading mechanism comprises a support and a yarn spreading roller arranged on the support, and the pre-impregnation mechanism comprises a film placing roller and a rubber dipping roller arranged on the upper and lower sides of the yarn.

[0028] The yarns in the at least two yarn rolls are transported to the yarn collecting mechanism through the creel mechanism and are transported to the yarn spreading mechanism along the same horizontal plane, the two resin film rolls are transported to the two sides of the spread yarn respectively through the film placing rollers, and are pre-impregnated together through the two rubber dipping rollers, and the pressing mechanism is used for pressing the prepreg.

[0029] Preferably, the heating mechanism is used for heating the prepreg in the pressing process, the ultrasonic mechanism is used for ultrasonically treating the yarn and the resin film in the pre-impregnation process, and the prepreg trimming mechanism is used for trimming the excess resin on the two sides of the prepreg.

[0030] In summary, the application proposes a brand-new automatic laying forming equipment, which can realize rapid pre-impregnation of the resin film and the continuous fiber, and directly input the obtained prepreg into the pressing mechanism of the laying equipment, thereby realizing the forming and preparation of the composite material, without the need to purchase expensive prepreg products, and the composite material can be efficiently prepared by using low-cost raw materials such as resin film and continuous fiber, thereby greatly reducing the preparation cost of the composite material and improving the preparation efficiency of the composite material.

[0031] Additional aspects and advantages of the present application will be made apparent from the following description. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 A flow chart of a method for laying up a composite material is shown;

[0033] Figure 2 A detailed view of step S101 is shown;

[0034] Figure 3 A flow chart of an automatic laying up process for a composite material is shown;

[0035] Figure 4 A schematic view of an automatic laying up device is shown.

[0036] Symbol explanation: 11 - fixed plate, 12 - yarn spool, 2 - yarn, 3 - yarn collecting mechanism, 41 - support, 42 - yarn spreading roller, 51 - upper film laying roller, 52 - lower film laying roller, 53 - upper glue dipping roller, 54 - lower glue dipping roller, 55 - upper PE film collecting roller, 56 - lower PE film collecting roller, 6 - ultrasonic mechanism, 8 - pressing mechanism, 9 - resin film, 7 - edge cutting mechanism, 10 - heating mechanism. DETAILED DESCRIPTION

[0037] In order to facilitate the understanding of the present application, a more comprehensive description of the present application will be made below with reference to the relevant drawings. Several embodiments of the present application are shown in the drawings. However, the present application can be realized in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present application more thorough and comprehensive.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. The terminology used in the specification of the present application is only for the purpose of describing specific embodiments and is not intended to limit the present application. The term "and / or" used herein includes any and all combinations of one or more of the associated listed items.

[0039] In this document, unless otherwise stated, the term "°C" means "degrees Celsius"; the term "MPa" means: megapascal; the term "mm / s" means: millimeters per second; the term "mm" means: millimeter; the term "g / m 2 " means: grams per square meter; the term "wt%" means: mass percentage; the term "KHz" means: kilohertz.

[0040] In this document, all ranges are inclusive. Combinations of ranges include the minimum and maximum of those ranges and subranges. For example, a range of 1 to 5 includes 1, 2, 3, 4, and 5, as well as subranges such as 2 to 5, 3 to 5, 2 to 3, 2 to 4, 1 to 4, and the like.

[0041] <First aspect>

[0042] As shown in the first aspect of the embodiments of the present application, a composite material laying forming method is provided, comprising the following steps S101-S102: Figure 1

[0043] S101: Composite the fiber yarn and the resin film to obtain a prepreg;

[0044] S102: Input the prepreg into a pressing mechanism, and heat the prepreg through a heating mechanism, set the mold temperature to be 20-150℃, the laying temperature to be 130-420℃, the pressure roller pressure to be 1-20MPa, and the laying speed to be 10-500mm / s, to lay and form the prepreg into a composite material.

[0045] In some embodiments, the heating mechanism is any one of a hot gas heater, an infrared heater, and a laser heater, and the heating temperature of the heating mechanism is 70-450℃, the heating mechanism is set to maintain the prepreg effect, for example, the heating temperature of the heating mechanism can be 70℃, 165℃, 260℃, 355℃, 450℃, and the like.

[0046] ​In some embodiments, in order to improve the interlaminar adhesion of the composite material during the forming process, reduce the voids of the continuous fibers and the resin in the bonding area, the present application sets the forming parameters such as mold temperature, laying temperature, roller pressure and laying speed. The mold temperature refers to the temperature of the mold or the bottom plate used for laying the prepreg, the laying temperature refers to the temperature set by the heater, the laying speed refers to the moving speed of the laying head, that is, the feeding speed (conveying speed) of the yarn and the resin film. For example, the mold temperature can be 20°C, 85°C, 170°C. If the mold temperature is too low, the first layer of laid prepreg will be difficult to adhere to the mold. If the mold temperature is too high, there is a risk that the first layer of laid prepreg may be thermally degraded. The laying temperature can be 130°C, 215°C, 300°C, 400°C, etc. If the laying temperature is too low, the prepreg is difficult to cure or consolidate, and there is a serious interlaminar bonding problem. If it is too high, the thermosetting prepreg will be cured too early and lose its adhesion, or the thermoplastic prepreg will be thermally degraded. The roller pressure can be 1 MPa, 10 MPa, 20 MPa, etc. If it is too low, the prepreg layers will be difficult to bond. If it is too high, glue overflow and fiber breakage will occur. The laying speed can be 10 mm / s, 100 mm / s, 200 mm / s, 300 mm / s, 400 mm / s, 500 mm / s. If it is too low, the production efficiency will be low. If it is too high, the product quality will be unstable.

[0047] As shown in Figure 2 some embodiments, step S101 further includes:

[0048] Step S1011: Fixing a plurality of yarn rolls of continuous fiber material on a creel mechanism, and making the yarns of the plurality of yarn rolls pass through a yarn collecting mechanism and then pass through a yarn spreading mechanism in the same horizontal plane to obtain a fiber sheet;

[0049] Step S1012: conveying an upper resin film and a lower resin film, and making the upper resin film and the lower resin film respectively pre-impregnated with the upper surface and the lower surface of the fiber sheet at a pre-impregnation mechanism to obtain a prepreg.

[0050] In some embodiments, the continuous fiber material is at least one of carbon fiber, glass fiber, aramid fiber, polyimide fiber, boron fiber, ultra-high molecular weight polyethylene fiber, polypropylene fiber, polyamide fiber, hemp fiber, alumina fiber, and silicon carbide fiber. For example, the continuous fiber can be one of carbon fiber, glass fiber, aramid fiber, polyimide fiber, boron fiber, ultra-high molecular weight polyethylene fiber, polypropylene fiber, polyamide fiber, hemp fiber, alumina fiber, and silicon carbide fiber. It can also be a combination of two or more fiber materials.

[0051] In some embodiments, the thickness of the fibrous sheet is 0.01-0.5 mm. For example, the thickness of the fibrous sheet can be 0.01 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, etc.

[0052] In some embodiments, the upper resin film and the lower resin film are both resin films, and are both one of a thermoplastic resin film or a thermosetting resin film. For the thermoplastic resin film, it is at least one of polyethylene, polypropylene, polyamide, polycarbonate, thermoplastic polyurethane, thermoplastic polyimide, polyphenylene sulfide, and polyaryletherketone. The grammage of the thermoplastic resin film is 9-70 g / m 2 In some embodiments, the grammage of the thermoplastic resin film can be 9 g / m 2 , 10 g / m 2 , 40 g / m 2 , 70 g / m 2 , etc. For the thermosetting resin film, it is one of unsaturated polyester resin, epoxy resin, phenolic resin, bismaleimide resin, benzoxazine resin, polyurethane resin, and polyimide resin. The grammage of the thermosetting resin film is 10-70 g / m 2 . For example, the grammage of the thermosetting resin film can be 10 g / m 2 , 20 g / m 2 , 42.5 g / m 2 , 65 g / m 2 , 70 g / m 2 , etc.

[0053] In some embodiments, the temperature of the impregnation mechanism is 70-450℃, the pressure of the impregnation mechanism is 1-20MPa, and the gap of the impregnation mechanism is 0.05-0.3mm. If the temperature of the impregnation mechanism is too high, the resin will be cured. If the temperature of the impregnation mechanism is too low, the resin will not be impregnated well due to poor fluidity. For example, the temperature of the impregnation mechanism can be 70℃, 165℃, 260℃, 355℃, 450℃, etc. If the pressure of the impregnation mechanism is too high, the fiber will be broken. If the pressure of the impregnation mechanism is too low, the fiber and the resin will not be impregnated well. For example, the pressure of the impregnation mechanism can be 1MPa, 10MPa, 20MPa, etc. The gap of the impregnation mechanism is 0.05-0.3mm. If the gap of the impregnation mechanism is too high or too low, the resin content in the prepreg will deviate from the designed value, affecting the subsequent laying process and product performance. For example, the gap of the impregnation mechanism can be 0.05mm, 0.1mm, 0.2mm, 0.3mm, etc. The resin content in the prepreg is 20wt%-50wt%. If the resin content in the prepreg is too low, the adhesion between the layers of the prepreg will be poor, and the composite product will be prone to glue deficiency. If the resin content in the prepreg is too high, the prepreg will overflow during the laying process, making it difficult to lay. For example, the resin content in the prepreg can be 20wt%, 30wt%, 40wt%, 50wt%, etc.

[0054] The present application provides a laying forming method of a composite material, which is suitable for a designed automatic laying forming equipment, and can realize efficient and low-cost preparation of a composite material while ensuring excellent mechanical properties of the composite material.

[0055] <Second aspect>

[0056] As shown in Figure 3 and Figure 4 The second aspect of the embodiments of the present application provides an automatic laying forming equipment, which comprises a creel mechanism, a yarn collecting mechanism, a yarn spreading mechanism, an impregnation mechanism and a pressing mechanism, wherein:

[0057] The creel mechanism comprises a fixed plate 11 and a plurality of yarn spools 12 arranged on the fixed plate 11, the yarn spools 12 are used to place yarn rolls, the yarn spreading mechanism comprises a support 41 and a plurality of yarn spreading rollers 42 arranged on the support 41, the pre-impregnation mechanism comprises an upper film placing roller 51 and a lower film placing roller 52 arranged on the upper and lower sides of the yarn, an upper impregnation roller 53 and a lower impregnation roller 54, and an upper PE film collecting roller 55 and a lower PE film collecting roller 56, the upper film placing roller 51 and the lower film placing roller 52 are used to place resin film rolls, the upper PE film collecting roller 55 and the lower PE film collecting roller 56 are used to collect PE film on the surface of the resin film roll, the yarn 2 in the yarn roll is conveyed to the yarn collecting mechanism 3 through the creel mechanism, and is conveyed to the yarn spreading mechanism along the same horizontal plane, the two resin film rolls are conveyed to the sides of the spread yarn 2 through the film placing rollers respectively, and are compounded through the two impregnation rollers, the pressing mechanism 8 is used for pressing the pre-impregnated material, in this embodiment, the yarn collecting mechanism 3 is a yarn collecting plate provided with a plurality of through holes, the yarn 2 on the four yarn spools 12 passes through the through holes in the yarn collecting plate respectively, and the pressing mechanism 8 is a laying press roller, the yarn 2 on the same horizontal plane is spread after passing through the plurality of yarn spreading rollers 42 in sequence, and then is compounded with the resin film 9 on both sides to obtain the pre-impregnated material, and then the pre-impregnated material is pressed and formed through the laying press roller to obtain the composite material.

[0058] In some embodiments, the automatic laying forming equipment further comprises an ultrasonic mechanism 6, an edge cutting mechanism 7 and a heating mechanism 10, the ultrasonic mechanism 6 is an ultrasonic device used for ultrasonic treatment of the yarn 2 and the resin film 9 during pre-impregnation. The edge cutting mechanism 7 is used to cut off the excess resin on both sides of the pre-impregnated material. The heating mechanism 10 is a heater used for heating the pre-impregnated material during pressing,

[0059] In summary, the automatic laying forming equipment proposed in the embodiments of the present application can realize rapid pre-impregnation of the resin film and the continuous fiber, and directly input the obtained pre-impregnated material into the pressing mechanism of the laying equipment, thereby realizing direct forming of the composite material, without the need to purchase expensive pre-impregnated material products, and the composite material can be efficiently prepared by using low-cost raw materials such as resin film and continuous fiber, which greatly reduces the preparation cost of the composite material and improves the preparation efficiency of the composite material.

[0060] Embodiment 1

[0061] The carbon fiber (T700-12K, provided by Toray Industries, Inc.) yarn is fixed on the yarn spool, passed through the yarn collecting plate, and then spread through the yarn spreading roller to obtain a thin layer of fiber with a thickness of 0.05 mm. The impregnation roller temperature is maintained at 90℃, the pressure is 10MPa, the gap between the impregnation roller and the platform is 0.08mm, and the resin film with a grammage of 20g / m 2The epoxy resin film is unwound, allowing it to be pre-impregnated with the aforementioned thin fiber layer at the impregnation roller. During pre-impregnation, the ultrasonic frequency is 10 kHz. The pre-impregnated material is then conveyed to the pressing mechanism (feeding system) of the laying equipment. The material sheet is heated using a laser heater, with a mold temperature of 30°C, a laying temperature of 150°C, and a pressure roller pressure of 2 MPa. The composite material is laid and formed at a laying speed of 100 mm / s. The laid composite material is then placed in an autoclave for vacuum curing. After curing at 140°C for 2 hours, the degree of curing of the carbon fiber reinforced epoxy composite material reaches 99%.

[0062] Example 2

[0063] Ultra-high molecular weight polyethylene (UHMWPE) fibers (SFG 1600, provided by Changshu Xiupo Company) are fixed on a yarn spool, passed through a yarn collecting plate, and then spread by a spreading roller to obtain a thin layer of fibers with a thickness of 0.1 mm. The temperature of the impregnation roller is maintained at 90℃, the pressure at 5 MPa, and the gap between the impregnation roller and the platform is 0.15 mm. The fiber weight is 30 g / m². 2 The epoxy resin film is unwound, allowing it to be pre-impregnated with the aforementioned thin-layer fibers at the impregnation roller. During pre-impregnation, the ultrasonic frequency is 20 kHz. The pre-impregnated material is then fed into the feeding system of the laying equipment. A laser heater is used to heat the material sheet, the mold temperature is 30°C, the laying temperature is 150°C, the pressure roller pressure is 5 MPa, and the composite material is laid at a laying speed of 200 mm / s. The laid composite material is then placed in an autoclave for vacuum curing. After curing at 140°C for 2 hours, the degree of curing of the ultra-high molecular weight polyethylene fiber-reinforced epoxy composite material reaches 99%.

[0064] Example 3

[0065] Ultra-high molecular weight polyethylene (SFG 1600, provided by Changshu Xiupo Company) fibers are fixed on a yarn spool, passed through a yarn collecting plate, and then spread by a spreading roller to obtain a thin layer of fibers with a thickness of 0.1 mm. The temperature of the impregnation roller is maintained at 130℃, the pressure at 20 MPa, and the gap between the impregnation roller and the platform is 0.15 mm. The fiber weight is 30 g / m². 2 The low-density polyethylene resin film is unwound and pre-impregnated with the aforementioned thin-layer fibers at the impregnation roller. During pre-impregnation, the ultrasonic frequency is 10 kHz. The pre-impregnated material is then fed into the feeding system of the laying equipment. The material sheet is heated using an infrared heater, the mold temperature is 50°C, the laying temperature is 130°C, the pressure roller pressure is 5 MPa, and the polyethylene self-reinforced composite material is laid and formed at a laying speed of 400 mm / s.

[0066] Example 4

[0067] Glass fiber (ER550-1080, provided by Chongqing International Composite Material Co., Ltd.) was fixed on a yarn spool, passed through a collector plate, and then passed through a spreader roller to spread the yarn to obtain a thin layer of fiber with a thickness of 0.25 mm. The temperature of the impregnation roller was maintained at 90°C, the pressure was 20 MPa, the gap between the impregnation roller and the platform was 0.05 mm, and an epoxy resin film with a grammage of 10 g / m 2 was unwound so as to be pre-impregnated with the thin layer of fiber at the impregnation roller. During the pre-impregnation, the ultrasonic frequency was 5 kHz. The pre-impregnated material was fed to the feeding system of a lay-up device, a laser heater was used to heat the material sheet, the mold temperature was 20°C, the lay-up temperature was 160°C, the pressure of the compression roller was 1 MPa, and the lay-up speed was 50 mm / s to form the composite material by lay-up. The laid-up composite material was placed in a hot press tank for vacuum curing, and after curing at "140°C, 2 h", the degree of curing of the glass fiber reinforced epoxy composite material reached 99%.

[0068] Example 5

[0069] Carbon fiber (T800-12K, provided by Toray Industries, Inc.) was fixed on a yarn spool, passed through a collector plate, and then passed through a spreader roller to spread the yarn to obtain a thin layer of fiber with a thickness of 0.25 mm. The temperature of the impregnation roller was maintained at 250°C, the pressure was 10 MPa, the gap between the impregnation roller and the platform was 0.15 mm, and a bismaleimide resin film with a grammage of 40 g / m 2 was unwound so as to be pre-impregnated with the thin layer of fiber at the impregnation roller. During the pre-impregnation, the ultrasonic frequency was 25 kHz. The pre-impregnated material was fed to the feeding system of a lay-up device, a laser heater was used to heat the material sheet, the mold temperature was 85°C, the lay-up temperature was 240°C, the pressure of the compression roller was 10 MPa, and the lay-up speed was 200 mm / s to form the composite material by lay-up. The laid-up composite material was placed in a hot press tank for vacuum curing, and after curing at "240°C, 4 h", the degree of curing of the carbon fiber reinforced bismaleimide composite material reached 99%.

[0070] Example 6

[0071] Para-aramid fiber (Kevlar, provided by DuPont) was fixed on a yarn spool, passed through a collector plate, and then passed through a spreader roller to spread the yarn to obtain a thin layer of fiber with a thickness of 0.25 mm. The temperature of the impregnation roller was maintained at 220°C, the pressure was 15 MPa, the gap between the impregnation roller and the platform was 0.15 mm, and a bismaleimide resin film with a grammage of 40 g / m 2The polypropylene resin film is unwound, and pre-impregnated with the aforementioned thin fiber at the impregnation roller. During pre-impregnation, the ultrasonic frequency is 30 kHz. The pre-impregnated material is then conveyed to the feeding system of the laying equipment. The material sheet is heated using a hot air heater, the mold temperature is 100°C, the laying temperature is 220°C, the pressure roller pressure is 15 MPa, and the composite material is laid and formed at a laying speed of 300 mm / s.

[0072] Example 7

[0073] Carbon fiber (IM7, provided by Hesse) is fixed onto a yarn spool, passed through a yarn collecting plate, and then spread by a spreading roller to obtain a thin layer of fiber with a thickness of 0.5 mm. The temperature of the impregnation roller is maintained at 450℃, the pressure at 10 MPa, and the gap between the impregnation roller and the platform is 0.3 mm. The fiber has a basis weight of 70 g / m². 2 The polyetheretherketone resin film is unwound, allowing it to be pre-impregnated with the aforementioned thin-layer fibers at the impregnation roller. During pre-impregnation, the ultrasonic frequency is 40 kHz. The pre-impregnated material is then fed into the feeding system of the laying equipment. A laser heater is used to heat the material sheet, the mold temperature is 150°C, the laying temperature is 420°C, the pressure roller pressure is 20 MPa, and the composite material is laid and formed at a laying speed of 500 mm / s.

[0074] Comparative Example 1

[0075] This comparative example is basically the same as Example 1, except that: this comparative example does not have ultrasonic treatment during prepreg, and the obtained composite material is placed in an autoclave for vacuum curing. After curing at 140°C for 2 hours, the degree of curing of the composite material reaches 99%.

[0076] Comparative Example 2

[0077] Carbon fibers (T700-12K, provided by Toray Industries) placed on a fiber rack are opened by a fiber spreading device after passing through a guide roller and enter a spraying system. The spray head sprays grafting agent (silane coupling agent, 0.2% of the continuous fiber weight) from a storage tank onto the surface of the carbon fibers. Afterward, the fibers are preheated in a preheating chamber. The preheated continuous fibers are then laminated with an epoxy resin film in a high-temperature chamber using hot-press rollers. Afterward, they are cooled using cold-press rollers after exiting the high-temperature chamber. Finally, they are trimmed by a cutting device and wound up by a winding device to obtain carbon fiber reinforced epoxy resin prepreg. The obtained prepreg is laid in 0° layup and then vacuum cured in an autoclave. After curing at 140°C for 2 hours, the composite material achieves a curing degree of 99%.

[0078] Results analysis:

[0079] The mechanical properties of the composite material were characterized by three-point bending strength. Please refer to Table 1 below, which shows the results of the composite materials prepared in Examples 1-7 and Comparative Examples 1-2, respectively.

[0080] Table 1

[0081]

[0082] As can be seen from Table 1, the method provided by the present application can realize the molding of various fiber reinforced composite materials such as carbon fiber, ultra-high molecular weight polyethylene fiber, para-aramid fiber and glass fiber. The bending strength of the composite materials in Example 1 and Comparative Example 1 is 1230 MPa and 1095 MPa respectively, which shows that the ultrasonic assisted impregnation effect proposed by the present application is remarkable. At the same time, as can be seen from Comparative Example 2, the bending strength of the carbon fiber reinforced epoxy composite material prepared by the chemical treatment method of grafting coupling agent reaches 1200 MPa, while the bending strength of the same level composite material prepared by the molding process parameter adjustment of the present application reaches 1230 MPa, that is, the reinforcing effect is better than that of the surface grafting method.

[0083] The above embodiments only express several embodiments of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the scope of the patent of the present application. It should be pointed out that for ordinary skilled in the art, without departing from the concept of the present application, several modifications and improvements can be made, which all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. A method of lay-up forming of a composite material, characterized in that, The method comprises: The fiber yarn is compounded with the resin film to obtain a prepreg; The prepreg is input into a pressing mechanism, and the prepreg is heated by a heating mechanism, the mold temperature is set to 20-150 ℃, the laying temperature is set to 130-420 ℃, the pressure roller pressure is set to 1-20 MPa, and the laying speed is set to 10-500 mm / s, so that the prepreg is subjected to composite material laying forming; The step of compounding the yarn with the resin film to obtain the prepreg comprises: A plurality of yarn rolls of continuous fiber material are fixed on a creel mechanism, and the yarns of the plurality of yarn rolls pass through a yarn collecting mechanism in the same horizontal plane, and then pass through a yarn spreading mechanism to obtain a fiber sheet; An upper resin film and a lower resin film are transported, and the upper resin film and the lower resin film are compounded with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain a prepreg; In the step of transporting the upper resin film and the lower resin film, and compounding the upper resin film and the lower resin film with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain a prepreg: The temperature of the impregnation mechanism is 70-450 ℃, the pressure of the impregnation mechanism is 1-20 MPa, and the gap of the impregnation mechanism is 0.05-0.3 mm; The resin content in the prepreg is 20wt%-50wt%; The thickness of the fiber sheet is 0.01-0.5 mm; During the prepreg process, the bonding area of the resin film and the fiber sheet is subjected to ultrasonic treatment, and the ultrasonic frequency is 5-40 KHz.

2. The method of placement forming of a composite material according to claim 1, characterized in that, In the step of fixing the plurality of yarn rolls of continuous fiber material on the creel mechanism: The continuous fiber material is at least one of carbon fiber, glass fiber, aramid fiber, polyimide fiber, boron fiber, ultra-high molecular weight polyethylene fiber, polypropylene fiber, polyamide fiber, hemp fiber, alumina fiber, and silicon carbide fiber.

3. The method of placement forming of composite materials according to claim 1, characterized in that, In the step of transporting the upper resin film and the lower resin film, and compounding the upper resin film and the lower resin film with the upper surface and the lower surface of the fiber sheet at the impregnation mechanism to obtain a prepreg: The upper resin film and the lower resin film are both one of thermoplastic resin film or thermosetting resin film; The thermoplastic resin film is one of polyethylene, polypropylene, polyamide, polycarbonate, thermoplastic polyurethane, thermoplastic polyimide, polyphenylene sulfide, and polyaryletherketone, and the grammage of the thermoplastic resin film is 9 to 70 g / m 2 ; The thermosetting resin film is one of unsaturated polyester resin, epoxy resin, phenol resin, bismaleimide resin, benzoxazine resin, polyurethane resin, and polyimide resin, and the grammage of the thermosetting resin film is 10 to 70 g / m 2 .

4. The method of placement forming of composite materials according to claim 1, characterized in that, In the step of inputting the prepreg into the pressing mechanism and heating the prepreg by the heating mechanism: The heating mechanism is any one of a hot gas heater, an infrared heater, and a laser heater, and the heating temperature of the heating mechanism is 70-450 ℃.

5. An automated tape laying (ATL) or automated fiber placement (AFP) apparatus for implementing the method of claim 1 to 4, wherein It comprises a creel mechanism, a yarn collecting mechanism, a yarn spreading mechanism, an impregnation mechanism, and a pressing mechanism; The creel mechanism is used for placing yarn rolls, the yarn spreading mechanism comprises a support and a yarn spreading roller arranged on the support, the impregnation mechanism comprises film placing rollers and impregnation rollers arranged on the upper and lower sides of the yarn, and the film placing rollers are used for placing resin film rolls; The yarns in the yarn rolls are transported to the yarn collecting mechanism through the creel mechanism, and are transported to the yarn spreading mechanism along the same horizontal plane, the two resin film rolls are transported to the two sides of the spread yarn through the film placing rollers respectively, and are pre-impregnated through the two impregnation rollers, and the pressing mechanism is used for pressing the prepreg.

6. The automated tape laying machine of claim 5, wherein, Also included are a heating mechanism for heating the prepreg in the pressing and an ultrasonic mechanism for ultrasonic treatment of the yarn and the resin film in the prepreg process.

7. The automated tape laying machine of claim 5, wherein, Also included is a prepreg trimming mechanism for trimming off the excess resin on both sides of the prepreg.

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