An apparatus and method for making a variable density flat panel preform

Abstract

The application discloses a preparation device and method of a variable-density flat plate preform. Firstly, multi-angle fiber cloth mats are simultaneously unwound on both sides, and then two roller needles rotate up and down to pierce the multi-angle fiber cloth mats on both sides, so that two multi-angle fiber cloth mat needle layers are connected together, the two multi-angle fiber cloth mats serve as base layers, then fiber cloth mats are laid on both sides of the base layers, and the roller needles repeatedly rotate up and down to pierce, so that a variable-density four-layer unit layer flat plate preform is formed, according to the required unit layer and density of the preform, the above steps are repeated, and finally, a variable-density flat plate preform based on multi-angle fiber cloth mats is prepared. The preparation device comprises an unwinding part, a needling part, a radial transmission part, a translation part and a support module, the variable-density flat plate preform is prepared through the method of two-side rolling and needling, the layer connection of the flat plate preform is greatly improved, and the production efficiency of the flat plate preform is doubled.

Description

Technical Field

[0001] This application relates to the field of production equipment technology, and in particular to a preparation apparatus and method for a variable density flat plate preform. Background Technology

[0002] Most existing flat preform needle punching equipment consists of a horizontal trawl plate and needle punching components. During production, the preform needs to be placed flat on the trawl plate for needle punching. It is more susceptible to the downward pressure of the needle punching components and the upward support force of the trawl plate, making it more suitable for the preparation of flat preforms with high and uniform density.

[0003] In the current production method, because the equipment is placed horizontally, gravity can easily cause the lower-layer precast material to compress, resulting in a higher density, while the upper-layer precast material remains at the preset density. This situation makes it impossible to produce precast materials with the desired uniform density.

[0004] Furthermore, due to changing production needs, different densities are required within the same flat slab preform in actual production. Currently, there is only one method: pressing a low-density flat slab preform onto a high-density flat slab preform. This cannot be done in reverse, as doing so would further compress the originally low-density bottom flat slab preform, causing it to deviate from its original density. Given the difficulty in ensuring uniform density, the technological and manufacturing challenges of variable-density flat slab preforms are even greater. Summary of the Invention

[0005] This invention provides an apparatus and method for preparing variable density flat plate preforms, which can solve the technical problem that existing technologies cannot prepare variable density flat plate preforms.

[0006] This invention provides an apparatus for preparing a variable density flat plate preform, the apparatus comprising:

[0007] The preparation apparatus includes an unwinding bearing assembly I, an unwinding roller, a lead screw I, an unwinding bearing assembly II, a bracket, a lead screw II, a lead screw nut, a nut roller connector, a roller bearing, a needle-punched roller, a needle, a radial displacement motor, a coupling I, a gear steering gear I, a connecting rod I, a coupling II, a gear steering gear II, a translation base, a radial displacement bearing assembly I, a radial displacement bearing assembly II, a suspension frame, a flattening roller I, a flattening roller II, a flattening roller fixing frame, a gear steering gear III, a coupling III, a connecting rod II, a slide rail slider module, a rack, a gear, and a translation motor;

[0008] The preparation device has a symmetrical structure with identical structures on both sides, and each side is mounted on a corresponding translational base.

[0009] Among them, the unwinding bearing assembly I includes two identical unwinding bearings I; the unwinding bearing assembly II includes two identical unwinding bearings II; each unwinding bearing I corresponds to one unwinding bearing II.

[0010] Among them, unwinding bearing assembly I and unwinding bearing assembly II are fixed above the bracket, and the unwinding roller is horizontally installed between unwinding bearing assembly I and unwinding bearing assembly II;

[0011] Two lead screws I are vertically installed, one end of which is installed together with radial displacement bearing assembly I and fixed to the suspension frame by a nut, and the other end is installed in gear steering gear III; the suspension frame is set next to unwinding bearing assembly I and unwinding bearing assembly II; gear steering gear III is set on translation base;

[0012] Gear steering gear I is provided with gear steering gear III on one side and gear steering gear II on the other side; wherein, gear steering gear III is fastened to connecting rod II by coupling III and connecting rod II is installed in gear steering gear I; similarly, connecting rod I is installed on the other side of gear steering gear I and connected to gear steering gear II by coupling II.

[0013] The radial translation motor is connected to the input end of the gear steering gear I via coupling I;

[0014] Lead screw II is installed in the same way as lead screw I, with its two ends respectively installed in gear steering gear II and unwinding bearing assembly II.

[0015] Furthermore, the translation base is mounted on two sets of slide rail slider modules, the extension direction of which is perpendicular to the extension direction of the unwinding roller; the slide rail slider modules enable the entire device to move along the extension direction; the rack is fixed to the translation base, parallel to the slide rail slider modules, and provides power to the translation base through gears and a translation motor.

[0016] The lead screw nut is installed between lead screw I and lead screw II, and is fixed to the needle-punching roller through the nut roller connector;

[0017] The needle-punching roller has a horizontal axis and rotates through a roller bearing. The needles are evenly arranged and installed on the needle-punching roller.

[0018] Flattening roller I and flattening roller II are mounted in the center of the support via a flattening roller fixing frame. The unwinding rollers and needle rollers on both sides must be kept at the same horizontal height.

[0019] Furthermore, the lead screw I is used to drive the roller needle to move up and down;

[0020] The unwinding speed of the unwinding roller is adjustable, and the rotation speed is uniform.

[0021] Furthermore, the needle has a certain angle of 45° and a length range of 2-3 mm.

[0022] Furthermore, the gear steering gear has a transmission ratio of 1:1 for all gears.

[0023] The present invention also provides a method for preparing a variable density flat plate preform, the method being implemented based on the apparatus provided by the present invention, the method comprising:

[0024] Step 1: First, load the two rolled-up fabric felts onto the unwinding rollers, and guide one end of the fabric felts between the two flattening rollers to flatten and stick the fabric felts together on both sides;

[0025] Step 2: Pull the two sides of the felt vertically down to the bottom of the device, so that the felt is placed between the two roller needles. Then the radial displacement motor is started, so that the screw rotates and drives the roller needles to move to the top.

[0026] Step 3: Start the translation motor, and the gear and rack module will drive the two roller needles to fit against the felt, leaving enough space for the needles to pierce.

[0027] Step 4: After the preparation is completed, start the radial displacement motor again to drive the roller needle to roll and needle the felt from top to bottom, so that the two pieces of felt are needled together to form a preform. Then the clamping device is started and clamps the upper end of the preform, and the felt is cut short.

[0028] Step 5: Repeat step 1 and place the two pieces of fabric on both sides of the precast body respectively; repeat step 4 to perform rolling needle punching, so that the two new pieces of fabric are needle punched and connected to both sides of the precast body to form two new unit layers.

[0029] Step 6: When it is necessary to increase the bulk density of the preform, start the translation motor to drive the needle rollers to step towards each other, thereby increasing the relative needle penetration depth of the preform; and slow down the speed of the radial displacement motor to reduce the vertical displacement speed of the needle rollers, thereby reducing the relative displacement speed between the preform and the needles, thus increasing the needle penetration density.

[0030] Step 7: When it is necessary to reduce the bulk density of the preform, start the translation motor to drive the needle roller to step relative to each other, thereby reducing the relative needle penetration depth of the preform; and increase the speed of the radial displacement motor to increase the up-and-down displacement speed of the needle roller, thereby increasing the relative displacement speed between the preform and the needle, thus reducing the needle penetration density; in order to reduce the density of the preform.

[0031] By adjusting steps 6 and 7, the volume density of the preform is adjusted steplessly to meet the requirements for preparing a variable density preform.

[0032] Step 8: Repeat cutting the top of the new felt and clamping it again. Repeat steps 5, 6 and 7 until all unit layers are needled to form a complete precast body.

[0033] Furthermore, the surface density of the felt in step 1 can be adjusted, with a density range of 136 g / m2 to 450 g / m2.

[0034] Furthermore, after the felt in step 1 passes through the flattening roller, its surface is uniform and wrinkle-free.

[0035] Furthermore, the felt in step 1 is made of two layers of mesh and one layer of fiber cloth pre-stitched together to form a sandwich structure of mesh fabric;

[0036] Fabric can be pre-laid with fiber yarn and pre-stitched.

[0037] Furthermore, the preform in step 4 can include microwave absorbing felt, prepreg, and other materials to replace the felt during the preparation process.

[0038] Compared with the prior art, the significant advancements of this invention are: 1. This invention enables stepless variable density production of flat preforms; 2. This invention enables the preparation of ultra-long and ultra-wide flat preforms; 3. This invention enables simultaneous needle punching preparation on both sides of the flat preform, greatly improving product production efficiency and enhancing competitiveness. Attached Figure Description

[0039] Figure 1 A diagram of a variable density flat plate preform preparation apparatus provided in an embodiment of the present invention;

[0040] Figure 2 The front view provided for an embodiment of the present invention;

[0041] Figure 3 A top view provided for an embodiment of the present invention;

[0042] Figure 4 A side view provided for an embodiment of the present invention;

[0043] The attached figures are labeled as follows: Unwinding bearing assembly I1, Unwinding roller 2, Lead screw I3, Unwinding bearing assembly II4, Support 5, Lead screw II6, Lead screw nut 7, Nut roller connector 8, Roller bearing 9, Needle roller 10, Needle 11, Radial displacement motor 12, Coupling I13, Gear steering gear I14, Connecting rod I15, Coupling II16, Gear steering gear II17, Translation base 18, Radial displacement bearing assembly I19, Radial displacement bearing assembly II20, Suspension frame 21, Flattening roller I22, Flattening roller II23, Flattening roller fixing frame 24, Gear steering gear III25, Coupling III26, Connecting rod II27, Slide rail slider module 28, Rack 29, Gear 30, Translation motor 31. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0045] The present invention provides a preparation device for a variable density flat plate preform. The preparation device includes an unwinding bearing assembly I1, an unwinding roller 2, a lead screw I3, an unwinding bearing assembly II4, a support 5, a lead screw II6, a lead screw nut 7, a nut roller connector 8, a roller bearing 9, a needle-punching roller 10, a needle 11, a radial displacement motor 12, a coupling I13, a gear steering gear I14, a connecting rod I15, a coupling II16, a gear steering gear II17, a translation base 18, a radial displacement bearing assembly I19, a radial displacement bearing assembly II20, a suspension frame 21, a flattening roller I22, a flattening roller II23, a flattening roller fixing frame 24, a gear steering gear III25, a coupling III26, a connecting rod II27, a slide rail slider module 28, a rack 29, a gear 30, and a translation motor 31.

[0046] The preparation device has a symmetrical structure with identical structures on both sides, and each side is mounted on the corresponding translation base 18.

[0047] Among them, the unwinding bearing assembly I1 includes two identical unwinding bearings I; the unwinding bearing assembly II4 includes two identical unwinding bearings II; each unwinding bearing I corresponds to one unwinding bearing II;

[0048] Among them, the unwinding bearing assembly I1 and the unwinding bearing assembly II4 are fixed above the bracket 5, and the unwinding roller 2 is horizontally installed between the unwinding bearing assembly I1 and the unwinding bearing assembly II4.

[0049] Two lead screws I3 are vertically arranged, one end of which is installed together with the radial displacement bearing assembly I19 and fixed to the suspension frame 21 by a nut, and the other end is installed in the gear steering gear III25; the suspension frame 21 is located next to the unwinding bearing assembly I1 and the unwinding bearing assembly II4; the gear steering gear III25 is located on the translation base 18;

[0050] Gear steering gear I14 is provided with gear steering gear III25 on one side and gear steering gear II17 on the other side; gear steering gear III25 is fastened to connecting rod II27 via coupling III26, and connecting rod II27 is installed in gear steering gear I14; similarly, connecting rod I15 is installed on the other side of gear steering gear I14 and connected to gear steering gear II17 via coupling II16;

[0051] The radial translation motor 12 is connected to the input end of the gear steering gear I 14 via coupling I 13;

[0052] The lead screw II6 is installed in the same way as the lead screw I3, with its two ends respectively installed in the gear steering gear II17 and the unwinding bearing assembly II4;

[0053] The translation base 18 is mounted on two sets of slide rail slider modules 28. The extension direction of the slide rail slider module 28 is perpendicular to the extension direction of the unwinding roller 2. The slide rail slider module 28 causes the entire device to move along the extension direction. The rack 29 is fixed to the translation base 18 and parallel to the slide rail slider module 28. It also provides power to the translation base 18 through the gear 30 and the translation motor 31.

[0054] The lead screw nut 7 is installed between lead screw I3 and lead screw II6, and is fixed to the needle-punching roller 10 through the nut roller connector 8;

[0055] The axis of the needle-punching roller 10 is horizontal, and the needle-punching roller 10 rotates through the roller bearing 9. The needles 11 are evenly arranged and installed on the needle-punching roller 10.

[0056] Flattening roller I 22 and flattening roller II 23 are installed in the center of bracket 5 via flattening roller fixing frame 24. The unwinding rollers and needle rollers on both sides must be kept at the same horizontal height to prevent deformation of the precast body caused by inconsistent unit layer laying speed and needle misalignment.

[0057] The lead screw I3 is used to drive the roller needle to move up and down. The movement method includes, but is not limited to, transmission devices such as worm gear, gear rack, and slider rail.

[0058] The unwinding speed of the unwinding roller 2 is adjustable, and the rotation speed is uniform.

[0059] The lead screw nut 7 is a machined part designed for use and has a certain load-bearing capacity.

[0060] The needle 11 has a certain angle, with an angle of 45°, and is relatively short, with a length range of 2-3 mm.

[0061] All gear steering gears have a 1:1 transmission ratio.

[0062] Both the radial displacement motor 12 and the translation motor 31 are geared motors.

[0063] The present invention also provides a method for preparing a variable density flat plate preform, comprising the following steps:

[0064] Step 1: First, load the two rolled-up felts onto the unwinding rollers, and guide one end of the felts between the two flattening rollers to flatten and stick the felts together on both sides.

[0065] Step 2: Pull the two sides of the felt vertically down to the bottom of the device, so that the felt is placed between the two roller needles. Then, start the radial displacement motor to make the screw rotate and drive the roller needles to the top.

[0066] Step 3: Start the translation motor. The gear and rack module drives the roller needles on both sides to fit against the felt, leaving enough space for the needles to pierce.

[0067] Step 4: After the preparation is completed, start the radial displacement motor again to drive the roller needle to roll and needle the felt from top to bottom, so that the two pieces of felt are needled together to form a preform. Then the clamping device is started and clamps the upper end of the preform, and the felt is cut short.

[0068] Step 5: Repeat step 1 and place the two pieces of fabric on both sides of the precast body respectively; repeat step 4 to perform rolling needle punching, so that the two new pieces of fabric are needle punched and connected to both sides of the precast body to form two new unit layers.

[0069] Step 6: When it is necessary to increase the bulk density of the preform, start the translation motor to drive the needle rollers to step towards each other, thereby increasing the relative needle penetration depth of the preform; and slow down the speed of the radial displacement motor to reduce the vertical displacement speed of the needle rollers and reduce the relative displacement speed between the preform and the needles, thereby increasing the needle penetration density; in order to improve the density of the preform.

[0070] Step 7: When it is necessary to reduce the bulk density of the preform, start the translation motor to drive the needle roller to step relative to each other, thereby reducing the relative needle penetration depth of the preform; and increase the speed of the radial displacement motor to increase the up-and-down displacement speed of the needle roller, thereby increasing the relative displacement speed between the preform and the needle, thus reducing the needle penetration density; in order to reduce the density of the preform.

[0071] By adjusting steps 6 and 7, the volume density of the preform is adjusted steplessly to meet the requirements for preparing a variable density preform.

[0072] Step 8: Repeat cutting the top of the new felt and clamping it again. Repeat steps 5, 6 and 7 until all unit layers are needled to form a complete precast body.

[0073] The surface density of the felt in step 1 is adjustable, ranging from 136 g / m2 to 450 g / m2.

[0074] After the felt in step 1 passes through the flattening roller, the surface is uniform and wrinkle-free.

[0075] The felt in step 1 is made of two layers of netting and one layer of fiber cloth pre-stitched together to form a sandwich structure of netting;

[0076] Fabric can be pre-laid with fiber yarn and pre-stitched, thereby increasing the long fiber content of the pre-made body.

[0077] The felt in step 1 includes any one or more of the following fiber fabrics: quartz plain weave fabric, quartz satin weave fabric, quartz twill weave fabric, carbon fiber spread fabric, carbon fiber satin weave fabric, and carbon fiber unidirectional fabric.

[0078] The preform in step 4 can be used to prepare a stepless variable density flat plate preform by adjusting the areal density of the fiber cloth and the mesh in each felt unit layer.

[0079] The preform in step 4 can include microwave absorbing felt, prepreg, and other materials to replace the felt during the preparation process, forming flat preforms with different properties.

[0080] The above embodiments of the present invention do not constitute a limitation on the scope of protection of the present invention.

Claims

1. An apparatus for preparing a variable-density flat plate preform, characterized in that, The preparation device includes unwinding bearing assembly I (1), unwinding roller (2), lead screw I (3), unwinding bearing assembly II (4), bracket (5), lead screw II (6), lead screw nut (7), nut roller connector (8), roller bearing (9), needle-punched roller (10), needle (11), radial displacement motor (12), coupling I (13), gear steering I (14), connecting rod I (15), coupling II (16), gear steering II (17), translation base (18), radial displacement bearing assembly I (19), radial displacement bearing assembly II (20), suspension frame (21), flattening roller I (22), flattening roller II (23), flattening roller fixing frame (24), gear steering III (25), coupling III (26), connecting rod II (27), slide rail slider module (28), rack (29), gear (30), and translation motor (31). The preparation device has a symmetrical structure with the same structure on both sides. Each component on either side is mounted on the corresponding translation base (18). Among them, the unwinding bearing assembly I (1) includes two identical unwinding bearings I; the unwinding bearing assembly II (4) includes two identical unwinding bearings II; each unwinding bearing I corresponds to one unwinding bearing II; Among them, the unwinding bearing assembly I (1) and the unwinding bearing assembly II (4) are fixed above the bracket (5), and the two unwinding rollers (2) are horizontally installed between the unwinding bearing assembly I (1) and the unwinding bearing assembly II (4); Two lead screws I (3) are vertically arranged, one end of which is installed together with the radial displacement bearing assembly I (19) and fixed to the suspension frame (21) by a nut, and the other end is installed in the gear steering gear III (25); the suspension frame (21) is set next to the unwinding bearing assembly I (1) and the unwinding bearing assembly II (4); the gear steering gear III (25) is set on the translation base (18); Gear steering gear I (14) is provided with gear steering gear III (25) on one side and gear steering gear II (17) on the other side; wherein, gear steering gear III (25) is fastened to one end of connecting rod II (27) through coupling III (26), and the other end of connecting rod II (27) is installed in gear steering gear I (14); similarly, one end of connecting rod I (15) is installed on the other side of gear steering gear I (14), and the other end of connecting rod I (15) is connected to gear steering gear II (17) through coupling II (16); The radial displacement motor (12) is connected to the input end of the gear steering gear I (14) via coupling I (13); Two lead screws II (6) are installed in the same way as two lead screws I (3), with their ends installed in gear steering gear II (17) and unwinding bearing assembly II (4), respectively; The translation bases (18) on both sides are mounted on two sets of slide rail slider modules (28). The extension direction of the slide rail slider module (28) is perpendicular to the extension direction of the unwinding roller (2). The slide rail slider module (28) moves the entire device along its extension direction. The rack (29) is fixed to the translation base (18). The rack (29) is parallel to the slide rail slider module (28) and provides power to the translation base (18) through the gear (30) and the translation motor (31). The lead screw nut (7) is installed between lead screw I (3) and lead screw II (6) and is fixed to the needle-punching roller (10) through the nut roller connector (8); The axis of the needle-punching roller (10) is horizontal. The needle-punching roller (10) rotates through the roller bearing (9). The needles (11) are evenly arranged and installed on the needle-punching roller (10). Flattening roller I (22) and flattening roller II (23) are installed in the middle of the bracket (5) through flattening roller fixing frame (24); the unwinding rollers and needle-punching rollers on both sides are kept at the same horizontal height; The gear ratios of gear steering gear I and gear steering gear II are both 1:

1.

2. The apparatus for preparing a variable density flat plate preform according to claim 1, characterized in that, The lead screw I (3) and lead screw II (6) are used to drive the needle-punching roller (10) to move up and down; The unwinding speed of the unwinding roller (2) can be adjusted and the rotation speed is uniform.

3. The apparatus for preparing a variable-density flat plate preform according to claim 1, characterized in that, The needle (11) has a certain angle of 45° and a length range of 2-3 mm.

4. A method for preparing a variable-density flat plate preform, characterized in that, The method is implemented based on any one of the preparation apparatuses described in claims 1 to 3, and the method includes: Step 1: First, place the two rolled-up fabric felts onto the two unwinding rollers respectively, and guide one end of the fabric felts between flattening roller I and flattening roller II to flatten the fabric felts on both sides and stick them together; Step 2: Pull the felt on both sides vertically down to the bottom of the device, so that the felt is placed between the two needle-punching rollers. Then, start the radial displacement motor to rotate lead screw I and lead screw II and drive the needle-punching rollers to the top. Step 3: Start the translation motor, and the slide rail slider module will drive the two needle-punching rollers to fit against the felt, leaving enough space for the needles to puncture. Step 4: After the preparation is completed, start the radial displacement motor again to drive the needle-punching roller to roll and needle the felt from top to bottom, so that the two pieces of felt are needle-punched together to form a preform. Then the clamping device is started and clamps the upper end of the preform and cuts the felt. Step 5: Repeat step 1 and place the two pieces of fabric on both sides of the precast body respectively; repeat step 4 to perform rolling needle punching, so that the two new pieces of fabric are needle punched and connected to both sides of the precast body to form two new unit layers. Step 6: When it is necessary to increase the bulk density of the preform, start the translation motor to drive the needle-punching rollers to step towards each other, thereby increasing the relative needle-punching depth of the preform; and slow down the speed of the radial displacement motor to reduce the vertical displacement speed of the needle-punching rollers, thereby reducing the relative displacement speed between the preform and the needles, thus increasing the needle-punching density. Step 7: When it is necessary to reduce the bulk density of the preform, start the translation motor to drive the needle-punching roller to step relative to each other, thereby reducing the relative needle-punching depth of the preform; and increase the speed of the radial displacement motor to increase the up-and-down displacement speed of the needle-punching roller, thereby increasing the relative displacement speed between the preform and the needle, thereby reducing the needle-punching density and reducing the density of the preform. By adjusting steps 6 and 7, the volume density of the preform is adjusted steplessly to meet the requirements for preparing a variable density preform. Step 8: Repeat cutting the top of the new felt and clamping it again. Repeat steps 5, 6 and 7 until all unit layers are needled to form a complete precast body.

5. The method for preparing a variable density flat plate preform according to claim 4, characterized in that, The surface density of the felt in step 1 can be adjusted, with a density range of 136g / L. ~450g / .

6. The method for preparing a variable density flat plate preform according to claim 4, characterized in that, In step 1, the felt is smooth and wrinkle-free after passing through flattening rollers I and II.

7. The method for preparing a variable density flat plate preform according to claim 4, characterized in that, The felt in step 1 is made of two layers of netting and one layer of fiber cloth pre-stitched together to form a sandwich structure of netting-cloth-netting.

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