Carbon fiber thermoplastic composite material forming device and process

Abstract

The invention provides a carbon fiber thermoplastic composite material forming device and process, relates to the field of composite material forming processes, and aims to solve the problem that the processing requirements of complex special-shaped products are difficult to meet at present. The laying flatness in the subsequent pre-forming process is guaranteed, and then the overall quality of the composite material product is guaranteed; a continuous reciprocating pre-forming laying technology is adopted, continuous and rapid laying of each single-layer pre-impregnated fabric is achieved through combined linkage operation of single-layer pre-impregnated fabric pushing, male mold air bag inflation pressurization attaching and pre-forming pressurization of a pre-pressing male mold, and meanwhile it is guaranteed that the fabric wrinkle elimination and interface bonding effect between layers is stable, and the resin and fiber infiltration effect is stable; and the laminated prepreg fabric obtained by stacking is subjected to stamping forming, so that interlayer infiltration of matrix resin in the forming process is ensured, the working efficiency of thermoplastic composite material forming is effectively ensured, and the processing requirements of complex special-shaped products are met.

Description

Technical Field

[0001] The invention relates to the field of composite material forming technology, and in particular to a carbon fiber thermoplastic composite material forming device and technology. Background Art

[0002] Thermoplastic composite materials use thermoplastic resin matrix and high-performance fibers for composite molding. While taking advantage of the comprehensive mechanical properties of high-performance fibers such as high strength and high modulus, the thermoplastic resin matrix material used gives the composite materials excellent process performance that can be repeatedly plasticized and molded. At the same time, thermoplastic resins have comprehensive excellent mechanical properties such as impact resistance, high toughness, and mechanical durability that traditional thermosetting resins do not have. Therefore, their products are widely used in vehicle transportation, oil extraction, power transmission, and military protection. The molding of traditional thermoplastic composite materials has great process difficulties due to the physical properties of thermoplastic resins such as high viscosity, low fluidity, and narrow processing temperature range. At the same time, the poor melt infiltration effect of thermoplastic resins and fiber-reinforced fabrics is also the main reason why internal defects in composite products are easily formed.

[0003] A Chinese patent (publication number CN 109624198 A) discloses a fiber cloth composite material molding method, which combines a hot stamping molding process with an injection molding process. A preform is manufactured by the hot stamping process, which greatly reduces the time for manually laying the preform when the RTM process is used. The hot stamping preform mold can be reused, which improves the utilization rate of the injection molding mold in the RTM process and ensures the molding consistency of the complex structure fiber composite material. However, the injection molding process used has many restrictions. When the injection molding process is used to process special-shaped products, the resin and fiber impregnation effect cannot be guaranteed, resulting in an unstable resin and fiber impregnation effect. The appearance of the product can only be limited to a plate with a simple shape, and it is difficult to process special-shaped products. Summary of the invention

[0004] The purpose of the present invention is to provide a carbon fiber thermoplastic composite material molding device and process in view of the defects of the prior art, which is equipped with a preheating component, a preforming component and a stamping molding component. Each single-layer preimpregnated fabric is fully preheated and softened to achieve continuous and rapid laying of each single-layer preimpregnated fabric, while ensuring the elimination of fabric wrinkles between layers and the interface bonding effect, the resin and fiber impregnation effect is stable, the interlayer infiltration of the matrix resin in the molding process is guaranteed, the working efficiency of the thermoplastic composite material molding is effectively guaranteed, and the processing requirements of complex special-shaped products are met.

[0005] The first object of the present invention is to provide a carbon fiber thermoplastic composite material molding device, which adopts the following scheme:

[0006] A preheating assembly comprises a support frame, a preheating element and a circulation mechanism arranged in the box, wherein the support frame is provided with multiple layers of support parts for carrying a single layer of preimpregnated fabric, and the preheating element and the circulation mechanism maintain the temperature in the box;

[0007] The preforming component comprises a female mold, a pre-pressed male mold and a male mold airbag, the male mold airbag cooperates with the female mold, a pre-forming cavity for accommodating sequentially stacked prepreg fabrics is provided between the male mold airbag and the female mold, and the pre-pressed male mold abuts against the male mold airbag to deform so as to extrude the stacked prepreg fabrics;

[0008] A stamping forming component includes a stamping male die and a female die shared with the preforming component, wherein the stamping male die and the female die cooperate to form a stamping cavity for accommodating the laminated prepreg fabric;

[0009] The conveying component is connected with the preheating component, the preforming component and the stamping component in sequence, and is used for conveying the prepreg fabric and the female mold.

[0010] Furthermore, a clamping mechanism for clamping a single layer of prepreg fabric is installed on the support frame, the clamping mechanism is connected to a tensioning mechanism, and the multiple layers of support parts are distributed at intervals.

[0011] Furthermore, the circulation mechanism and the preheating element are installed on both sides of the box, and the circulation mechanism forms circulating air in the box.

[0012] Furthermore, the male mold airbag is connected to an inflation mechanism to adjust the expansion state of the male mold airbag to squeeze or release the prepreg fabric in the preforming cavity.

[0013] Furthermore, the pre-pressing male mold and the female mold are respectively equipped with heating elements, which act on the preimpregnated fabric in the preforming cavity. The pre-pressing male mold is connected to a pre-pressing power mechanism to adjust the distance between the pre-pressing male mold and the female mold.

[0014] Furthermore, the female mold is equipped with a cooling mechanism, which acts on the laminated prepreg fabric in the stamping cavity. The stamping male mold is connected to a stamping power mechanism to adjust the distance between the stamping male mold and the female mold, and squeeze the deflated male mold airbag to deform the male mold airbag.

[0015] Furthermore, the cooling mechanism includes a cooling channel and a circulation device, the cooling channel is arranged in the female mold and the stamping male mold, the circulation device is located outside the female mold, and the cooling channel is connected to the circulation device.

[0016] Furthermore, the conveying assembly is connected to the multi-layer supporting parts respectively to convey the single-layer prepreg fabric into the preforming cavity layer by layer.

[0017] The second object of the present invention is to provide a carbon fiber thermoplastic composite material molding process, using the carbon fiber thermoplastic composite material molding device as described in the first object, comprising:

[0018] A plurality of single-layer preimpregnated fabrics are laid in the support portion of the support frame, and the single-layer preimpregnated fabrics are preheated by a preheating element and a circulation mechanism;

[0019] The preheated and softened single-layer prepreg fabric is transferred into the preforming cavity, the male mold airbag is expanded to make the single-layer prepreg fabric adhere to the preforming cavity, and the pre-pressing male mold is used to pre-press and mold the single-layer prepreg fabric;

[0020] Conveying multiple single-layer prepreg fabrics to the preforming cavity in sequence for stacking, attaching and pre-pressing each time they are stacked;

[0021] The female mold and the preimpregnated fabric carried by it are transferred to the stamping molding component, and the laminated preimpregnated fabric is stamped and molded by the cooperation of the stamping male mold and the female mold, and the composite material special-shaped product is obtained after demoulding.

[0022] Furthermore, when the prepreg fabric is in the preforming cavity of the preforming assembly, the female mold and the pre-pressing male mold are heated, and after the laminated prepreg fabric is punched and formed in the punching and forming assembly, the female mold is cooled.

[0023] Compared with the prior art, the present invention has the following advantages and positive effects:

[0024] (1) In view of the problem that it is difficult to meet the processing requirements of complex special-shaped products, a preheating component is configured to preheat the spaced carbon fiber thermoplastic preimpregnated fabric, and each single layer of preimpregnated fabric is fully preheated and softened to ensure the flatness of the subsequent preforming process and thus the overall quality of the composite product; a preforming component is configured to adopt a continuous reciprocating preforming stacking technology, through the combined linkage operation of pushing the single layer of preimpregnated fabric, inflating and pressurizing the male mold airbag, and pre-pressing the male mold, to achieve continuous and rapid laying of each single layer of preimpregnated fabric, while ensuring the elimination of fabric wrinkles between layers and the interface bonding effect, and the stable resin and fiber impregnation effect; a stamping molding component is configured to stamp and form the stacked preimpregnated fabric, ensuring the interlayer infiltration of the matrix resin in the molding process, effectively ensuring the working efficiency of thermoplastic composite molding, and meeting the processing requirements of complex special-shaped products.

[0025] (2) Utilizing the principle of flexible preforming, a male mold airbag is configured to contact a single-layer preimpregnated fabric downward, and gas is quickly filled into the male mold airbag through an inflation mechanism. Under the action of the male mold airbag expansion and pressure, the single-layer preimpregnated fabric is attached to the surface of the preforming cavity of the female mold, thereby improving the layering efficiency. At the same time, the expansion action of the male mold airbag during the expansion process is utilized to enable the single-layer preimpregnated fabric to be extended and expanded, thereby eliminating fabric wrinkles between layers. The gas in the male mold airbag is depressurized, and the single-layer preimpregnated fabric is stamped and preformed by the pre-pressing male mold, thereby completing a preforming and stacking process of a single layer of preimpregnated fabric. Each layer is preformed separately to meet the forming requirements of special-shaped products with complex features.

[0026] (3) A heating element is arranged inside the pre-pressing male mold. After the male mold is moved downward to close the mold with the female mold, the laminated thermoplastic prepreg fabric is softened and heated simultaneously. After the stamping and forming of the stamping and forming assembly is completed, the cooling mechanism is used to quickly cool the composite material special-shaped product. The pre-pressing male mold is heated and the stamping male mold and female mold are cooled to ensure the interlayer infiltration of the matrix resin during the forming process, and at the same time, the rapid cooling and demolding of the product after forming is achieved, which effectively ensures the working efficiency of thermoplastic composite material forming. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0028] Figure 1 Schematic diagram of the preheating assembly in Examples 1 and 2 of the present invention.

[0029] Figure 2 Schematic diagram of the preformed components in Examples 1 and 2 of the present invention.

[0030] Figure 3 Schematic diagram of the stamping components in Examples 1 and 2 of the present invention.

[0031] Among them, 1. Support frame; 2. Tensioning mechanism; 3. Clamping mechanism; 4. Preheating element; 5. Circulation mechanism; 6. Conveying assembly; 7. Female mold; 8. Male mold airbag; 9. Pre-pressing male mold; 10. Heating element; 11. Pre-pressing power mechanism; 12. Inflating mechanism; 13. Stamping male mold; 14. Stamping power mechanism; 15. Cooling mechanism. DETAILED DESCRIPTION

[0032] Example 1

[0033] In a typical embodiment of the present invention, Figure 1-Figure 3 As shown, a carbon fiber thermoplastic composite material molding device is provided.

[0034] In the prior art, the preform is made by hot stamping process, aiming to reduce the time of manual preform laying when using RTM (resin transfer molding) process, improve the utilization rate of mold and ensure the molding consistency. However, this method has the limitation of injection molding process, especially for the processing of special-shaped products, the impregnation effect of resin and fiber cannot be guaranteed, resulting in the appearance of the product being limited to simple-shaped plates, which is difficult to meet the processing requirements of complex special-shaped products. Based on this, this embodiment provides a carbon fiber thermoplastic composite molding device, which is equipped with a preheating component, a preforming component and a stamping molding component, as well as a conveying component 6, to achieve full preheating and softening of each single-layer prepreg fabric, to ensure continuous and rapid laying, to ensure the elimination of fabric wrinkles between layers and the interface bonding effect, as well as the stability of the resin and fiber impregnation effect, to ensure the interlayer infiltration of matrix resin during the molding process, to effectively improve the working efficiency of thermoplastic composite molding, to meet the processing requirements of complex special-shaped products, and to overcome the limitations of the prior art.

[0035] In this embodiment, the carbon fiber thermoplastic composite material forming device uses a single-layer pre-impregnated fabric of carbon fiber unidirectional or planar two-dimensional fabric reinforced thermoplastic resin, and with the help of a flexible pre-forming stamping die, through rapid lamination stamping integrated forming technology, a composite thermoplastic shell component with a special structure can be prepared. The carbon fiber thermoplastic composite material forming device mainly includes three parts: a preheating component, a pre-forming component, and a stamping forming component, and also includes a transmission component 6 for connecting the pre-impregnated fabric and the mold between the three parts. The processed raw material is a single layer of carbon fiber thermoplastic pre-impregnated fabric, that is, a single layer of pre-impregnated fabric.

[0036] like Figure 1 As shown, the preheating assembly includes a support frame 1, a preheating element 4 and a circulation mechanism 5 arranged in the box body. The support frame 1 is provided with multiple layers of support parts for carrying a single layer of preimpregnated fabric. The preheating element 4 can heat the box body to increase the temperature in the box body. The circulation mechanism 5 can make the temperature in the box body evenly distributed to maintain the temperature in the box body.

[0037] Specifically, the support frame 1 is provided with multiple layers of support parts, each layer can carry a single layer of prepreg fabric, and a certain spacing distance is set between each layer of support parts. The number of layers of support parts is determined according to the design requirements of the number of layers in the composite material molding process. A clamping mechanism 3 for clamping a single layer of prepreg fabric is installed on the support frame 1, and the clamping mechanism 3 is connected to the tensioning mechanism 2. Specifically, the clamping mechanism 3 is arranged on the edges of each layer of support parts to ensure that the edges of the single layer of prepreg fabric are clamped by the clamping mechanism 3, and the tensioning mechanism 2 maintains an appropriate tension force to make the single layer of prepreg fabric flat.

[0038] The support frame 1 of the preheating assembly is located in a closed box, and the circulation mechanism 5 and the preheating element 4 are installed on both sides of the box. The circulation mechanism 5 forms a circulating wind in the box. A certain number of preheating elements 4 and circulation mechanisms 5 are arranged at specific positions in the box space. The circulation mechanism 5 can use a circulating blower, etc., and the preheating element 4 can use an infrared heater, etc. The heating temperature is controlled within the softening temperature range of the thermoplastic resin of the prepreg fabric to fully preheat and soften the single-layer prepreg fabric in the box. The preheating time is flexibly designed according to the softening degree of the single layer of fabric. After each single layer of prepreg fabric is fully preheated, each single layer of prepreg fabric is synchronously conveyed into the preforming assembly for the next step.

[0039] like Figure 2 As shown, the preforming assembly includes a female mold 7, a male mold airbag 8 for flexible preforming stamping, and a pre-pressing male mold 9. The male mold airbag 8 is connected to an inflation mechanism 12, and the male mold airbag 8 cooperates with the female mold. A preforming cavity for accommodating sequentially stacked preimpregnated fabrics is provided between the male mold airbag 8 and the female mold 7. The pre-pressing male mold 9 abuts against the male mold airbag 8 to deform to extrude the stacked preimpregnated fabrics, adjust the expansion state of the male mold airbag 8, and extrude or release the preimpregnated fabrics in the preforming cavity. The inflation mechanism 12 can use a high-pressure gas source such as an air pump or a gas cylinder. The pre-pressing male mold 9 and the female mold 7 are respectively equipped with heating elements 10, which act on the preimpregnated fabrics in the preforming cavity. The pre-pressing male mold 9 is connected to a pre-pressing power mechanism 11 to adjust the distance between the pre-pressing male mold 9 and the female mold 7.

[0040] The single-layer preimpregnated fabrics that have been preheated are driven by the conveying component 6 to be fed layer by layer to the surface of the female mold 7; then, the male mold airbag 8 used for flexible preforming stamping is moved downward to contact the single layer of preimpregnated fabric, and gas is quickly injected into the male mold airbag 8 through the inflation mechanism 12. Under the action of the expansion and pressurization of the male mold airbag 8, the single-layer preimpregnated fabric is applied to the surface of the female mold 7; then, the pre-pressed male mold 9 is fed into the male mold airbag 8, and the preimpregnated fabric is pre-pressed by the male mold airbag 8. At the same time, the gas in the male mold airbag 8 is depressurized, so that the position where the male mold airbag 8 contacts the pre-pressed male mold 9 forms the required characteristic shape, and the extrusion preforming is completed in combination with the female mold 7, thereby completing the preforming and stacking process of a single layer of preimpregnated fabric.

[0041] The conveying assembly 6 may be equipped with a conveyor belt, a conveying platform, etc., which are dedicated to conveying a single layer of prepreg fabric, so that the single layer of prepreg fabric can be conveyed from the load-bearing portion to the preforming cavity. The conveying assembly 6 pushes one layer or a certain number of prepreg fabric single layers each time, and this action is reciprocated and linked with the subsequent punching and stacking action of the single layer of prepreg fabric.

[0042] A heating element 10 is arranged inside the female mold 7 to ensure that the single layer of preimpregnated fabric is within the softening temperature range during the continuous preforming, laminating and stamping process, thereby achieving the stability of the flexibility of the single layer of preimpregnated fabric and the specific ductility of the fabric, thereby achieving a close fit with the female mold 7.

[0043] like Figure 2 As shown, the female mold 7 can be a flat structure or a special-shaped structure, and the cavity surface is subjected to special demoulding pretreatment before the stacking and stamping preforming to ensure the smooth release of the final laminated prepreg after multiple layering processes. The male mold airbag 8 used for flexible preforming stamping is made of tear-resistant and high-temperature resistant flexible silicone material. The end of the male mold airbag 8 is equipped with a pre-pressing power mechanism 11, which can use a hydraulic power descending device, and the male mold airbag 8 is equipped with a rapid inflation mechanism 12.

[0044] The pre-pressing male mold 9 can be a flat structure or a special-shaped structure, and its external design is synchronized with the female mold 7 to form a stable cavity with a specific special-shaped structure, ensuring the pre-molded external stability and thickness uniformity of the thermoplastic prepreg fabric laminate. A heating element 10 is arranged inside the pre-pressing male mold 9, and after it completes the mold closing action with the female mold 7 in the downward movement, it simultaneously performs a softening heating treatment on the laminated thermoplastic prepreg fabric.

[0045] The conveying of the single-layer prepreg fabric, the downward inflation and pressurization of the stamping male mold 13 airbag 8, the downward pressurization of the pre-pressing male mold 9, and the gas pressure relief process are all multiple reciprocating operation processes to continuously realize the continuous stacking and stamping preforming of the single-layer prepreg fabric. After the continuous stacking and stamping preforming of the multi-layer prepreg fabric are completed, the pre-pressing male mold 9 is upwardly withdrawn by the pre-pressing power mechanism 11, and then the female mold 7 and the preformed laminated prepreg fabric therein are sent to the next step as a whole.

[0046] like Figure 3 As shown, the stamping molding component adopts a stamping male mold 13, which cooperates with the female mold 7 of the preforming component to complete the overall stamping molding of the laminated thermoplastic prepreg fabric. At this time, the heating element 10 of the female mold 7 stops heating, and the stamping male mold 13 moves downward to complete the rapid stamping molding. The entire molding pressure and pressurization time are flexibly adjusted according to the requirements of the molded product.

[0047] The female mold 7 is equipped with a cooling mechanism 15, which acts on the laminated prepreg fabric in the stamping cavity. The stamping male mold 13 is connected to a stamping power mechanism 14 to adjust the distance between the stamping male mold 13 and the female mold 7; the cooling mechanism 15 includes a cooling channel and a circulation device. The cooling channel is arranged in the female mold 7 and the stamping male mold 13, and the circulation device is located outside the female mold 7, and the cooling channel is connected to the circulation device.

[0048] When the rapid stamping is completed, the cooling mechanism 15 in the device is turned on to pass the cooling liquid medium into the female mold 7 and the pre-pressing male mold 9 to complete the rapid cooling of the composite material special-shaped product.

[0049] The cooling liquid phase medium can be cooling water or cooling oil, and the liquid phase medium completes the cooling of the composite material special-shaped product under the temperature setting of the refrigeration module of the circulation equipment.

[0050] After the rapid stamping process is completed, the hydraulic device drives the stamping male die 13 upward to open the die, and the composite material special-shaped product is taken out from the female die 7, completing the entire molding preparation process.

[0051] In this embodiment, the carbon fiber thermoplastic composite material molding device has the following technical advantages compared with other thermoplastic composite material molding devices:

[0052] First, the preheating treatment of the spaced carbon fiber thermoplastic preimpregnated fabric is used to fully preheat and soften each single layer of preimpregnated fabric to ensure the flatness of the subsequent preforming process and thus ensure the overall quality of the composite product.

[0053] Secondly, the continuous reciprocating rapid stamping preheating forming and stacking technology is adopted. Through the reciprocating linkage operation of the combined processes such as the pushing of single-layer preimpregnated fabric, the inflation and pressurization of the flexible male mold airbag 8, and the preforming and pressurization of the metal hot pressure head, the continuous and rapid laying of each single-layer preimpregnated fabric is achieved, while ensuring the elimination of fabric wrinkles between layers and the interface bonding effect.

[0054] Third, the use of a combination of metal hot pressing heads and cold pressing heads for stamping and molding not only ensures the interlayer infiltration of the matrix resin during the molding process, but also achieves rapid cooling and demolding of the product after molding, effectively ensuring the working efficiency of thermoplastic composite material molding.

[0055] Figure 1 It is a schematic diagram of a preheating assembly for preheating a single layer of carbon fiber thermoplastic preimpregnated fabric, wherein the preimpregnated fabric is placed on a support frame 1 and is fed into the preheating assembly through a box door. The preimpregnated fabric is flatly stacked through the linkage of a tensioning mechanism 2 and a clamping mechanism 3, is preheated under the action of a preheating element 4, and maintains a uniform temperature under the action of a circulation mechanism 5.

[0056] Figure 2 It is a schematic diagram of the structure of the preforming component, in which the female mold 7 and the pre-pressing male mold 9 of the entire system are provided with heating elements 10 inside, and the entire system completes the pressurization action through the pre-pressing power mechanism 11. At the same time, the male mold airbag 8 used for flexible preforming stamping is equipped with an inflation mechanism 12 to inflate and pressurize the laminated preimpregnated fabric on the surface of the female mold 7.

[0057] Figure 3It is a structural schematic diagram of the stamping forming component, which uses a stamping male die 13 to cooperate with a female die 7 to complete the overall stamping forming of the laminated thermoplastic prepreg fabric. At this time, the heating element 10 of the female die 7 stops heating, and the stamping male die 13 completes rapid stamping forming when the stamping power mechanism 14 moves downward, and then the cooling mechanism 15 is turned on to quickly cool the composite material special-shaped product.

[0058] Combination Figure 1-Figure 3 A heating element 10 is arranged inside the pre-pressing male mold 9. After the pre-pressing male mold 9 completes the mold closing action with the female mold 7, the laminated thermoplastic prepreg fabric is softened and heated synchronously; after the stamping and forming of the stamping and forming assembly is completed, the cooling mechanism 15 is used to complete the rapid cooling of the composite material special-shaped product. The combined stamping and forming process of heating the pre-pressing male mold 9 and cooling the stamping male mold 13 and the female mold 7 is adopted, which not only ensures the interlayer infiltration of the matrix resin in the forming process, but also realizes the rapid cooling and demoulding after the product is formed, effectively ensuring the working efficiency of the thermoplastic composite material forming.

[0059] Example 2

[0060] In another typical embodiment of the present invention, Figure 1-Figure 3 As shown, a carbon fiber thermoplastic composite material molding process is provided, using the carbon fiber thermoplastic composite material molding device as in Example 1.

[0061] A carbon fiber thermoplastic composite material molding process, comprising:

[0062] A plurality of single-layer preimpregnated fabrics are laid in the support portion of the support frame, and the single-layer preimpregnated fabrics are preheated by the preheating element 4 and the circulation mechanism 5;

[0063] The preheated and softened single-layer prepreg fabric is transferred into the preforming cavity, the male mold airbag 8 is expanded to make the single-layer prepreg fabric adhere to the preforming cavity, and the pre-pressing male mold 9 pre-presses and forms the single-layer prepreg fabric;

[0064] Conveying multiple single-layer prepreg fabrics to the preforming cavity in sequence for stacking, attaching and pre-pressing each time they are stacked;

[0065] The female mold 7 and the prepreg fabric carried by it are transferred to the stamping and forming assembly, and the laminated prepreg fabric is stamped and formed by the cooperation of the stamping male mold 13 and the female mold 7, and a composite material special-shaped product is obtained after demoulding.

[0066] When the prepreg fabric is in the preforming cavity of the preforming assembly, the female mold 7 and the pre-pressing male mold 9 are heated, and after the laminated prepreg fabric is punched and formed in the punching and forming assembly, the female mold 7 is cooled.

[0067] Example 3

[0068] In another typical embodiment of the present invention, Figure 1-Figure 3 As shown, a carbon fiber thermoplastic composite material molding process is provided, using the carbon fiber thermoplastic composite material molding device as in Example 1.

[0069] A carbon fiber thermoplastic composite material forming device includes three parts: a preheating component, a preforming component and a stamping forming component. A carbon fiber thermoplastic composite material forming process uses a carbon fiber thermoplastic composite material forming device, and the forming process includes:

[0070] The preheating component is provided with a 10-layer preimpregnated fabric support frame 1 with an interval of 10 cm. The edges of the support frame 1 are equipped with clamping and fixing devices with appropriate tensioning force. The multi-layer support frame 1 is located in a closed heating box in which a certain number of preheating elements 4 and a circulation mechanism 5 are arranged. The preimpregnated fabric is preheated at 120°C for 30 minutes.

[0071] The preheated multi-layer preimpregnated fabric is sent to the surface of the female mold 7 of the preforming component under the drive of the conveying component 6. The surface of the female mold 7 is pre-coated with silicone grease for demoulding. Then, the male mold airbag 8 made of tear-resistant and high-temperature resistant silicone material for flexible preforming stamping is moved downward to contact the preimpregnated fabric. Air is quickly injected into the male mold airbag 8 through the inflation mechanism 12. The male mold airbag 8 expands and applies the single-layer preimpregnated fabric to the surface of the female mold 7 under the action of 2MPa pressure. Then, the pre-pressed male mold 9 is sent into the male mold airbag 8, and the gas in the male mold airbag 8 is depressurized at the same time, completing the preforming and stacking process of a single layer of preimpregnated fabric. The above-mentioned reciprocating stamping and stacking actions form a linkage action to complete the stacking, and at the same time, the heating element 10 set inside the female mold 7 is turned on, and the temperature control is synchronized with the temperature of the preheating system to achieve a close fit between the stacked preimpregnated fabric and the female mold 7.

[0072] After that, the pre-pressing male mold 9 is moved downwards in synchronization with the female mold 7, and the male mold pressure head and the female mold 7 cavity form a stable cavity with a specific special-shaped structure. A heating element 10 is arranged inside the pre-pressing male mold 9. After the pre-pressing male mold 9 completes the mold closing action with the female mold 7, the laminated thermoplastic prepreg fabric is heated at 240°C. After the continuous stacking and stamping preforming of the multi-layer prepreg fabric are completed, the pre-pressing male mold 9 is removed upwards by the power mechanism, and then the female mold 7 and the preformed laminated prepreg fabric therein are sent as a whole into the stamping molding assembly.

[0073] The stamping male die 13 is used in conjunction with the female die 7 of the preforming component to complete the overall stamping molding of the laminated thermoplastic prepreg fabric. At this time, the heating element 10 of the female die 7 stops heating, and the stamping male die 13 moves downward to complete the rapid stamping molding. The entire molding process controls the pressure at 5MPa and the pressurizing time is 30s.

[0074] After the rapid stamping is completed, the cooling mechanism 15 in the device is turned on to pass cooling oil into the female mold 7 and the pre-pressing male mold 9 to complete the rapid cooling of the composite material special-shaped product.

[0075] Example 4

[0076] In another typical embodiment of the present invention, Figure 1-Figure 3 As shown, a carbon fiber thermoplastic composite material molding process is provided, using the carbon fiber thermoplastic composite material molding device as in Example 1.

[0077] A carbon fiber thermoplastic composite material forming device includes three parts: a preheating component, a preforming component and a stamping forming component. A carbon fiber thermoplastic composite material forming process uses a carbon fiber thermoplastic composite material forming device, and the forming process includes:

[0078] The preheating component is provided with a 14-layer preimpregnated fabric support frame 1 with an interval of 15 cm. The edges of the frame are equipped with clamping and fixing devices with appropriate tensioning force. The multi-layer support frame 1 is located in a closed heating box in which a certain number of preheating elements 4 and a circulation mechanism 5 are arranged. The preimpregnated fabric is preheated at 130°C for 20 minutes.

[0079] The preheated multi-layer preimpregnated fabric is sent to the surface of the female mold 7 of the preforming component under the drive of the conveying component 6. The surface of the female mold 7 is pre-coated with silicone grease for demoulding. Then, the male mold airbag 8 made of tear-resistant and high-temperature resistant silicone material for flexible preforming stamping is moved downward to contact the preimpregnated fabric. Air is quickly injected into the male mold airbag 8 through the inflation mechanism 12. The male mold airbag 8 expands and applies the single-layer preimpregnated fabric to the surface of the female mold 7 under the action of 4MPa pressure. Then, the pre-pressed male mold 9 is sent into the male mold airbag 8, and the gas in the male mold airbag 8 is depressurized at the same time, completing the preforming and stacking process of a single layer of preimpregnated fabric. The above-mentioned reciprocating stamping and stacking actions form a linkage action to complete the stacking, and at the same time, the heating element 10 set inside the female mold 7 is turned on, and the temperature control is synchronized with the temperature of the preheating system to achieve a close fit between the stacked preimpregnated fabric and the female mold 7.

[0080] After that, the pre-pressing male mold 9 is moved downwards in synchronization with the female mold 7, and the male mold pressure head and the female mold 7 cavity form a stable cavity with a specific special-shaped structure. A heating element 10 is arranged inside the pre-pressing male mold 9. After the pre-pressing male mold 9 completes the mold closing action with the female mold 7, the laminated thermoplastic prepreg fabric is heated at 220°C. After the continuous stacking and stamping preforming of the multi-layer prepreg fabric are completed, the pre-pressing male mold 9 is removed upwards by the power mechanism, and then the female mold 7 and the preformed laminated prepreg fabric therein are sent as a whole into the stamping molding assembly.

[0081] The stamping male die 13 is used in conjunction with the female die 7 of the preforming component to complete the overall stamping molding of the laminated thermoplastic prepreg fabric. At this time, the heating element 10 of the female die 7 stops heating, and the stamping male die 13 moves downward to complete the rapid stamping molding. The entire molding process controls the pressure at 6MPa and the pressurizing time is 20s.

[0082] After the rapid stamping is completed, the cooling mechanism 15 in the device is turned on to pass cooling oil into the female mold 7 and the pre-pressing male mold 9 to complete the rapid cooling of the composite material special-shaped product.

[0083] Example 5

[0084] In another typical embodiment of the present invention, Figure 1-Figure 3 As shown, a carbon fiber thermoplastic composite material molding process is provided, using the carbon fiber thermoplastic composite material molding device as in Example 1.

[0085] A carbon fiber thermoplastic composite material forming device includes three parts: a preheating component, a preforming component and a stamping forming component. A carbon fiber thermoplastic composite material forming process uses a carbon fiber thermoplastic composite material forming device, and the forming process includes:

[0086] The preheating component is provided with an 18-layer preimpregnated fabric support frame 1 with an interval of 12 cm. The edges of the frame are equipped with clamping and fixing devices with appropriate tensioning force. The multi-layer support frame 1 is located in a closed heating box in which a certain number of preheating elements 4 and a circulation mechanism 5 are arranged. The preimpregnated fabric is preheated at 150°C for 25 minutes.

[0087] The preheated multi-layer preimpregnated fabric is sent to the surface of the female mold 7 of the preforming component under the drive of the conveying component 6. The surface of the female mold 7 is pre-coated with silicone grease for demoulding. Then, the male mold airbag 8 made of tear-resistant and high-temperature resistant silicone material for flexible preforming stamping is moved downward to contact the preimpregnated fabric. Air is quickly injected into the male mold airbag 8 through the inflation mechanism 12. The male mold airbag 8 expands and applies the single-layer preimpregnated fabric to the surface of the female mold 7 under the action of 4MPa pressure. Then, the pre-pressed male mold 9 is sent into the male mold airbag 8, and the gas in the male mold airbag 8 is depressurized at the same time, completing the preforming and stacking process of a single layer of preimpregnated fabric. The above-mentioned reciprocating stamping and stacking actions form a linkage action to complete the stacking, and at the same time, the heating element 10 set inside the female mold 7 is turned on, and the temperature control is synchronized with the temperature of the preheating system to achieve a close fit between the stacked preimpregnated fabric and the female mold 7.

[0088] After that, the pre-pressing male mold 9 is moved downwards in synchronization with the female mold 7, and the male mold pressure head and the female mold 7 cavity form a stable cavity with a specific special-shaped structure. A heating element 10 is arranged inside the pre-pressing male mold 9. After the pre-pressing male mold 9 completes the mold closing action with the female mold 7, the laminated thermoplastic prepreg fabric is heated at 235°C. After the continuous stacking and stamping preforming of the multi-layer prepreg fabric are completed, the pre-pressing male mold 9 is removed upwards by the power mechanism, and then the female mold 7 and the preformed laminated prepreg fabric therein are sent as a whole into the stamping molding assembly.

[0089] The stamping male die 13 is used in conjunction with the female die 7 of the preforming component to complete the overall stamping molding of the laminated thermoplastic prepreg fabric. At this time, the heating element 10 of the female die 7 stops heating, and the stamping male die 13 moves downward to complete the rapid stamping molding. The entire molding process controls the pressure to 8MPa and the pressurizing time to 50s.

[0090] After the rapid stamping is completed, the cooling mechanism 15 in the device is turned on to pass cooling oil into the female mold 7 and the pre-pressing male mold 9 to complete the rapid cooling of the composite material special-shaped product.

[0091] Example 6

[0092] In another typical embodiment of the present invention, Figure 1-Figure 3 As shown, a carbon fiber thermoplastic composite material molding process is provided, using the carbon fiber thermoplastic composite material molding device as in Example 1.

[0093] A carbon fiber thermoplastic composite material forming device includes three parts: a preheating component, a preforming component and a stamping forming component. A carbon fiber thermoplastic composite material forming process uses a carbon fiber thermoplastic composite material forming device, and the forming process includes:

[0094] The preheating component is provided with a 22-layer preimpregnated fabric support frame 1 with an interval of 16 cm. The edges of the frame are equipped with clamping and fixing devices with appropriate tensioning force. The multi-layer support frame 1 is located in a closed heating box in which a certain number of preheating elements 4 and a circulation mechanism 5 are arranged. The preimpregnated fabric is preheated at 110°C for 25 minutes.

[0095] The preheated multi-layer preimpregnated fabric is sent to the surface of the female mold 7 of the preforming component under the drive of the conveying component 6. The surface of the female mold 7 is pre-coated with silicone grease for demoulding. Then, the male mold airbag 8 made of tear-resistant and high-temperature resistant silicone material for flexible preforming stamping is moved downward to contact the preimpregnated fabric. Air is quickly injected into the male mold airbag 8 through the inflation mechanism 12. The male mold airbag 8 expands and applies the single-layer preimpregnated fabric to the surface of the female mold 7 under the action of 5MPa pressure. Then, the pre-pressed male mold 9 is sent into the male mold airbag 8, and the gas in the male mold airbag 8 is depressurized at the same time, completing the preforming and stacking process of a single layer of preimpregnated fabric. The above-mentioned reciprocating stamping and stacking actions form a linkage action to complete the stacking, and at the same time, the heating element 10 set inside the female mold 7 is turned on, and the temperature control is synchronized with the temperature of the preheating system to achieve a close fit between the stacked preimpregnated fabric and the female mold 7.

[0096] After that, the pre-pressing male mold 9 is moved downwards in synchronization with the female mold 7, and the male mold pressure head and the female mold 7 cavity form a stable cavity with a specific special-shaped structure. A heating element 10 is arranged inside the pre-pressing male mold 9. After the pre-pressing male mold 9 completes the mold closing action with the female mold 7, the laminated thermoplastic prepreg fabric is heated at 230°C. After the continuous stacking and stamping preforming of the multi-layer prepreg fabric are completed, the pre-pressing male mold 9 is removed upwards by the power mechanism, and then the female mold 7 and the preformed laminated prepreg fabric therein are sent as a whole into the stamping molding assembly.

[0097] The stamping male die 13 is used in conjunction with the female die 7 of the preforming component to complete the overall stamping molding of the laminated thermoplastic prepreg fabric. At this time, the heating element 10 of the female die 7 stops heating, and the stamping male die 13 moves downward to complete the rapid stamping molding. The entire molding process controls the pressure at 5MPa and the pressurizing time is 60s.

[0098] After the rapid stamping is completed, the cooling mechanism 15 in the device is turned on to pass cooling oil into the female mold 7 and the pre-pressing male mold 9 to complete the rapid cooling of the composite material special-shaped product.

[0099] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A carbon fiber thermoplastic composite material molding device, characterized in that: include: A preheating assembly comprises a support frame, a preheating element and a circulation mechanism arranged in the box, wherein the support frame is provided with multiple layers of support parts for carrying a single layer of preimpregnated fabric, and the preheating element and the circulation mechanism maintain the temperature in the box; The preforming component comprises a female mold, a pre-pressed male mold and a male mold airbag, the male mold airbag cooperates with the female mold, a pre-forming cavity for accommodating sequentially stacked prepreg fabrics is provided between the male mold airbag and the female mold, and the pre-pressed male mold abuts against the male mold airbag to deform so as to extrude the stacked prepreg fabrics; A stamping forming component includes a stamping male die and a female die shared with the preforming component, wherein the stamping male die and the female die cooperate to form a stamping cavity for accommodating the laminated prepreg fabric; The conveying component is connected with the preheating component, the preforming component and the stamping component in sequence, and is used for conveying the prepreg fabric and the female mold.

2. The carbon fiber thermoplastic composite material molding device according to claim 1, characterized in that: The support frame is provided with a clamping mechanism for clamping a single-layer prepreg fabric, the clamping mechanism is connected with a tensioning mechanism, and the multi-layer support parts are distributed at intervals.

3. The carbon fiber thermoplastic composite material molding device according to claim 1 or 2, characterized in that: The circulation mechanism and the preheating element are installed on both sides of the box body, and the circulation mechanism forms circulating air in the box body.

4. The carbon fiber thermoplastic composite material molding device according to claim 1, characterized in that: The male mold airbag is connected to an inflation mechanism to adjust the expansion state of the male mold airbag and squeeze or release the prepreg fabric in the preforming cavity.

5. The carbon fiber thermoplastic composite material molding device according to claim 4, characterized in that: The pre-pressing male mold and female mold are respectively equipped with heating elements, which act on the preimpregnated fabric in the preforming cavity. The pre-pressing male mold is connected to a pre-pressing power mechanism to adjust the distance between the pre-pressing male mold and the female mold, and squeeze the deflated male mold airbag to deform the male mold airbag.

6. The carbon fiber thermoplastic composite material molding device according to claim 1, characterized in that: The female mold is equipped with a cooling mechanism, which acts on the laminated prepreg fabric in the punching cavity. The punching male mold is connected with a punching power mechanism to adjust the distance between the punching male mold and the female mold.

7. The carbon fiber thermoplastic composite material molding device according to claim 6, characterized in that: The cooling mechanism comprises a cooling channel and a circulation device. The cooling channel is arranged in the female mold and the punching male mold. The circulation device is located outside the female mold, and the cooling channel is connected to the circulation device.

8. The carbon fiber thermoplastic composite material molding device according to claim 1, characterized in that: The conveying components are connected with the multi-layer supporting parts respectively to convey the single-layer prepreg fabric into the preforming cavity layer by layer.

9. A carbon fiber thermoplastic composite material molding process, using the carbon fiber thermoplastic composite material molding device as claimed in any one of claims 1 to 8, characterized in that: include: A plurality of single-layer preimpregnated fabrics are laid in the support part of the support frame, and the single-layer preimpregnated fabrics are preheated by a preheating element and a circulation mechanism; the preheated and softened single-layer preimpregnated fabrics are transferred to the preforming cavity, the male mold airbag is expanded to make the single-layer preimpregnated fabric adhere to the preforming cavity, and the pre-pressing male mold is used to pre-press and form the single-layer preimpregnated fabric; Conveying multiple single-layer prepreg fabrics to the preforming cavity in sequence for stacking, attaching and pre-pressing each time they are stacked; The female mold and the preimpregnated fabric carried by it are transferred to the stamping molding component, and the laminated preimpregnated fabric is stamped and molded by the cooperation of the stamping male mold and the female mold, and the composite material special-shaped product is obtained after demoulding.

10. The carbon fiber thermoplastic composite material molding process according to claim 9, characterized in that: When the prepreg fabric is in the preforming cavity of the preforming assembly, the female mold and the pre-pressing male mold are heated, and after the laminated prepreg fabric is punched and formed in the punching and forming assembly, the female mold is cooled.

Images