Melt impregnation mold and method for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape

Abstract

The invention relates to the technical field of prepreg tape dipping molds, in particular to a melt dipping mold and method for preparing a continuous fiber reinforced thermoplastic resin based prepreg tape, which comprises a mold main body consisting of three parts, namely an upper cover plate, a lower cover plate and a side plate for connecting the upper cover plate and the lower cover plate, and further comprises a plurality of electric heating rods, the tops of the upper cover plates penetrate through the upper cover plates; a plurality of supporting frames are arranged, first sliding grooves are formed in the two sides of each supporting frame, first rotating shafts and second rotating shafts are installed in the first sliding grooves in a penetrating mode, molten resin is gradually immersed into fiber bundles through impregnation pressure gradient classification, the impregnation degree of a prepreg tape (material) is ensured while fiber damage is reduced as much as possible, and the impregnation efficiency of the prepreg tape (material) is improved. The problem that high-viscosity resin is difficult to impregnate can be effectively solved, heat generated by the electric heating rod is used for heating the interior of the mold main body, and hot air sizing is carried out on an impregnated product.

Description

Technical Field

[0001] The invention relates to the technical field of prepreg impregnation molds, in particular to a mold and a method for preparing a continuous fiber reinforced thermoplastic resin-based prepreg melt impregnation mold. Background Art

[0002] Continuous fiber reinforced thermoplastic composite resin (FRTP) has excellent impact resistance, fatigue resistance, heat resistance and durability, as well as short molding time and secondary processing. It is being increasingly widely used in aerospace, medical, energy, automotive and other fields.

[0003] Although continuous fiber reinforced thermoplastic composite resins have excellent performance and high application value, there is still a big gap between China and foreign countries in terms of resin preparation technology and equipment. The common preparation method of continuous fiber reinforced thermoplastic composite resins is to form them through prepreg tapes (materials). The quality of the preparation of prepreg tapes (materials) greatly affects the performance of the composite resin. Therefore, it is very important to prepare continuous fiber reinforced thermoplastic composite resin prepreg tapes (materials) with high impregnation degree and excellent performance. The main reason for the difficulty in preparing continuous fiber reinforced thermoplastic composite resin prepreg tapes (materials) is that thermoplastic resins such as PEEK and PP have extremely high viscosity and poor fluidity. It is difficult to achieve good impregnation of the resin melt into the fiber during the preparation process, which affects the performance of the prepreg tape (material). Therefore, if you want to prepare continuous fiber reinforced thermoplastic composite resin prepreg tapes (materials) with high impregnation degree and low porosity, the key issue is to improve the impregnation mold and process, which is also a technical problem that my country urgently needs to break through.

[0004] Existing impregnation molds are divided into encapsulating type, curved type and other impregnation molds according to their structures. The encapsulating type impregnation mold fills the entire internal cavity of the mold with molten resin through the injection port, which makes it impossible to form a closed space and establish effective impregnation pressure. In addition, the molten resin may be carbonized and the resin performance may deteriorate if it is exposed to high temperature for a long time.

[0005] In view of the above problems, it is urgent to propose a preparation equipment and process method for continuous fiber reinforced thermoplastic composite resin prepreg tape (material) with high production efficiency, low cost, simple operation and high impregnation quality without damaging the fiber. To this end, we propose a melt impregnation mold and method for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape. Summary of the invention

[0006] In order to solve the above technical problems, the present invention provides a mold for preparing a continuous fiber reinforced thermoplastic resin-based prepreg tape melt impregnation, including a mold body, the mold body is composed of three parts, namely an upper cover plate, a lower cover plate and a side plate connecting the two, and also includes:

[0007] There are several electric heating rods, which are arranged in two rows and the tops of the electric heating rods all penetrate the upper cover plate;

[0008] A support frame, the support frame has a plurality of first slide grooves on both sides of the support frame, a first rotating shaft and a second rotating shaft are installed through the first slide grooves, and the distance between the first rotating shaft and the second rotating shaft in the support frame decreases from the inlet end to the outlet end of the mold body, and all the first rotating shafts are in the same straight line, and all the second rotating shafts are in the same straight line, and there is an intersection between the two straight lines, and the first rotating shaft and the second rotating shaft are sleeved with a pressure roller;

[0009] An angle guide mechanism, which is installed on the mold body and connected to the first rotating shaft and the second rotating shaft, and which adjusts the angles between all the straight lines formed by the first rotating shafts and the straight lines formed by the second rotating shafts, thereby controlling the distance between the pressure rollers by changing the distance between the first rotating shaft and the second rotating shaft;

[0010] A circle center changing mechanism, which is installed on one side of the mold body and connected to the angle guiding mechanism. The circle center changing mechanism changes the intersection position of the two straight lines, thereby changing the coefficient of variation of the distance between the pressure rollers in the mold body;

[0011] The stirring mechanism is installed on the upper cover plate and connected to the electric heating rod, and the stirring mechanism stirs the resin around the electric heating rod.

[0012] Preferably, the angle guiding mechanism comprises a first supporting plate fixed on one side of the mold body, a second supporting plate is installed on the first supporting plate, a supporting column is installed through the second supporting plate, a first sliding groove is provided on the supporting column, a first sliding block and a second sliding block are installed on the first sliding groove, a first supporting rod and a second supporting rod are installed on the first sliding block and the second sliding block respectively, a first supporting frame and a second supporting frame are fixed on the first supporting rod and the second supporting rod respectively, and the first supporting frame and the second supporting frame are penetrated by a first rotating shaft and a second rotating shaft respectively;

[0013] A fine-tuning mechanism is installed on the mold body, and the fine-tuning mechanism is connected to the angle guiding mechanism for accurately adjusting the angle between the first support frame and the second support frame, thereby controlling the distance change between the pressure rollers by changing the distance between the first rotating shaft and the second rotating shaft.

[0014] Preferably, the fine-tuning mechanism includes a third support plate fixed to one side of the mold main body, the third support plate being installed with a fourth support plate, the fourth support plate being provided with a second slide groove, the fourth support plate being penetrated and installed with a first bolt, there being a certain gap at the connection between the first bolt and the fourth support plate, the second slide groove being penetrated, a third sliding block being sleeved on the first bolt, the third sliding block corresponding to the second slide groove, and a screw groove corresponding to the first bolt being provided in the middle portion, the fifth support plate being fixed on the third sliding block, the fifth support plate being relatively provided with a third slide groove, sliding rods being installed in the third slide groove, and fourth slide grooves being relatively provided on the fourth support plate, the fourth slide grooves being oblique grooves and being mirror-imaged, the third support frame and the fourth support frame being respectively fixed with the third support frame and the second support frame at the top ends, the third support frame and the fourth support frame being mirror-imaged, and after the two sliding rods penetrate the third support frame and the fourth support frame respectively, they then penetrate the fourth slide grooves at corresponding positions.

[0015] Preferably, the circle center changing mechanism comprises a square column fixed on the support column, a fifth slide groove is provided on the second support plate, and the square column passes through the fifth slide groove;

[0016] A limiting mechanism is installed on the square column, and the limiting mechanism limits the changed position of the supporting column.

[0017] Preferably, the limiting mechanism comprises a screw hole opened on the square column, a second bolt is installed through the screw hole, a limiting cover is fixed on the second bolt, and the limiting cover is in contact with the second support plate.

[0018] Preferably, the stirring mechanism includes a third rotating shaft installed on the lower cover plate, the number of the third rotating shaft is consistent with the electric heating rods, and the distribution positions correspond to the positions of the electric heating rods, and all of them pass through the upper cover plate, and a plurality of stirring plates are arranged on the third rotating shaft, and the stirring plates are located inside the mold body and on one side of the electric heating rod. The stirring rods on the two rows of the third rotating shaft are arranged in a mirror image, and also include a driving member installed on the upper cover plate.

[0019] Preferably, the driving member comprises a turbine sleeved on the third rotating shaft, the turbine is located above the upper cover plate, the third rotating shaft is sleeved with a square tube, a closed cover is installed between the square tubes, the bottom end of the closed cover is fixed to the top end of the upper cover plate, an air pump is installed on the upper cover plate, the air pump is connected to the first closed cover, and guide blocks are installed in the square tubes, one side of the guide block is an inclined surface, and the other side blocks most of the square tube, and the two rows of guide blocks are arranged in a mirror image;

[0020] A heating mechanism is provided at the outlet end of the mold body, and the heating mechanism is connected to the driving member and the electric heating rod, and is used for hot-air shaping of the impregnated prepreg tape.

[0021] Preferably, a guide roller is arranged opposite to the inlet end of the mold body, a sealing plate is arranged at the outlet end of the mold body, an angular hole is opened on the sealing plate, the pressure rollers are plated with chromium with a thickness of not less than 0.2 mm, and a semicircular cover is fixed on the lower cover plate. There are several semicircular covers, which surround one side of the stirring plate, and the opening directions are all toward the middle of the mold body.

[0022] Preferably, the heating mechanism comprises a hollow cover installed at the outlet end of the mold body, the inner wall of the hollow cover is provided with air holes, the end of the square tube is connected to a Y-shaped tube, and the other end of the Y-shaped tube is connected to the hollow cover.

[0023] A method for preparing a continuous fiber reinforced thermoplastic resin-based prepreg melt impregnation mold:

[0024] S1: According to the type of prepreg tape, the staff adjusts the distance between the pressure rollers on the support frame through the fine-tuning mechanism and the circle center changing mechanism. After adjusting to the appropriate step spacing, the position of the circle center changing mechanism is limited by the limiting mechanism;

[0025] S2: Turn on the electric heating rod to preheat the inside of the mold body, so that the temperature inside the mold body is higher than the melting temperature of the resin, ensuring that the resin is in a flowing state after entering the mold body and can immediately impregnate the fiber under the driving action of the impregnation pressure;

[0026] S3: Pull the continuous glass fiber bundle from the inlet end of the mold body into the mold, pass through the gaps between the pressure rollers in the support frame in turn, and then pass out from the outlet end of the mold body, and be fixed at the pulling device;

[0027] S4: Turn on the air pump and the extruder control switch, extrude the resin and apply it flat on the upper surface of the fiber bundle and turn on the traction device. The coated fiber bundle passes through the adjustable height impregnation roller with gradually increasing height to gradually deepen the impregnation of the resin melt into the fiber bundle and finally achieve complete impregnation. At the same time, since the impregnation pressure at the inlet end of the mold body is relatively small, the carbon fiber is protected from damage;

[0028] S5: The fully impregnated fiber bundle passes through the angular hole on the blocking plate from the outlet end of the mold body, and after the excess resin is scraped off, it is led out by the traction device;

[0029] S6: The prepreg tape pulled out from the outlet end of the mold body is dried by a heating mechanism and then shaped.

[0030] The present invention has at least the following beneficial effects:

[0031] 1. Under the action of the angle guiding mechanism and the fine-adjusting mechanism, the staff only needs to rotate the first bolt to control the distance change between the stepped pressure rollers in each support frame, so that the present invention is applicable to more products;

[0032] 2. Under the action of the circle center changing mechanism and the limiting mechanism, the staff can adjust the distance coefficient change between the stepped pressure rollers in each support frame by sliding the square column in the fifth slide groove and limiting it by the second bolt, thereby further increasing the application scope of the present invention;

[0033] 3. Through the gradient grading of impregnation pressure, the molten resin is gradually impregnated into the fiber bundle, while minimizing fiber damage as much as possible and ensuring the impregnation degree of the prepreg tape (material), which can effectively solve the problem of difficulty in impregnation of high-viscosity resin;

[0034] 4. Under the action of the stirring mechanism and the heating mechanism, the heat generated by the electric heating rod not only heats the inside of the mold body, but also performs hot air shaping on the impregnated product. At the same time, during the movement of the hot air, the wind pressure accelerates the flow speed of the resin around the electric heating rod inside the mold body, which can avoid poor resin flow and carbonization near the electric heating rod for a long time. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0036] Figure 2 It is a rear view structural schematic diagram of the present invention;

[0037] Figure 3 It is a schematic diagram of the internal side structure of the present invention;

[0038] Figure 4 It is a schematic diagram of the cross-sectional structure of the fine-tuning mechanism of the present invention;

[0039] Figure 5 For the present invention Figure 4 Schematic diagram of the structure at A in the middle;

[0040] Figure 6 It is a schematic diagram of the cross-sectional structure of the stirring mechanism of the present invention;

[0041] Figure 7 For the present invention Figure 6 Schematic diagram of the structure at B in the middle;

[0042] Figure 8 It is a schematic diagram of the exploded cross-sectional structure of the limiting mechanism of the present invention;

[0043] Fig. 9 It is a schematic diagram of the top cross-sectional structure of the stirring mechanism of the present invention.

[0044] In the figure: 1. mold body; 11. upper cover plate; 12. lower cover plate; 13. side plate; 14. guide roller; 15. blocking plate; 16. angular hole; 17. semicircular cover; 2. electric heating rod; 31. support frame; 32. sliding groove; 33. first rotating shaft; 34. second rotating shaft; 35. pressing roller; 4. angle guiding mechanism; 41. first supporting plate; 42. second supporting plate; 43. supporting column; 44. first sliding groove; 45. first sliding block; 46. second sliding block; 47. first supporting rod; 48. second supporting rod; 49. first supporting frame; 410. second supporting frame; 5. fine adjustment mechanism; 51. third supporting plate; 52. fourth supporting plate; 5 3. Second slide groove; 54. First bolt; 55. Third slider; 56. Fifth support plate; 57. Third slide groove; 58. Sliding rod; 59. Fourth slide groove; 510. Third support frame; 511. Fourth support frame; 6. Center point changing mechanism; 61. Square column; 62. Fifth slide groove; 7. Limiting mechanism; 71. Screw hole; 72. Second bolt; 73. Limiting cover; 8. Stirring mechanism; 81. Third rotating shaft; 82. Stirring plate; 83. Driving member; 831. Turbine; 832. Square tube; 833. Sealed cover; 834. Air pump; 835. Guide block; 9. Heating mechanism; 91. Hollow cover; 92. Air hole; 93. Y-shaped tube. DETAILED DESCRIPTION

[0045] The technical solutions in the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. 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.

[0046] Example 1

[0047] See also Figure 1-9 The present invention provides a technical solution: a mold for preparing a continuous fiber reinforced thermoplastic resin-based prepreg tape melt impregnation, comprising a mold body 1, the mold body 1 is composed of three parts, namely an upper cover plate 11, a lower cover plate 12 and a side plate 13 connecting the two, and also includes:

[0048] There are several electric heating rods 2, which are arranged in two rows, and the tops of the electric heating rods 2 all penetrate the upper cover plate 11;

[0049] Support frame 31, there are several support frames 31, and both sides of the support frames are provided with sliding grooves 32, and the first rotating shaft 33 and the second rotating shaft 34 are installed in the sliding grooves 32, and the distance between the first rotating shaft 33 and the second rotating shaft 34 in the support frame 31 is reduced from the inlet end to the outlet end of the mold body 1, and all the first rotating shafts 33 are in the same straight line, and all the second rotating shafts 34 are in the same straight line, and there is an intersection between the two straight lines, and the first rotating shaft 33 and the second rotating shaft 34 are sleeved with a pressing roller 35;

[0050] An angle guide mechanism 4, which is mounted on the mold body 1 and connected to the first rotating shaft 33 and the second rotating shaft 34. The angle guide mechanism 4 adjusts the angles between the straight lines formed by all the first rotating shafts 33 and the straight lines formed by all the second rotating shafts 34, thereby controlling the distance between the pressure rollers 35 by changing the distance between the first rotating shafts 33 and the second rotating shafts 34;

[0051] The center changing mechanism 6 is installed on one side of the mold body 1 and connected to the angle guiding mechanism 4. The center changing mechanism 6 changes the intersection position of the two straight lines, thereby changing the coefficient of variation of the distance between the pressing rollers 35 in the mold body 1;

[0052] The stirring mechanism 8 is installed on the upper cover plate 11 and connected to the electric heating rod 2 . The stirring mechanism 8 stirs the resin around the electric heating rod 2 .

[0053] The angle guide mechanism 4 includes a first support plate 41 fixed to one side of the mold body 1, a second support plate 42 is mounted on the first support plate 41, a support column 43 is installed through the second support plate 42, a first slide groove 44 is provided on the support column 43, a first slide block 45 and a second slide block 46 are mounted on the first slide groove 44, a first support rod 47 and a second support rod 48 are respectively mounted on the first slide block 45 and the second slide block 46, a first support frame 49 and a second support frame 410 are respectively fixed on the first support rod 47 and the second support rod 48, and the first support frame 49 and the second support frame 410 are respectively penetrated by the first rotating shaft 33 and the second rotating shaft 34;

[0054] A fine-tuning mechanism 5 is installed on the mold body 1, and the fine-tuning mechanism 5 is connected to the angle guiding mechanism 4 for accurately adjusting the angle between the first support frame 49 and the second support frame 410, thereby controlling the distance change between the pressure rollers 35 by changing the distance between the first rotating shaft 33 and the second rotating shaft 34.

[0055] The fine-tuning mechanism 5 includes a third support plate 51 fixed to one side of the mold body 1, a fourth support plate 52 is installed on the third support plate 51, a second slide groove 53 is opened on the fourth support plate 52, a first bolt 54 is installed through the fourth support plate 52, there is a certain gap between the first bolt 54 and the fourth support plate 52, the second slide groove 53 is penetrated, a third slider 55 is sleeved on the first bolt 54, the third slider 55 corresponds to the second slide groove 53, and a screw groove corresponding to the first bolt 54 is opened in the middle, and a fifth support plate 55 is fixed on the third slider 55. 6. The fifth support plate 56 is provided with a third slide groove 57, and a sliding rod 58 is installed in the third slide groove 57. The fourth support plate 52 is provided with a fourth slide groove 59, and the fourth slide groove 59 is an inclined groove and is arranged in a mirror image. The third support frame 510 and the fourth support frame 511 are fixed to the top of the first support frame 49 and the second support frame 410 respectively. The third support frame 510 and the fourth support frame 511 are arranged in a mirror image. After the two sliding rods 58 penetrate the third support frame 510 and the fourth support frame 511 respectively, they then penetrate the fourth slide groove 59 at the corresponding position.

[0056] According to the type and requirements of the prepreg tape, the distance between the pressure rollers 35 is appropriately adjusted, and the specific operation is as follows:

[0057] The first bolt 54 is rotated. Due to the restriction of the fourth support plate 52, the first bolt 54 rotates in place. During the rotation, the third slider 55 is driven to move in the second slide groove 53. While the third slider 55 moves, it drives the fifth support portion to move horizontally synchronously. The fifth support plate 56 drives the sliding rod 58 to move synchronously. Since the sliding rod 58 penetrates the fourth slide groove 59, and the two fourth slide grooves 59 are mirror-image inclined, in the process of the fifth support plate 56 driving the sliding rod 58 to move, due to the restriction of the fourth slide groove 59, the two sliding rods 58 move along the fourth slide groove 59, approaching or moving away from each other, and the sliding rod 58 penetrates the third support frame 510 and the fourth support frame 511. When the rod 58 moves, the first support frame 49 and the second support frame 410 are driven to move closer or farther away through the third support frame 510 and the fourth support frame 511, and the first support frame 49 and the second support frame 410 are respectively rotated closer or farther away from each other around the axis of the support column 43 under the guidance of the first slider 45 and the second slider 46 corresponding to the first support rod 47 and the second support rod 48. During this process, if the angle between the first support frame 49 and the second support frame 410 becomes larger, the pressure roller 35 corresponding to the first rotating shaft 33 in the first support frame 49 and the pressure roller 35 corresponding to the second rotating shaft 34 in the second support frame 410 increase in distance steps, so that this distance can be adjusted to a suitable change gradient.

[0058] The circle center changing mechanism 6 includes a square column 61 fixed on the support column 43, a fifth slide groove 62 is provided on the second support plate 42, and the square column 61 passes through the fifth slide groove 62;

[0059] A limiting mechanism 7 is installed on the square column 61 , and the limiting mechanism 7 limits the changed position of the supporting column 43 .

[0060] The limiting mechanism 7 includes a screw hole 71 opened on the square column 61 . A second bolt 72 is installed through the screw hole 71 . A limiting cover 73 is fixed on the second bolt 72 . The limiting cover 73 is in contact with the second support plate 42 .

[0061] Since there are many kinds of pre-impregnated resins and their pre-impregnation processes are also different, the following situations will occur:

[0062] (1) When the prepreg requires more contact with the resin in the early stage and is impregnated in the later stage, the worker applies force to the square column 61 to make it slide in the fifth slide groove 62, so that the square column 61 moves closer to the mold body 1. Since the position of the support frame 31 remains unchanged, the upper and lower rows of rollers 35 form a larger angle, and the distance between the rollers 35 in each support frame 31 and the distance difference between adjacent rollers 35 will increase, that is, the distance between the rollers 35 at the inlet part of the mold body 1 is large, and the distance between the rollers 35 at the outlet part is small, and the distance change gradient is large. Soon after the prepreg tape enters the mold body 1, the resin can fully wrap the prepreg tape. As the prepreg tape continues to be driven, the distance between the rollers 35 is reduced before pressurized impregnation is performed;

[0063] (2) When the prepreg tape requires full impregnation, the worker applies force to the square column 61 to make it slide in the fifth slide groove 62, so that the square column 61 moves away from the mold body 1. Similarly, the upper and lower rows of pressure rollers 35 form a smaller angle, so the distance between the pressure rollers 35 in each support frame 31 and the distance difference between adjacent pressure rollers 35 will be reduced. The distance between the pressure rollers 35 will gradually decrease from the entrance to the exit of the mold body 1, and the distance change gradient is small. When the prepreg passes through the inside of the mold body 1, it will always be subjected to a certain impregnation pressure, and this pressure will increase step by step to ensure the impregnation effect of the prepreg.

[0064] The stirring mechanism 8 includes a third rotating shaft 81 installed on the lower cover plate 12. The number of the third rotating shafts 81 is consistent with the electric heating rods 2, and the distribution positions correspond to the positions of the electric heating rods 2, and all of them pass through the upper cover plate 11. A plurality of stirring plates 82 are arranged on the third rotating shaft 81. The stirring plates 82 are located inside the mold body 1 and on one side of the electric heating rod 2. The stirring rods on the two rows of third rotating shafts 81 are arranged in a mirror image, and also include a driving member 83 installed on the upper cover plate 11.

[0065] The driving member 83 includes a turbine 831 sleeved on the third rotating shaft 81, the turbine 831 is located above the upper cover plate 11, a square tube 832 is sleeved on the third rotating shaft 81, a sealed cover 833 is installed between the square tubes 832, the bottom end of the sealed cover 833 is fixed to the top of the upper cover plate 11, an air pump 834 is installed on the upper cover plate 11, the air pump 834 is connected to the first sealed cover 833, and a guide block 835 is installed in the square tube 832, one side of the guide block 835 is an inclined surface, and the other side blocks most of the square tube 832, and the two rows of guide blocks 835 are arranged in a mirror image;

[0066] A heating mechanism 9 is provided at the outlet end of the mold body 1 , and the heating mechanism 9 is connected to the driving member 83 and the electric heating rod 2 , and is used for hot-air shaping of the impregnated prepreg tape.

[0067] After the temperature in the mold body 1 is raised to a suitable temperature through the electric heating rod 2, resin is added to the mold body 1. As the prepreg is continuously pulled by the traction device, the air pump 834 is turned on. The air pump 834 extracts gas from the outside and injects this part of the gas into the square tube 832 through the closed cover 833. As the space suddenly becomes smaller, the air flow speed increases. Under the guidance of the inclined surface of the guide block 835 in the square tube 832, the blades on one side of the turbine 831 are blown, and the turbine 831 is driven to rotate, and enters the adjacent closed cover 833 through the square tube 832. The rotation of the turbine 831 will drive the stirring plate 82 to rotate through the third shaft 81, and stir the resin around the electric heating rod 2 in the mold body 1 to prevent the resin from staying around the electric heating rod 2 for too long and causing carbonization due to poor fluidity.

[0068] A guide roller 14 is arranged opposite to the inlet end of the mold body 1, and a sealing plate 15 is arranged at the outlet end of the mold body 1. An angular hole 16 is opened on the sealing plate. The pressure rollers 35 are plated with chromium with a thickness of not less than 0.2 mm. A semicircular cover 17 is fixed on the lower cover plate 12. There are several semicircular covers 17, which surround one side of the stirring plate 82, and the opening directions are all toward the middle of the mold body 1.

[0069] Since the fibers and resin are not combined at the inlet end of the mold body 1, the fiber filaments are very easy to be damaged under the action of the impregnation pressure during the contact between the fiber bundle and the pressure roller 35. The present invention sets a guide roller 14 at the inlet end of the mold to reduce the pressure and friction of the impregnation roller on the fiber bundle. As the fibers and resin are gradually combined, the fiber filaments are not easy to break at this time, and the impregnation pressure can be gradually increased to improve the impregnation quality, which can effectively solve the problem of easy damage to the fibers during the preparation process. The angular hole 16 can scrape off the excess resin when the prepreg is about to be pulled out of the mold body 1. The chrome plating of the pressure roller 35 can ensure its smooth surface, which makes the impregnation of the prepreg smoother. The presence of the semicircular cover 17 makes the resin stirred by the stirring plate 82 always concentrate in the middle of the mold body 1 and toward the outlet, which plays a certain pressurizing role.

[0070] The heating mechanism 9 includes a hollow cover 91 installed at the outlet end of the mold body 1 , the inner wall of the hollow cover 91 is provided with air holes 92 , and the terminal square tube 832 is connected to a Y-shaped tube 93 , and the other end of the Y-shaped tube 93 is connected to the hollow cover 91 .

[0071] The air drawn by the air pump 834 is heated by the electric heating rod 2 when passing through the sealed cover 833. At this time, the airflow has a certain temperature. After being conducted through the square tube 832 and the sealed cover 833, it enters the Y-shaped tube 93 and the hollow cover 91, and is ejected from the air holes 92 on the hollow cover 91 to dry and shape the impregnated prepreg.

[0072] A method for preparing a continuous fiber reinforced thermoplastic resin-based prepreg melt impregnation mold:

[0073] S1: According to the type of prepreg tape, the staff adjusts the distance between the pressure rollers 35 on the support frame 31 through the fine adjustment mechanism 5 and the center change mechanism 6, and after adjusting to a suitable step spacing, the position of the center change mechanism 6 is limited by the limit mechanism 7;

[0074] S2: Turn on the electric heating rod 2 to preheat the inside of the mold body 1, so that the temperature inside the mold body 1 is higher than the melting temperature of the resin, ensuring that the resin is in a flowing state after entering the mold body 1 and can immediately impregnate the fiber under the driving action of the impregnation pressure;

[0075] S3: The continuous glass fiber bundle is pulled into the mold from the inlet end of the mold body 1, passes through the gaps between the pressure rollers 35 in the support frame 31 in sequence, and then passes out from the outlet end of the mold body 1, and is fixed at the pulling device;

[0076] S4: Turn on the air pump 834 and the extruder control switch, extrude the resin and apply it flat on the upper surface of the fiber bundle and turn on the traction device. The coated fiber bundle passes through the adjustable height impregnation roller with gradually increasing height to gradually deepen the impregnation of the fiber bundle with the resin melt and finally achieve complete impregnation. At the same time, since the impregnation pressure at the inlet end of the mold body 1 is relatively small, the carbon fiber is protected from damage;

[0077] S5: The completely impregnated fiber bundle passes through the angular hole 16 on the blocking plate 15 from the outlet end of the mold body 1, and after the excess resin is scraped off, it is led out by the traction device;

[0078] S6: The prepreg tape drawn out from the outlet end of the mold body 1 is dried by the heating mechanism 9 and then shaped.

[0079] The following are examples of the use of the present invention:

[0080] 1. Preparation of continuous glass fiber reinforced nylon 6 (PA6) prepreg tape (material)

[0081] Step 1: The staff adjusts the distance between the pressure rollers 35 on the support frame 31 through the fine adjustment mechanism 5 and the circle center changing mechanism 6, so that the distance between the end support frame 31 and the square column 61 is 200 mm, and the angle between the first support frame 49 and the second support frame 410 is 1 to 1.5°;

[0082] Step 2: The temperature of the electric heating rod 2 is gradually increased through the control circuit to be higher than the melting temperature of the PA6 resin. Before the preparation begins, the internal temperature of the mold body 1 is controlled between 250°C and 270°C and kept constant to ensure that the resin is in a flowing state after entering the mold and can immediately impregnate the fiber under the driving action of the impregnation pressure;

[0083] Step 3: A certain number of continuous glass fiber bundles are pulled into the mold from the mold inlet end, passed through the gaps between the pressure rollers 35 in the support frame 31 in sequence, and then passed out from the mold outlet end and fixed at the pulling device;

[0084] Step 4: Turn on the air pump 834 and the extruder control switch, extrude the resin and apply it flat on the upper surface of the fiber bundle and turn on the traction device. The coated fiber bundle passes through the adjustable height impregnation roller with gradually increasing height to gradually deepen the impregnation of the resin melt into the fiber bundle and finally achieve complete impregnation. At the same time, since the impregnation pressure at the inlet end of the mold is relatively small, the carbon fiber is protected from damage;

[0085] Step 5: The fully impregnated fiber bundle passes through the angular hole 16 on the blocking plate 15 from the outlet end of the mold body 1, and after the excess resin is scraped off, it is led out by the traction device;

[0086] Step 6: The prepreg tape pulled out from the outlet end of the mold body 1 is dried by the heating mechanism 9 and then shaped to be a continuous glass fiber reinforced PA6 resin prepreg tape (material).

[0087] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0088] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A mold for preparing a continuous fiber reinforced thermoplastic resin-based prepreg tape melt impregnation mold, comprising a mold body (1), wherein the mold body (1) is composed of three parts, namely an upper cover plate (11), a lower cover plate (12) and a side plate (13) connecting the two, characterized in that: Also includes: There are a plurality of electric heating rods (2), which are arranged in two rows and the tops of the electric heating rods (2) all penetrate the upper cover plate (11); A support frame (31), wherein the support frame (31) has a plurality of support frames (31), and both sides of the support frame (31) are provided with sliding grooves (32), and a first rotating shaft (33) and a second rotating shaft (34) are installed through the sliding grooves (32), and the distance between the first rotating shaft (33) and the second rotating shaft (34) in the support frame (31) is reduced from the inlet end to the outlet end of the mold body (1), and all the first rotating shafts (33) are in the same straight line, and all the second rotating shafts (34) are in the same straight line, and there is an intersection between the two straight lines, and the first rotating shaft (33) and the second rotating shaft (34) are sleeved with a pressure roller (35); An angle guiding mechanism (4), the angle guiding mechanism (4) being mounted on the mold body (1) and connected to the first rotating shaft (33) and the second rotating shaft (34), the angle guiding mechanism (4) adjusting the angles between all the straight lines formed by the first rotating shafts (33) and the straight lines formed by all the second rotating shafts (34), thereby controlling the distance between the pressure rollers (35) by changing the distance between the first rotating shafts (33) and the second rotating shafts (34); A circle center changing mechanism (6), the circle center changing mechanism (6) being installed on one side of the mold body (1) and connected to the angle guiding mechanism (4), the circle center changing mechanism (6) changing the intersection position of the two straight lines, thereby changing the coefficient of variation of the distance between the pressure rollers (35) in the mold body (1); A stirring mechanism (8), wherein the stirring mechanism (8) is installed on the upper cover plate (11) and is connected to the electric heating rod (2), and the stirring mechanism (8) stirs the resin around the electric heating rod (2).

2. The melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 1, characterized in that: The angle guiding mechanism (4) comprises a first supporting plate (41) fixed on one side of the mold body (1), a second supporting plate (42) being mounted on the first supporting plate (41), a supporting column (43) being mounted through the second supporting plate (42), a first sliding groove (44) being provided on the supporting column (43), a first sliding block (45) and a second sliding block (46) being mounted on the first sliding groove (44), a first supporting rod (47) and a second supporting rod (48) being mounted on the first sliding block (45) and the second sliding block (46), respectively, a first supporting frame (49) and a second supporting frame (410) being fixed on the first supporting rod (47) and the second supporting rod (48), respectively, the first supporting frame (49) and the second supporting frame (410) being respectively penetrated by the first rotating shaft (33) and the second rotating shaft (34); A fine-tuning mechanism (5) is installed on the mold body (1), and the fine-tuning mechanism (5) is connected to the angle guiding mechanism (4) and is used to accurately adjust the angle between the first support frame (49) and the second support frame (410), thereby controlling the distance change between the pressure rollers (35) by changing the distance between the first rotating shaft (33) and the second rotating shaft (34).

3. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 2, characterized in that: The fine adjustment mechanism (5) comprises a third support plate (51) fixed to one side of the mold body (1), a fourth support plate (52) is installed on the third support plate (51), a second slide groove (53) is provided on the fourth support plate (52), a first bolt (54) is installed through the fourth support plate (52), a certain gap exists between the first bolt (54) and the fourth support plate (52), and the second slide groove (53) is passed through, a third slider (55) is sleeved on the first bolt (54), the third slider (55) corresponds to the second slide groove (53), and a screw groove corresponding to the first bolt (54) is provided in the middle, and a fifth support plate is fixed on the third slider (55). (56), the fifth support plate (56) is provided with a third slide groove (57) on the opposite side, and a sliding rod (58) is installed in the third slide groove (57), the fourth support plate (52) is provided with a fourth slide groove (59) on the opposite side, and the fourth slide groove (59) is an inclined groove and is arranged in a mirror image, the first support frame (49) and the second support frame (410) are respectively fixed with a third support frame (510) and a fourth support frame (511) on the top, and the third support frame (510) and the fourth support frame (511) are arranged in a mirror image, and the two sliding rods (58) respectively penetrate the third support frame (510) and the fourth support frame (511), and then penetrate the fourth slide groove (59) at the corresponding position.

4. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 3, characterized in that: The center-of-circle changing mechanism (6) comprises a square column (61) fixed on the support column (43); a fifth slide groove (62) is provided on the second support plate (42); and the square column (61) passes through the fifth slide groove (62); A limiting mechanism (7) is installed on the square column (61), and the limiting mechanism (7) limits the changed position of the supporting column (43).

5. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 4, characterized in that: The limiting mechanism (7) comprises a screw hole (71) opened on the square column (61), a second bolt (72) is installed through the screw hole (71), a limiting cover (73) is fixed on the second bolt (72), and the limiting cover (73) is in contact with the second support plate (42).

6. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 5, characterized in that: The stirring mechanism (8) comprises a third rotating shaft (81) mounted on the lower cover plate (12); the number of the third rotating shafts (81) is consistent with the electric heating rods (2), and the distribution positions correspond to the positions of the electric heating rods (2), and all of them penetrate the upper cover plate (11); a plurality of stirring plates (82) are arranged on the third rotating shaft (81), and the stirring plates (82) are located inside the mold body (1) and on one side of the electric heating rod (2); the stirring rods on the two rows of third rotating shafts (81) are arranged in a mirror image, and also include a driving member (83) mounted on the upper cover plate (11).

7. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 6, characterized in that: The driving member (83) comprises a turbine (831) sleeved on the third rotating shaft (81), the turbine (831) is located above the upper cover plate (11), a square tube (832) is sleeved on the third rotating shaft (81), a sealed cover (833) is installed between the square tubes (832), the bottom end of the sealed cover (833) is fixed to the top end of the upper cover plate (11), an air pump (834) is installed on the upper cover plate (11), the air pump (834) is connected to the first sealed cover (833), a guide block (835) is installed in each of the square tubes (832), one side of the guide block (835) is an inclined surface, and the other side blocks most of the square tube (832), and the two rows of guide blocks (835) are arranged in a mirror image; A heating mechanism (9) is provided at the outlet end of the mold body (1), and the heating mechanism (9) is connected to the driving member (83) and the electric heating rod (2) and is used for hot-air shaping of the impregnated prepreg tape.

8. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 7, characterized in that: A guide roller (14) is arranged opposite to the inlet end of the mold body (1), and a sealing plate (15) is arranged at the outlet end of the mold body (1). An angular hole (16) is opened on the sealing plate. The pressure roller (35) is plated with chromium with a thickness of not less than 0.2 mm. A semicircular cover (17) is fixed on the lower cover plate (12). There are several semicircular covers (17) that surround one side of the stirring plate (82), and the opening directions are all toward the middle of the mold body (1).

9. A melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 8, characterized in that: The heating mechanism (9) comprises a hollow cover (91) installed at the outlet end of the mold body (1), the inner wall of the hollow cover (91) is provided with air holes (92), and the square tube (832) at the end is connected to a Y-shaped tube (93), and the other end of the Y-shaped tube (93) is connected to the hollow cover (91).

10. A method for using the melt impregnation mold for preparing continuous fiber reinforced thermoplastic resin-based prepreg tape according to claim 9, characterized in that: The following steps are involved: S1: According to the type of prepreg tape, the staff adjusts the distance between the pressure rollers (35) on the support frame (31) through the fine adjustment mechanism (5) and the center change mechanism (6), and after adjusting to a suitable step spacing, limits the position of the center change mechanism (6) through the limit mechanism (7); S2: turning on the electric heating rod (2) to preheat the inside of the mold body (1), so that the temperature inside the mold body (1) is higher than the melting temperature of the resin, ensuring that the resin is in a flowing state after entering the mold body (1) and can immediately impregnate the fiber under the driving action of the impregnation pressure; S3: pulling the continuous glass fiber bundle from the inlet end of the mold body (1) into the mold, passing through the gaps between the pressure rollers (35) in the support frame (31) in turn, and then passing out from the outlet end of the mold body (1), and fixed to the pulling device; S4: Turn on the air pump (834) and the extruder control switch, extrude the resin and apply it to the upper surface of the fiber bundle, and turn on the traction device. The coated fiber bundle passes through the adjustable height impregnation roller with gradually increasing height, so that the resin melt gradually impregnates the fiber bundle and finally achieves complete impregnation. At the same time, since the impregnation pressure at the inlet end of the mold body (1) is relatively small, the carbon fiber is not damaged; S5: The completely impregnated fiber bundle passes through the angular hole (16) on the blocking plate (15) from the outlet end of the mold body (1), and after the excess resin is scraped off, it is led out by the traction device; S6: The prepreg tape drawn out from the outlet end of the mold body (1) is dried by the heating mechanism (9) and then shaped.

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