Production device and method for carbon fiber carbonization online monofilament prepreg

Abstract

The invention discloses a carbon fiber carbonization online monofilament prepreg production device and method, and belongs to the technical field of carbon fiber composite production, the carbon fiber carbonization online monofilament prepreg production device comprises a carbonization production line and a prepreg production line, and the carbonization production line is connected with the prepreg production line; the carbonization production line comprises a protofilament creel, an oxidation furnace, a low-temperature carbonization furnace, a high-temperature carbonization furnace, a surface treatment device, a hot roller drying device, a sizing device, a hot air drying device and a carbon fiber winding machine which are connected in sequence; the prepreg production line comprises a carbon fiber creel, a filament spreading and heating device, a coating and presoaking device, a cooling and shaping device, a prepreg winding machine and special formula resin, and the quality and production efficiency of the prepreg are remarkably improved through the innovation points of turning type unwinding, single-filament multi-channel presoaking, slitting-free and release-paper-free winding and the like.

Description

Technical Field

[0001] The invention relates to the technical field of carbon fiber composite material production, and more specifically to a production device and method for carbon fiber carbonization online monofilament prepreg. Background Art

[0002] In the field of carbon fiber composite material production, the production of prepreg is a crucial link, and its quality directly affects the performance of the final composite material. In the traditional carbon fiber prepreg production process, the carbonization line and the prepreg production line are usually set up separately. This layout not only occupies a large production space, but also increases the complexity and cost of the production process. Specifically, the carbonized carbon fiber tows often need to go through processes such as sizing and hot roller drying before they can enter the prepreg production line. This process not only wastes sizing liquid and increases drying energy consumption, but may also lead to loss of fiber performance.

[0003] According to patent CN107841801 A, the traditional prepreg production process often requires cutting after hot pressing impregnation and cooling to obtain prepreg of a specific size. However, the cutting process often affects the uniformity of the fibers, resulting in uneven prepreg properties such as strength. At the same time, the waste edges generated during the cutting process also increase the waste of raw materials. In the traditional prepreg production process, release paper is often required for isolation to prevent fibers from sticking together in subsequent processes. The use of release paper not only increases production costs, but also makes the production process more complicated. Removing the release paper in subsequent processes also requires additional steps and equipment, further reducing production efficiency.

[0004] In summary, the traditional carbon fiber prepreg production process has a lot of room for improvement in production efficiency, production cost and product quality. The present invention proposes a production technology for carbon fiber carbonization online monofilament thermosetting prepreg, aiming to solve the above problems through innovative production process and equipment design, and achieve higher quality carbon fiber prepreg production. Summary of the invention

[0005] Technical issues to be solved In order to solve the shortcomings of existing production and equipment technology, the present invention proposes a production technology of online monofilament prepreg for carbon fiber carbonization, which significantly improves the quality and production efficiency of prepreg through innovative features such as folding unwinding, multi-channel prepreg of monofilaments, no slitting and no release paper winding.

[0006] Technical Solution To solve the above problems, the present invention adopts the following technical solutions: A production device and method for carbon fiber carbonization online monofilament prepreg, comprising a carbonization production line and a prepreg production line, wherein the carbonization production line and the prepreg production line are connected, wherein the carbonization production line comprises a precursor yarn rack, an oxidation furnace, a low-temperature carbonization furnace, a high-temperature carbonization furnace, a surface treatment device, a hot roller drying device, a sizing device, a hot air drying device and a carbon fiber winder connected in sequence; wherein the prepreg production line comprises a carbon fiber yarn rack, a yarn spreading and heating device, a coating prepreg device, a cooling and shaping device, a prepreg winder and a special formula resin; The hot roller drying device of the carbonization production line is connected to the filament spreading heating device of the prepreg production line.

[0007] As a preferred solution of the present invention, the carbon fiber creel adopts a folding unwinding method.

[0008] As a preferred solution of the present invention, the yarn spreading and heating device uses an adjustable yarn separation comb to position the yarn bundle.

[0009] As a preferred solution of the present invention, the coating prepreg device adopts a single filament bundle precise prepreg process.

[0010] As a preferred solution of the present invention, the filament bundle of the cooling and shaping device is coated and pre-impregnated and then passed through grooved rollers for multiple times to spread and close the filament bundle.

[0011] As a preferred solution of the present invention, the prepreg winding machine reduces the influence of the reciprocating lateral friction force on the width of the prepreg by adjusting the winding ratio of the winding device and the 90° turning wire path.

[0012] As a preferred solution of the present invention, the specially formulated resin maintains fluidity at a temperature of 80° C. in the coating prepreg device.

[0013] A method for producing carbon fiber carbonization online monofilament prepreg comprises the following steps: S1, the precursor yarn frame draws out the carbon fiber precursor, maintains a stable tension through the tension control device, and sends it to the oxidation furnace; in the oxidation furnace, the carbon fiber precursor is oxidized under predetermined temperature and atmosphere conditions to improve its surface properties and prepare for the subsequent carbonization process. The oxidized carbon fiber enters the low-temperature carbonization furnace and the high-temperature carbonization furnace in turn, and a carbonization reaction occurs at high temperature to form a high-strength, high-modulus carbon fiber; the carbonized carbon fiber passes through the surface treatment device to activate the fiber interface, is washed with water to remove impurities, and then enters the hot roller drying device for drying to remove surface moisture; S2. The fibers after this step can enter the sizing device to enhance the bonding strength between the carbon fiber and the resin, and then enter the carbon fiber winding machine after being dried in the hot air drying device. The sizing concentration is 2%, and the hot air drying temperature is 180°C; S3, the carbon fiber enters the filament spreading and heating device, is positioned by an adjustable filament comb, the filament spacing is adjusted to 10mm, and the fiber is preheated by an infrared heating device at a heating temperature of 80°C to improve the coating effect of the resin. The preheated carbon fiber enters the coating prepreg device, and the coated fiber passes through a reciprocating roller to impregnate the fiber and the resin. The carbon fiber coated with resin enters the cooling and shaping device, and the prepreg after cooling and shaping is directly sent to the prepreg winding machine for winding.

[0014] Beneficial Effects Compared with the prior art, the advantages of the present invention are: (1) In this solution, carbon fiber can directly enter the prepreg production line before sizing on the carbonization line. The integrated production line saves space and also saves the cost of sizing materials, as well as the energy consumption of the sizing device, hot air drying device and winder, thereby reducing investment and operating costs.

[0015] (2) In this scheme, the carbon fiber yarn frame adopts a reciprocating wire feeding method and a matte surface treatment to reduce the problem of fiber damage caused by reciprocating spindle unwinding and mechanical friction during the yarn unwinding process, thereby ensuring the strength performance and integrity of the fiber.

[0016] (3) In this scheme, the single filament bundle is precisely pre-impregnated. After cooling, shaping and width control, the prepreg does not need to be cut, and no cutting waste is generated. The prepreg can directly enter the next winding process, avoiding the problem of fiber damage caused by cutting and improving production efficiency.

[0017] (4) In this scheme, the prepreg winding machine adopts a non-reciprocating and precisely staggered phase balanced winding method, which reduces the influence of friction on the width of the prepreg and ensures the performance of the spindle rewinding.

[0018] (5) In this solution, a special formula resin is used to eliminate the need for release paper isolation during winding, thereby simplifying the product structure and reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a flow chart of the integrated production line of the present invention; Figure 2 It is a schematic diagram of the structure of the integrated production line of the present invention; Figure 3 It is a schematic diagram of the raw silk creel of the present invention; Figure 4 It is a schematic diagram of an oxidation furnace of the present invention; Figure 5 It is a schematic diagram of a low temperature carbonization furnace of the present invention; Figure 6 It is a schematic diagram of a high temperature carbonization furnace of the present invention; Figure 7It is a schematic diagram of the surface treatment, hot roller drying, sizing and hot air drying of the present invention; Figure 8 It is a schematic diagram of a carbon fiber winding machine of the present invention; Fig. 9 The invention provides a carbon fiber creel, a yarn spreading heating, a coating prepreg, a cooling and shaping, and a prepreg winding machine.

[0020] Description of the numbers in the figure: 1. Raw yarn creel; 2. Oxidation furnace; 3. Low-temperature carbonization furnace; 4. High-temperature carbonization furnace; 5. Surface treatment device; 6. Hot roller drying device; 7. Sizing device; 8. Hot air drying device; 9. Carbon fiber winder; 10. Carbon fiber creel; 11. Fiber spreading and heating device; 12. Coating prepreg device; 13. Cooling and shaping device; 14. Prepreg winder. DETAILED DESCRIPTION

[0021] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0022] Example: See also Figure 1-9 A production device for carbon fiber carbonization online monofilament prepreg, comprising a carbonization production line and a prepreg production line, the carbonization production line and the prepreg production line are connected, the carbonization production line comprises a precursor yarn rack 1, an oxidation furnace 2, a low-temperature carbonization furnace 3, a high-temperature carbonization furnace 4, a surface treatment device 5, a hot roller drying device 6, a sizing device 7, a hot air drying device 8 and a carbon fiber winder 9 connected in sequence; the prepreg production line comprises a carbon fiber yarn rack 10, a yarn spreading and heating device 11, a coating prepreg device 12, a cooling and shaping device 13, a prepreg winder 14 and a special formula resin; The hot roller drying device 6 of the carbonization production line is connected to the filament spreading heating device 11 of the prepreg production line.

[0023] In this embodiment, the hot roller drying of the carbonization production line is connected to the fiber spreading heating device of the prepreg production line. The fibers can be selected to enter the sizing device on the carbonization line, or enter the fiber spreading heating device of the prepreg production line. In the monofilament prepreg production line, the carbon fiber is placed on the carbon fiber roving frame, and the mechanical damage is reduced by the folding unwinding method, and the folding method is 2 sections of 90°.

[0024] Specifically, the carbon fiber creel adopts a folding unwinding method.

[0025] In this embodiment, the carbon fiber creel adopts a folding unwinding method, and the filament bundle is unwound and turned 90 degrees away from the reel. The filament bundle is gathered and the tension is controlled by the guide wheel and the tension controller.

[0026] Specifically, the wires are spread and heated, and the wire bundles are positioned using an adjustable wire separation comb.

[0027] In this embodiment, the filaments are spread and heated, and the filament bundles are positioned using an adjustable filament separation comb. The carbon fibers are then preheated using infrared heating, the heating setting temperature is 80° C., and the spread rollers are treated with a matte surface.

[0028] Specifically, the coating prepreg is processed by precise prepreg of single filament bundles.

[0029] In this embodiment, after passing through the wire spreading device, multiple fiber bundles enter the multi-channel prepreg system respectively. Each channel of the prepreg system accurately and independently controls the coating amount and speed of the resin through a pump. The resin content can be adjusted from 10 to 50%. Furthermore, the coated fibers pass through a reciprocating roller to impregnate the fibers and the resin, and the hot air temperature is set to 60°C.

[0030] Specifically, the filaments are cooled and shaped, and then the filaments are coated and pre-impregnated and then passed through grooved rollers for multiple times of spreading and narrowing.

[0031] In this embodiment, the prepreg winding machine 14 reduces the influence of the reciprocating lateral friction on the width of the prepreg by adjusting the winding ratio of the winding device and the 90° turning wire path. Furthermore, after cooling and shaping, the prepreg does not need to be cut and can directly enter the next winding process.

[0032] Specifically, the prepreg winding machine reduces the influence of the reciprocating lateral friction force on the width of the prepreg by adjusting the winding ratio of the winding device and the 90° turning wire path.

[0033] In this embodiment, the winding method adopts micro-staggered precision winding. Furthermore, the winding machine is equipped with an online width detector to detect the width of the prepreg in real time, issue a warning and assist in adjustment.

[0034] Specifically, the specially formulated resin maintains fluidity at 80°C when coating the prepreg.

[0035] In this embodiment, under the cooling and setting room temperature, a certain viscosity can be adjusted and maintained to ensure close adhesion between the resin and the fiber and avoid sticking, so that when winding into an ingot, there is no need to use additional release film and release paper, as well as a laminating mechanism.

[0036] The carbon fiber enters the filament spreading and heating device, is positioned by an adjustable filament separation comb, the filament spacing is adjusted to 10 mm, and the fiber is preheated by an infrared heating device at a heating temperature of 80°C to improve the coating effect of the resin.

[0037] The preheated carbon fiber enters the coating prepreg process. The system adopts a multi-channel design, and each channel independently controls the coating amount and speed of the resin, and matches the production line output to ensure that each carbon fiber tow is evenly coated with resin, with a resin content of 29%. The coated fiber passes through 5 pairs of reciprocating rollers to impregnate the fiber and resin. The hot air temperature is set at 60°C.

[0038] After the resin is coated, the carbon fiber enters the cooling and shaping device, and the groove roller is used to spread the fiber and the pressure roller is used to control the width to 6mm, and the pressure of the pressure roller is 0.3Mpa. At the same time, the prepreg is cooled by the air cooling device, and the cold air temperature is set at 10℃ to maintain its dimensional stability and shape consistency.

[0039] After cooling and shaping, the prepreg is directly sent to the prepreg winder for winding. During the winding process, the winding ratio and wire path are adjusted, and the 90° turning type is used to reduce the influence of friction on the width of the prepreg. The width of the prepreg is monitored in real time through an online width detector.

[0040] Specially formulated resin, resin and curing agent are mixed in a ratio of 100:4.2, heated and stirred evenly, and the temperature is controlled at 50°C. Then cooled at room temperature and transferred to the coating prepreg process.

[0041] In the carbon fiber carbonization line, the precursor yarn frame draws out the carbon fiber precursor, maintains a stable tension through the tension control device, and sends it to the oxidation furnace. In the oxidation furnace, the carbon fiber precursor is oxidized under predetermined temperature and atmosphere conditions to improve its surface properties and prepare for the subsequent carbonization process. The oxidized carbon fiber enters the low-temperature carbonization furnace and the high-temperature carbonization furnace in turn, and a carbonization reaction occurs at high temperature to form high-strength and high-modulus carbon fiber. The carbonized carbon fiber undergoes surface treatment to activate the fiber interface, and is washed with water to remove impurities. It then enters the hot roller drying device for drying to remove surface moisture, and the fiber is sent to the single-filament prepreg production line for the fiber spreading and heating process.

[0042] According to actual needs, the fiber after this step can enter the sizing treatment to enhance the bonding strength between the carbon fiber and the resin, and enter the carbon fiber winding machine after hot air drying. The sizing concentration is 2%, and the hot air drying temperature is 180℃.

[0043] A method for producing carbon fiber carbonization online monofilament prepreg comprises the following steps: S1, the precursor yarn rack 1 draws out the carbon fiber precursor, keeps a stable tension through the tension control device, and sends it to the oxidation furnace 2; in the oxidation furnace 2, the carbon fiber precursor is oxidized under predetermined temperature and atmosphere conditions to improve its surface properties and prepare for the subsequent carbonization process. The oxidized carbon fiber enters the low-temperature carbonization furnace 3 and the high-temperature carbonization furnace 4 in turn, and a carbonization reaction occurs at high temperature to form a high-strength and high-modulus carbon fiber; the carbonized carbon fiber passes through the surface treatment device 5 to activate the fiber interface, washes with water to remove impurities, and then enters the hot roller drying device 6 for drying to remove surface moisture; S2, the fiber after this step can enter the sizing device 7 to enhance the bonding force between the carbon fiber and the resin, and then enter the carbon fiber winder 9 after being dried in the hot air drying device 8. The sizing concentration is 2%, and the hot air drying temperature is 180°C; S3, the carbon fiber enters the filament spreading and heating device 11, is positioned by an adjustable filament comb, the filament spacing is adjusted to 10 mm, and the fiber is preheated by an infrared heating device at a heating temperature of 80°C to improve the coating effect of the resin. The preheated carbon fiber enters the coating prepreg device 12, and the coated fiber passes through 5 pairs of reciprocating rollers to impregnate the fiber and the resin. The carbon fiber coated with the resin enters the cooling and shaping device 13, and the prepreg after cooling and shaping is directly sent to the prepreg winding machine 14 for winding.

[0044] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and improved concepts of the present invention within the technical scope disclosed by the present invention, and they should be covered by the protection scope of the present invention.

Claims

1. A production device for carbon fiber carbonization online monofilament prepreg, comprising a carbonization production line and a prepreg production line, characterized in that: The carbonization production line is connected to the prepreg production line, and the carbonization production line comprises a precursor yarn rack (1), an oxidation furnace (2), a low-temperature carbonization furnace (3), a high-temperature carbonization furnace (4), a surface treatment device (5), a hot roller drying device (6), a sizing device (7), a hot air drying device (8) and a carbon fiber winder (9) which are connected in sequence; the prepreg production line comprises a carbon fiber yarn rack (10), a yarn spreading and heating device (11), a coating prepreg device (12), a cooling and shaping device (13), a prepreg winder (14) and a special formula resin; The hot roller drying device (6) of the carbonization production line is connected to the filament spreading heating device (11) of the prepreg production line.

2. The device for producing carbon fiber carbonization online monofilament prepreg according to claim 1, characterized in that: The carbon fiber creel (10) adopts a folding unwinding method.

3. The device for producing carbon fiber carbonization online monofilament prepreg according to claim 2, characterized in that: The yarn spreading and heating device (11) uses an adjustable yarn separation comb to position the yarn bundle.

4. The device for producing carbon fiber carbonization online monofilament prepreg according to claim 3, characterized in that: The coating prepreg device (12) adopts a single-filament bundle precise prepreg process.

5. The device for producing carbon fiber carbonization online monofilament prepreg according to claim 4, characterized in that: The cooling and shaping device (13) passes the filament bundle through grooved rollers for multiple times of filament spreading and width reduction after being coated and pre-impregnated.

6. The device for producing carbon fiber carbonization online monofilament prepreg according to claim 5, characterized in that: The prepreg winding machine (14) reduces the influence of reciprocating lateral friction force on the width of the prepreg by adjusting the winding ratio of the winding device and the 90° turning wire path.

7. The device for producing carbon fiber carbonization online monofilament prepreg according to claim 6, characterized in that: The specially formulated resin maintains fluidity at a temperature of 80° C. in the prepreg coating device (12).

8. A method for producing carbon fiber carbonization online monofilament prepreg, characterized in that: The production device of the carbon fiber carbonization online monofilament prepreg according to claim 7 comprises the following steps: S1, the precursor yarn rack (1) draws out the carbon fiber precursor, maintains a stable tension through a tension control device, and feeds it into an oxidation furnace (2); in the oxidation furnace (2), the carbon fiber precursor is subjected to oxidation treatment under predetermined temperature and atmosphere conditions to improve its surface properties and prepare for the subsequent carbonization process, and the oxidized carbon fiber enters the low-temperature carbonization furnace (3) and the high-temperature carbonization furnace (4) in turn, undergoes a carbonization reaction at high temperature, and forms high-strength, high-modulus carbon fiber; the carbonized carbon fiber passes through a surface treatment device (5) to activate the fiber interface, is washed with water to remove impurities, and then enters a hot roller drying device (6) for drying treatment to remove surface moisture; S2. After this step, the fiber can enter the sizing device (7) to enhance the bonding strength between the carbon fiber and the resin, and then enter the carbon fiber winding machine (9) after being dried in the hot air drying device (8). The sizing concentration is 2%, and the hot air drying temperature is 180°C; S3, the carbon fiber enters the filament spreading and heating device (11), is positioned by an adjustable filament separation comb, the filament spacing is adjusted to 10 mm, and the fiber is preheated by an infrared heating device at a heating temperature of 80°C to improve the coating effect of the resin. The preheated carbon fiber enters the coating prepreg device (12), and the coated fiber passes through 5 pairs of reciprocating rollers to impregnate the fiber and the resin. The carbon fiber coated with the resin enters the cooling and shaping device (13), and the prepreg after cooling and shaping is directly sent to the prepreg winding machine (14) for winding.

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