Carbon fiber thermoplastic composite forming apparatus and process

Abstract

The application provides a carbon fiber thermoplastic composite material forming device and process, relates to the field of composite material forming process, and aims at the problem that the machining requirement of complex special-shaped products is difficult to meet at present. Each single-layer pre-impregnated fabric is fully preheated and softened to ensure the laying flatness of the subsequent preforming process and the overall quality of the composite material product. The continuous reciprocating preforming laying technology is adopted to realize the continuous and rapid layering of each single-layer pre-impregnated fabric through the preforming pressurizing combination linkage operation of single-layer pre-impregnated fabric pushing, male mold air bag inflation pressurizing fitting and pre-pressing male mold, meanwhile, the fabric wrinkle elimination and interface bonding effect between layers are ensured, and the resin and fiber impregnation effect is stable. The laminated pre-impregnated fabric obtained through stacking is subjected to stamping forming, the interlayer melting and infiltration of the matrix resin in the forming process are ensured, the working efficiency of the thermoplastic composite material forming is effectively ensured, and the machining requirement of complex special-shaped products is met.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of composite material forming process, in particular to a carbon fiber thermoplastic composite material forming device and process. BACKGROUND

[0002] The thermoplastic composite material is formed by thermoplastic resin matrix and high-performance fiber, which can exert the advantages of high strength and high modulus of the high-performance fiber, and the thermoplastic resin matrix can also make the composite material have the excellent performance of repeated plastic forming. The thermoplastic resin has the excellent mechanical properties such as impact resistance, high toughness and mechanical durability, which are not possessed by traditional thermosetting resin, so the products have wide application in the fields of vehicle transportation, oil exploitation, power transmission and military protection. The traditional thermoplastic composite material forming has great process difficulty due to the high viscosity, low flowability and narrow processing temperature range of the thermoplastic resin, and the poor infiltration effect of the thermoplastic resin and the fiber reinforced fabric is also the main reason for the easy formation of internal defects of the composite material product.

[0003] A fiber cloth composite material forming method is disclosed in Chinese patent (publication number CN 109624198 A), which combines hot stamping forming process and injection forming process to manufacture a preform by hot stamping process, greatly reduces the time of manually laying the preform in RTM process, the mold for hot stamping preforming can be repeatedly used, improves the utilization rate of the injection forming mold in RTM process, and ensures the consistency of the complex structure fiber composite material forming; but the injection forming process has many limitations, and the infiltration effect of the resin and the fiber cannot be guaranteed when the injection forming process is used for processing special-shaped products, which leads to unstable infiltration effect of the resin and the fiber, and the shape of the product can only be limited to simple plate shape, and it is difficult to process special-shaped products. SUMMARY

[0004] The present application aims to solve the defects in the prior art, and provides a carbon fiber thermoplastic composite material forming device and process, which is configured with a preheating assembly, a preforming assembly and a stamping forming assembly, each single-layer pre-impregnated fabric is fully preheated and softened, the continuous and rapid layering of each single-layer pre-impregnated fabric is realized, the fabric wrinkles between the layers are eliminated and the interface bonding effect is guaranteed, the resin and the fiber have stable infiltration effect, the interlayer infiltration of the matrix resin in the forming process is guaranteed, the working efficiency of the thermoplastic composite material forming is effectively guaranteed, and the processing requirements of complex special-shaped products are met.

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

[0006] The preheating assembly comprises a support frame, a preheating element and a circulating mechanism arranged in the box, the support frame is provided with a plurality of layers of support portions for carrying single-layer prepreg fabrics, and the preheating element and the circulating mechanism maintain the temperature in the box.

[0007] The preforming assembly comprises a female mold, a pre-pressing male mold and a male mold air bag, the male mold air bag is matched with the female mold, a preforming cavity for accommodating the prepreg fabrics stacked in sequence is arranged between the male mold air bag and the female mold, and the pre-pressing male mold is deformed to press the stacked prepreg fabrics by abutting against the male mold air bag.

[0008] The stamping forming assembly comprises a stamping male mold and a female mold shared by the preforming assembly, the stamping male mold and the female mold are matched, and a stamping cavity for accommodating the stacked prepreg fabrics is formed between the stamping male mold and the female mold.

[0009] The conveying assembly sequentially connects the preheating assembly, the preforming assembly and the stamping forming assembly, and is used for conveying the prepreg fabrics and the female mold.

[0010] Further, the support frame is provided with a clamping mechanism for clamping the single-layer prepreg fabrics, the clamping mechanism is connected with a tensioning mechanism, and the plurality of layers of support portions are distributed at intervals.

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

[0012] Further, the male mold air bag is connected with an inflation mechanism, the inflation mechanism adjusts the inflation state of the male mold air bag, and the prepreg fabrics in the preforming cavity are pressed or released.

[0013] Further, the pre-pressing male mold and the female mold are respectively provided with heating elements, the heating elements act on the prepreg fabrics in the preforming cavity, and the pre-pressing male mold is connected with a pre-pressing power mechanism to adjust the distance between the pre-pressing male mold and the female mold.

[0014] Further, the female mold is provided with a cooling mechanism, the cooling mechanism acts on the stacked prepreg fabrics in the stamping cavity, and the stamping male mold is connected with a stamping power mechanism to adjust the distance between the stamping male mold and the female mold and to press the deflated male mold air bag to deform the male mold air bag.

[0015] Further, the cooling mechanism comprises a cooling channel and a circulating device, the cooling channel is arranged in the female mold and the stamping male mold, the circulating device is located outside the female mold, and the cooling channel is connected to the circulating device.

[0016] Further, the conveying assembly is respectively connected with the plurality of layers of support portions, and the single-layer prepreg fabrics are sent into the preforming cavity layer by layer.

[0017] The second object of the present application is to provide a carbon fiber thermoplastic composite material forming process, which utilizes the carbon fiber thermoplastic composite material forming device as described in the first object, and comprises the following steps:

[0018] The plurality of single-layer pre-impregnated fabrics are laid in the support part of the support frame, and the single-layer pre-impregnated fabrics are preheated by the preheating element and the circulating mechanism;

[0019] The single-layer pre-impregnated fabric preheated and softened is conveyed into the preforming cavity, the male mold air bag is inflated to make the single-layer pre-impregnated fabric adhere to the preforming cavity, and the pre-pressing male mold is used for pre-pressing and forming the single-layer pre-impregnated fabric;

[0020] The plurality of single-layer pre-impregnated fabrics are conveyed to the preforming cavity in sequence for stacking, and the adhering and pre-pressing forming are performed at each time of stacking;

[0021] The female mold and the pre-impregnated fabric carried are conveyed to the stamping forming assembly, the stamping male mold and the female mold are matched to stamp and form the stacked pre-impregnated fabric, and the composite material special-shaped product is obtained after demolding.

[0022] Further, the female mold and the pre-pressing male mold are heated when the pre-impregnated fabric is in the preforming cavity of the preforming assembly, and the female mold is cooled after the stacked pre-impregnated fabric is stamped and formed in the stamping forming assembly.

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

[0024] (1) In view of the problem that the processing requirements of complex special-shaped products are difficult to meet at present, the preheating assembly is configured to adopt interval type carbon fiber thermoplastic pre-impregnated fabric preheating treatment, each single-layer pre-impregnated fabric is fully preheated and softened to ensure the stacking flatness of the subsequent preforming process and the overall quality of the composite material product; the preforming assembly is configured to adopt continuous reciprocating preforming stacking technology, through the combination linkage operation of single-layer pre-impregnated fabric pushing, male mold air bag inflation and pressurization adhesion, pre-pressing male mold preforming pressurization, the continuous and rapid layering of each single-layer pre-impregnated fabric is realized, and the fabric wrinkle elimination and interface bonding effect between layers are ensured, and the resin and fiber impregnation effect is stable; the stamping forming assembly is configured to stamp and form the stacked pre-impregnated fabric obtained by stacking, the interlayer fusion of the matrix resin in the forming process is ensured, the working efficiency of the thermoplastic composite material forming is effectively ensured, and the processing requirements of complex special-shaped products are met.

[0025] (2) The flexible preforming principle is used, the male mold air bag is configured to contact the single-layer pre-impregnated fabric downward, the gas in the male mold air bag is quickly filled through the inflation mechanism, the single-layer pre-impregnated fabric is adhered to the surface of the preforming cavity of the female mold under the inflation and pressurization of the male mold air bag, the layering efficiency is improved, and the single-layer pre-impregnated fabric can be extended outwardly through the unfolding action of the male mold air bag in the inflation process, so that the fabric wrinkle between layers is eliminated; the gas in the male mold air bag is depressurized, the single-layer pre-impregnated fabric is pre-formed and pressed through the pre-pressing male mold, and the preforming and stacking process of the single-layer pre-impregnated fabric is completed, each layer is pre-formed respectively, and the forming requirements of complex special-shaped products are met.

[0026] (3) The heating element is arranged inside the pre-pressing male die, and after the downwardly moving of the male die is completed, the softening and heating treatment of the laminated thermoplastic prepreg fabric is simultaneously performed; after the stamping forming of the stamping forming assembly is completed, the rapid cooling of the composite profiled product is completed by using the cooling mechanism; the stamping forming treatment of the combination of the pre-pressing male die heating, the stamping male die and the female die cooling is adopted, which not only ensures the interlayer melting and infiltration of the matrix resin in the forming process, but also realizes the rapid cooling and demolding after the product forming, and effectively ensures the working efficiency of the thermoplastic composite forming. BRIEF DESCRIPTION OF DRAWINGS

[0027] The accompanying drawings, which form a part of the present description, are included to provide a further understanding of the application and are incorporated in and constitute a part of this application. The embodiments of the present application, and their

[0028] Figure 1 The schematic diagram of the preheating assembly in the embodiment 1 and 2 of the present application.

[0029] Figure 2 The schematic diagram of the preforming assembly in the embodiment 1 and 2 of the present application.

[0030] Figure 3 The schematic diagram of the stamping forming assembly in the embodiment 1 and 2 of the present application.

[0031] Wherein, 1, support frame; 2, tensioning mechanism; 3, clamping mechanism; 4, preheating element; 5, circulating mechanism; 7, female die; 8, male die air bag; 9, pre-pressing male die; 10, heating element; 11, pre-pressing power mechanism; 12, inflating mechanism; 13, stamping male die; 14, stamping power mechanism; 15, cooling mechanism. DETAILED DESCRIPTION

[0032] Embodiment 1

[0033] In a typical embodiment of the present application, as shown in Figures 1-3 , a carbon fiber thermoplastic composite forming device is given.

[0034] The prior art makes a preform by a hot stamping process, aiming to reduce the time of manually laying up the preform when using the RTM (resin transfer molding) process, and improve the utilization rate of the mold and ensure the molding consistency. However, this method has the limitation of the injection molding process, especially for the processing of special-shaped products, and cannot guarantee the resin and fiber infiltration effect, resulting in that the shape of the product is limited to simple plate, and it is difficult to meet the processing needs of complex special-shaped products. Based on this, the embodiment provides a carbon fiber thermoplastic composite forming device, which is configured with a preheating assembly, a preforming assembly and a stamping forming assembly, and a conveying assembly, realizes sufficient preheating and softening of each single-layer pre-impregnated fabric, guarantees continuous and rapid layering, guarantees the elimination of fabric wrinkles and interface bonding effect between layers, and the stability of resin and fiber infiltration effect, guarantees the interlayer melting and infiltration of the matrix resin in the molding process, effectively improves the working efficiency of the thermoplastic composite molding, meets the processing needs of complex special-shaped products, and overcomes the limitation of the prior art.

[0035] In the embodiment, the carbon fiber thermoplastic composite forming device uses single-layer pre-impregnated fabric of carbon fiber unidirectional or planar two-dimensional fabric reinforced thermoplastic resin, and can prepare a special-shaped composite thermoplastic shell part by means of a flexible preforming stamping die and through a rapid stacking stamping integrated molding technology. The carbon fiber thermoplastic composite forming device mainly includes a preheating assembly, a preforming assembly and a stamping forming assembly, and also includes a conveying assembly for conveying the pre-impregnated fabric and the die between the three parts. The raw material processed is single-layer carbon fiber thermoplastic pre-impregnated fabric, i.e. single-layer pre-impregnated fabric.

[0036] As shown in Figure 1 The preheating assembly includes a support frame 1 arranged in a box, a preheating element 4 and a circulating mechanism 5. The support frame 1 is provided with multiple layers of support portions for carrying single-layer pre-impregnated fabric. The preheating element 4 can heat the inside of the box to increase the temperature inside the box. The circulating mechanism 5 can make the temperature distribution in the box uniform and maintain the temperature inside the box.

[0037] Specifically, the support frame 1 is provided with multiple layers of support portions, each of which can carry single-layer pre-impregnated fabric. The support portions are arranged at a certain interval distance. The number of layers of support portions is determined according to the design requirements of the number of layers in the composite molding process. The support frame 1 is provided with a clamping mechanism 3 for clamping the single-layer pre-impregnated fabric. The clamping mechanism 3 is connected with a tensioning mechanism 2. Specifically, the clamping mechanism 3 is arranged around the edges of each layer of support portions, so as to clamp the edges of the single-layer pre-impregnated fabric and keep the single-layer pre-impregnated fabric flat by maintaining appropriate tension force through the tensioning mechanism 2.

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

[0039] As shown in Figure 2 The preforming assembly includes a female die 7, a male die air bag 8 for flexible preforming stamping, and a pre-pressing male die 9. The male die air bag 8 is connected with an inflation mechanism 12, the male die air bag 8 cooperates with the female die, a preforming cavity for accommodating the pre-impregnated fabric stacked in sequence is arranged between the male die air bag 8 and the female die 7, and the pre-pressing male die 9 abuts against the male die air bag 8 to deform to extrude the stacked pre-impregnated fabric, the inflation state of the male die air bag 8 is adjusted, and the pre-impregnated fabric in the preforming cavity is extruded or released. The inflation mechanism 12 can be a gas pump, a gas cylinder or other high-pressure gas source. The pre-pressing male die 9 and the female die 7 are respectively provided with heating elements 10, the heating elements 10 act on the pre-impregnated fabric in the preforming cavity, and the pre-pressing male die 9 is connected with a pre-pressing power mechanism 11 to adjust the distance between the pre-pressing male die 9 and the female die 7.

[0040] The single-layer pre-impregnated fabric preheated before is driven by the conveying assembly to send the single-layer pre-impregnated fabric into the surface of the female die 7 layer by layer; then the male die air bag 8 for flexible preforming stamping is lowered to contact the single-layer pre-impregnated fabric, gas is rapidly injected into the male die air bag 8 through the inflation mechanism 12, and the single-layer pre-impregnated fabric is attached to the surface of the female die 7 under the inflation and pressurization of the male die air bag 8; then the pre-pressing male die 9 is sent into the male die air bag 8, the pre-impregnated fabric is pre-pressed by the male die air bag 8, and the position where the male die air bag 8 contacts the pre-pressing male die 9 forms a required feature shape under the gas pressure relief in the male die air bag 8, so that the extrusion preforming is completed in combination with the female die 7, and the preforming and stacking process of the single-layer pre-impregnated fabric is completed.

[0041] The conveying assembly can be configured with a conveying belt or a conveying table dedicated to conveying the single-layer pre-impregnated fabric, so that the single-layer pre-impregnated fabric can be conveyed from the bearing part to the preforming cavity. The conveying assembly pushes one layer or a certain number of single-layer pre-impregnated fabrics at a time, and the action is reciprocated and linked with the subsequent stamping and stacking action of the single-layer pre-impregnated fabric.

[0042] The female die 7 is provided with heating elements 10 inside to ensure that the single-layer pre-impregnated fabric is in the softening temperature range during the continuous preforming and stacking stamping process, realize the stability of the flexibility of the single-layer pre-impregnated fabric and the specific ductility of the fabric, and thus achieve the close attachment to the female die 7.

[0043] As Figure 2 shown, the female die 7 can be a flat structure or a special-shaped structure, and the cavity surface is specially treated before the lay-up stamping preforming to ensure the smooth ejection of the final laminated prepreg after multiple lay-up processes. The male die bladder 8 for flexible preforming stamping is made of tear-resistant and high-temperature-resistant flexible silica gel material, and the pre-pressing power mechanism 11 is arranged at the end of the male die bladder 8. The pre-pressing power mechanism 11 can be a hydraulic power descending device, and the male die bladder 8 is internally provided with a rapid inflation mechanism 12.

[0044] The pre-pressing male die 9 can be a flat structure or a special-shaped structure, and its external design is synchronized with that of the female die 7 to form a stable cavity with a specific special-shaped structure, thereby ensuring the stability of the preforming shape and the uniformity of the thickness of the thermoplastic pre-impregnated fabric layer. The pre-pressing male die 9 is internally provided with a heating element 10, which is used for synchronous softening and heating treatment of the laminated thermoplastic pre-impregnated fabric after the descending and clamping action with the female die 7.

[0045] The conveying of the single-layer pre-impregnated fabric, the descending and inflation of the stamping male die bladder 8, the descending and inflation of the pre-pressing male die 9, and the gas pressure relief process are all multiple reciprocating operation processes, which continuously realize the continuous lay-up and stamping preforming of the single-layer pre-impregnated fabric. After the continuous lay-up and stamping preforming of the multi-layer pre-impregnated fabric are completed, the pre-pressing male die 9 is pulled up by the pre-pressing power mechanism 11, and then the female die 7 and the preformed laminated prepreg therein are sent to the next step as a whole.

[0046] As Figure 3 shown, the stamping forming assembly uses the stamping male die 13 to cooperate with the female die 7 of the preforming assembly to complete the overall stamping forming of the laminated thermoplastic pre-impregnated fabric. At this time, the heating element 10 of the female die 7 stops heating, the stamping male die 13 descends to complete the rapid stamping forming, and the entire forming pressure and pressure time can be flexibly adjusted according to the requirements of the formed product.

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

[0048] When the rapid stamping forming is completed, the cooling mechanism 15 in the device is started, and the cooling liquid phase medium is introduced into the female die 7 and the pre-pressing male die 9 to complete the rapid cooling of the composite special-shaped product.

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

[0050] After the rapid stamping forming process is completed, the hydraulic device drives the stamping male die 13 to move upward to open the mold, and the composite profiled product is taken out of the female die 7, and the whole molding preparation process is completed.

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

[0052] First, the preheating treatment of the interval type carbon fiber thermoplastic pre-impregnated fabric is adopted, each single layer of pre-impregnated fabric is preheated and softened sufficiently, so as to ensure the flatness of the subsequent preforming process and the overall quality of the composite product.

[0053] Second, the continuous reciprocating rapid stamping preheating forming lamination technology is adopted, through the reciprocating linkage operation of the combination processes such as single layer pre-impregnated fabric pushing, flexible male die air bag 8 inflation and pressurization fitting, metal hot press head preforming pressurization, the continuous rapid lamination of each single layer of pre-impregnated fabric is realized, and the fabric wrinkle elimination and interface bonding effect between layers are ensured.

[0054] Third, the combination stamping forming treatment of metal hot press head and cold press head is adopted, which not only ensures the interlayer infiltration of the matrix resin in the forming process, but also realizes the rapid cooling demolding after the product forming, and effectively ensures the working efficiency of the thermoplastic composite forming.

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

[0056] Figure 2 It is a structural schematic diagram of the preforming assembly, wherein the female die 7 and the pre-pressing male die 9 of the whole system are provided with heating elements 10, the whole system completes the pressurizing action through the pre-pressing power mechanism 11, and the male die air bag 8 for flexible preforming stamping is provided with the inflation mechanism 12 for inflating and pressurizing the stacked pre-impregnated fabric on the surface of the female die 7.

[0057] Figure 3 It is a structural schematic diagram of the stamping forming assembly, which adopts the stamping male die 13 cooperating with the female die 7 to complete the overall stamping forming of the stacked thermoplastic pre-impregnated fabric. At this time, the heating element 10 of the female die 7 stops heating, the stamping male die 13 completes the rapid stamping forming under the descending of the stamping power mechanism 14, and then the cooling mechanism 15 is opened to cool the composite profiled product rapidly.

[0058] Combination Figures 1-3The pre-pressing male die 9 is internally provided with a heating element 10, and after the downwardly completed die closing action with the female die 7, the softening heating treatment of the laminated thermoplastic pre-impregnated fabric is synchronously performed; after the stamping forming of the stamping forming assembly is completed, the rapid cooling of the composite profiled product is completed by using the cooling mechanism 15, and the stamping forming treatment of the combination of the pre-pressing male die 9 heating, the stamping male die 13 and the female die 7 cooling is adopted, which not only ensures the interlayer infiltration of the matrix resin in the forming process, but also realizes the rapid cooling and demolding after the product forming, and effectively ensures the working efficiency of the thermoplastic composite material forming.

[0059] Embodiment 2

[0060] In another typical embodiment of the present application, as shown in Figures 1-3 A carbon fiber thermoplastic composite material forming process is given, which utilizes the carbon fiber thermoplastic composite material forming device in embodiment 1.

[0061] A carbon fiber thermoplastic composite material forming process comprises:

[0062] A plurality of single-layer pre-impregnated fabrics are laid in the support part of the support frame, and the single-layer pre-impregnated fabrics are preheated by the preheating element 4 and the circulating mechanism 5;

[0063] The preheated and softened single-layer pre-impregnated fabric is conveyed into the preforming cavity, the male die air bag 8 is inflated to make the single-layer pre-impregnated fabric adhere to the preforming cavity, and the pre-pressing male die 9 is used for pre-pressing forming of the single-layer pre-impregnated fabric;

[0064] The plurality of single-layer pre-impregnated fabrics are sequentially conveyed to the preforming cavity for stacking, and the adhering and pre-pressing forming are performed each time the stacking is performed;

[0065] The female die 7 and the pre-impregnated fabric carried thereby are conveyed to the stamping forming assembly, the stamping male die 13 and the female die 7 are used to stamp and form the stacked pre-impregnated fabric, and the composite profiled product is obtained after demolding.

[0066] In the pre-impregnated fabric in the preforming cavity of the preforming assembly, the female die 7 and the pre-pressing male die 9 are heated, and after the stamping forming of the stacked pre-impregnated fabric in the stamping forming assembly, the female die 7 is cooled.

[0067] Embodiment 3

[0068] In another typical embodiment of the present application, as shown in Figures 1-3 A carbon fiber thermoplastic composite material forming process is given, which utilizes the carbon fiber thermoplastic composite material forming device in embodiment 1.

[0069] A carbon fiber thermoplastic composite material forming device comprises three parts: a preheating assembly, a preforming assembly and a stamping forming assembly. A carbon fiber thermoplastic composite material forming process utilizes the carbon fiber thermoplastic composite material forming device, and the forming process comprises the following steps:

[0070] The preheating assembly is provided with a 10-layer pre-impregnated fabric support frame 1 with a spacing of 10 cm, and the support frame 1 is provided with clamping and fixing devices with appropriate tension force at the four peripheral edges. The multi-layer support frame 1 is located in a closed heating box body in which a certain number of preheating elements 4 and a circulating mechanism 5 are arranged, and the pre-impregnated fabric is preheated at 120℃ for 30 min.

[0071] The multi-layer pre-impregnated fabric after preheating is sent to the surface of the female die 7 of the preforming assembly under the driving of the conveying assembly, and the surface of the female die 7 is pre-coated with silicone grease for demolding. Then, the pre-impregnated fabric is contacted by the male die air bag 8 for flexible preforming stamping made of tear-resistant and high-temperature-resistant silicone rubber material. The male die air bag 8 is rapidly filled with air through the inflation mechanism 12, and the single-layer pre-impregnated fabric is attached to the surface of the female die 7 under the action of the 2MPa pressure of the expanded male die air bag 8. Then, the pre-pressing male die 9 is sent into the male die air bag 8, and the gas in the male die air bag 8 is simultaneously released, thereby completing the preforming and laying process of the single layer of pre-impregnated fabric. The reciprocating stamping and laying action is formed by the linkage action to complete the layer-by-layer laying, and the heating element 10 arranged in the female die 7 is turned on to control the temperature synchronously with the preheating system, so that the stacked pre-impregnated fabric is tightly attached to the female die 7.

[0072] Then, the pre-pressing male die 9 is lowered synchronously with the female die 7, and the male die head and the cavity of the female die 7 form a stable cavity with a specific special-shaped structure. The heating element 10 arranged in the pre-pressing male die 9 performs heating treatment on the stacked thermoplastic pre-impregnated fabric at 240℃ after the closing action of the female die 7 is completed. After the continuous laying and stamping preforming of the multi-layer pre-impregnated fabric are completed, the pre-pressing male die 9 is raised by the power mechanism, and then the female die 7 and the preformed stacked pre-impregnated fabric therein are sent into the stamping forming assembly.

[0073] The stamping male die 13 is used to complete the overall stamping forming of the stacked thermoplastic pre-impregnated fabric in cooperation with the female die 7 of the preforming assembly. At this time, the heating element 10 of the female die 7 stops heating, the stamping male die 13 is lowered to complete the rapid stamping forming, and the whole forming process is controlled at a pressure of 5MPa and a pressing time of 30s.

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

[0075] Example 4

[0076] In another typical embodiment of the present application, asFigures 1-3 As shown, a carbon fiber thermoplastic composite forming process is given, using the carbon fiber thermoplastic composite forming device as in Example 1.

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

[0078] The preheating assembly is provided with a 14-layer pre-impregnated fabric support frame 1 with a spacing of 15 cm, and the frame is provided with clamping and fixing devices with appropriate tension force on the four peripheral edges. The multi-layer support frame 1 is located in a closed heating box body in which a certain number of preheating elements 4 and a circulating mechanism 5 are arranged, and the pre-impregnated fabric is preheated at 130°C for 20 min.

[0079] The multi-layer pre-impregnated fabric after preheating is sent to the surface of the female die 7 of the preforming assembly under the drive of the conveying assembly, and the surface of the female die 7 is pre-coated with silicone grease for demolding. Then, the pre-impregnated fabric is contacted by the male die air bag 8 for flexible preforming stamping made of tear-resistant and high-temperature-resistant silicone material. The male die air bag 8 is rapidly filled with air through the inflation mechanism 12, and the single-layer pre-impregnated fabric is attached to the surface of the female die 7 under the action of the 4 MPa pressure of the male die air bag 8. Then, the pre-pressing male die 9 is sent into the male die air bag 8, and the gas in the male die air bag 8 is simultaneously released, completing the preforming and laying process of the single layer of pre-impregnated fabric. The reciprocating stamping and laying action is completed by the linkage action, and the heating element 10 arranged in the female die 7 is turned on at the same time, so that the temperature control is synchronized with the preheating system temperature, and the close attachment of the stacked pre-impregnated fabric and the female die 7 is achieved.

[0080] Then, the pre-pressing male die 9 is lowered synchronously with the female die 7, and the male die head and the female die 7 cavity form a stable cavity with a specific special-shaped structure. The heating element 10 arranged in the pre-pressing male die 9 performs heating treatment on the stacked thermoplastic pre-impregnated fabric at 220°C after the closing action of the female die 7 is completed. After the continuous laying and stamping preforming of the multi-layer pre-impregnated fabric are completed, the pre-pressing male die 9 is raised by the power mechanism, and then the female die 7 and the preformed stacked pre-impregnated fabric therein are sent as a whole to the stamping forming assembly.

[0081] The stamping male die 13 is used to complete the overall stamping forming of the stacked thermoplastic pre-impregnated fabric in cooperation with the female die 7 of the preforming assembly. At this time, the heating element 10 of the female die 7 stops heating, and the stamping male die 13 is lowered to complete the rapid stamping forming. The entire forming process is controlled at a pressure of 6 MPa and a pressing time of 20 s.

[0082] After the rapid stamping forming is completed, the cooling mechanism 15 in the device is opened, and cooling oil is introduced into the female die 7 and the inside of the pre-pressing male die 9, so that the rapid cooling of the composite profile product is completed.

[0083] Embodiment 5

[0084] In another typical embodiment of the present application, as shown in Figures 1-3 a carbon fiber thermoplastic composite material forming process is given, which utilizes the carbon fiber thermoplastic composite material forming device as in Embodiment 1.

[0085] A carbon fiber thermoplastic composite material forming device comprises three parts of a preheating assembly, a preforming assembly and a stamping forming assembly. A carbon fiber thermoplastic composite material forming process utilizes the carbon fiber thermoplastic composite material forming device, and the forming process comprises:

[0086] The preheating assembly is provided with an 18-layer pre-impregnated fabric support frame 1 with a spacing of 12 cm, and the frame is provided with clamping and fixing devices with appropriate tension force on the four peripheral edges. The multi-layer support frame 1 is located in a closed heating box body in which a certain number of preheating elements 4 and a circulating mechanism 5 are arranged, and the pre-impregnated fabric is preheated at 150℃ for 25 min.

[0087] The preheated multi-layer pre-impregnated fabric is sent to the surface of the female die 7 of the preforming assembly under the driving of the conveying assembly, and the surface of the female die 7 is pre-coated with silicone grease for demolding. Then the pre-impregnated fabric is contacted by the male die air bag 8 for flexible preforming stamping made of tear-resistant and high-temperature-resistant silicone rubber material, air is rapidly injected into the male die air bag 8 through the inflation mechanism 12, and the single-layer pre-impregnated fabric is attached to the surface of the female die 7 under the action of the 4MPa pressure of the expanded male die air bag 8. Then the pre-pressing male die 9 is sent into the male die air bag 8, and the gas in the male die air bag 8 is released, and the preforming and laying process of the single layer of pre-impregnated fabric is completed. The reciprocating stamping and laying action is formed by the linkage action to complete the layer laying, and the heating element 10 arranged in the female die 7 is turned on to control the temperature synchronously with the preheating system temperature, so that the layered pre-impregnated fabric is tightly attached to the female die 7.

[0088] Then the pre-pressing male die 9 is lowered synchronously with the female die 7, and the male die head and the female die 7 cavity form a stable cavity with a specific profile structure. The heating element 10 arranged in the pre-pressing male die 9 performs heating treatment on the layered thermoplastic pre-impregnated fabric at 235℃ after the closing action of the female die 7 is completed. After the continuous laying and stamping preforming of the multi-layer pre-impregnated fabric are completed, the pre-pressing male die 9 is raised by the power mechanism, and then the female die 7 and the preformed layered pre-impregnated fabric therein are sent into the stamping forming assembly as a whole.

[0089] The stamping male die 13 is used in combination with the preforming female die 7 to complete the overall stamping forming of the laminated thermoplastic pre-impregnated fabric, at this time, the heating element 10 of the female die 7 stops heating, the stamping male die 13 is lowered to complete the rapid stamping forming, and the overall forming process controls the pressure of 8 MPa and the pressurization time of 50 s.

[0090] After the rapid stamping forming is completed, the cooling mechanism 15 in the device is opened, the cooling oil is introduced into the female die 7 and the pre-pressing male die 9, and the rapid cooling of the composite profile product is completed.

[0091] Embodiment 6

[0092] In another typical embodiment of the present application, as shown in Figures 1-3 A carbon fiber thermoplastic composite material forming process is given, which utilizes the carbon fiber thermoplastic composite material forming device as in Embodiment 1.

[0093] A carbon fiber thermoplastic composite material forming device includes a preheating assembly, a preforming assembly and a stamping forming assembly. The carbon fiber thermoplastic composite material forming process utilizes the carbon fiber thermoplastic composite material forming device, and the forming process includes:

[0094] The preheating assembly is provided with a 22-layer pre-impregnated fabric support frame 1 with a spacing of 16 cm, and the frame is provided with clamping and fixing devices with appropriate tension force on the four peripheral edges. The multi-layer support frame 1 is located in the closed heating box body in which a certain number of preheating elements 4 and a circulating mechanism 5 are arranged, and the pre-impregnated fabric is preheated at 110℃ for 25 min.

[0095] The multi-layer pre-impregnated fabric after preheating is sent to the surface of the female die 7 of the preforming assembly under the driving of the conveying assembly, and the surface of the female die 7 is pre-coated with silicone grease for demolding. Then the male die air bag 8 for flexible preforming stamping made of tear-resistant and high-temperature-resistant silicone rubber material is lowered to contact the pre-impregnated fabric, air is rapidly injected into the male die air bag 8 through the inflation mechanism 12, and the single-layer pre-impregnated fabric is attached to the surface of the female die 7 under the action of the male die air bag 8 inflated at a pressure of 5 MPa. Then the pre-pressing male die 9 is sent into the male die air bag 8, and the gas in the male die air bag 8 is released, completing the preforming laying process of the single-layer pre-impregnated fabric. The above-mentioned reciprocating stamping and laying action forms a linkage action to complete the laminated laying, and at the same time, the heating element 10 arranged in the female die 7 is opened, the temperature control is synchronized with the preheating system temperature, and the close attachment of the laminated pre-impregnated fabric and the female die 7 is achieved.

[0096] Afterwards, the pre-pressing punch 9 which keeps the same shape with the female die 7 goes down, the punch head of the pre-pressing punch 9 and the cavity of the female die 7 form a stable cavity with special shape, the heating element 10 is arranged in the pre-pressing punch 9, after the pre-pressing punch 9 goes down and completes the die closing action with the female die 7, the heating treatment of 230℃ is carried out on the laminated thermoplastic prepreg fabric. After the continuous lamination and stamping pre-forming of the multi-layer prepreg fabric are completed, the pre-pressing punch 9 is pulled up by the power mechanism, and then the female die 7 and the pre-formed laminated prepreg fabric in the female die 7 are sent into the stamping forming assembly as a whole.

[0097] The stamping punch 13 is used to complete the whole stamping forming of the laminated thermoplastic prepreg fabric together with the female die 7 of the pre-forming assembly, at this time, the heating element 10 of the female die 7 stops heating, the stamping punch 13 goes down to complete the rapid stamping forming, and the whole forming process is controlled at 5MPa pressure and 60s of pressurizing time.

[0098] After the rapid stamping forming is completed, the cooling mechanism 15 in the device is opened, the cooling oil is fed into the female die 7 and the pre-pressing punch 9, and the rapid cooling of the composite special-shaped product is completed.

[0099] The above only describes the preferred embodiments of the present application and is not used to limit the present application, for those skilled in the art, the present application can have various changes and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A carbon fiber thermoplastic composite molding apparatus, characterized in that, include: The preheating assembly includes a support frame, preheating elements and a circulation mechanism arranged inside the chamber. The support frame has multiple support sections for supporting a single layer of prepreg fabric, and the preheating elements and circulation mechanism maintain the temperature inside the chamber. The preforming component includes a female mold, a pre-compression male mold, and a male mold airbag. The male mold airbag works in conjunction with the female mold. A preforming cavity is provided between the male mold airbag and the female mold to accommodate the sequentially stacked prepreg fabrics. The pre-compression male mold abuts against the male mold airbag to deform and compress the stacked prepreg fabrics. The stamping assembly includes a stamping male die and a female die shared with the preforming assembly. The stamping male die and the female die cooperate to form a stamping cavity for accommodating the laminated prepreg fabric. The conveying assembly, which is sequentially connected to the preheating assembly, the preforming assembly, and the stamping assembly, is used to convey the prepreg fabric and the die.

2. The carbon fiber thermoplastic composite material molding apparatus as described in claim 1, characterized in that, The support frame is equipped with a clamping mechanism for holding a single layer of prepreg fabric. The clamping mechanism is connected to a tensioning mechanism, and the multi-layer support parts are spaced apart.

3. The carbon fiber thermoplastic composite material molding apparatus as described in claim 1 or 2, characterized in that, The circulation mechanism and preheating element are installed on both sides of the box, and the circulation mechanism generates circulating air inside the box.

4. The carbon fiber thermoplastic composite material molding apparatus as described in 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 apparatus as described in claim 4, characterized in that, The pre-compression male mold and female mold are respectively equipped with heating elements. The heating elements act on the pre-impregnated fabric in the pre-forming cavity. The pre-compression male mold is connected to a pre-compression power mechanism to adjust the distance between the pre-compression male mold and female mold, and to squeeze the deflated male mold air bladder to deform the male mold air bladder.

6. The carbon fiber thermoplastic composite molding apparatus as described in claim 1, characterized in that, The female die is equipped with a cooling mechanism that acts on the laminated prepreg fabric in the stamping cavity. The male die is connected to a stamping power mechanism to adjust the distance between the male and female dies.

7. The carbon fiber thermoplastic composite material molding apparatus as described in claim 6, characterized in that, The cooling mechanism includes a cooling channel and a circulation device. The cooling channel is arranged inside the female mold and the stamping male mold, and the circulation device is located outside the female mold. The cooling channel is connected to the circulation device.

8. The carbon fiber thermoplastic composite material molding apparatus as described in claim 1, characterized in that, The conveying component is connected to the multi-layer support section respectively, and feeds the single-layer prepreg fabric into the preforming cavity layer by layer.

9. A carbon fiber thermoplastic composite molding process, utilizing the carbon fiber thermoplastic composite molding apparatus as described in any one of claims 1-8, characterized in that, include: Multiple single-layer prepreg fabrics are laid in the support part of the support frame. The single-layer prepreg fabrics are preheated by the preheating element and the circulation mechanism. The preheated and softened single-layer prepreg fabrics are conveyed to the preforming cavity. The male mold airbag expands to make the single-layer prepreg fabrics adhere to the preforming cavity. The pre-compression male mold pre-compresses the single-layer prepreg fabrics. Multiple single-layer prepreg fabrics are sequentially conveyed to the preforming cavity for stacking, and each stacking is performed by attachment and pre-compression forming. The female mold and the prepreg fabric it carries are conveyed to the stamping assembly. The male and female molds work together to stamp and form the laminated prepreg fabric. After demolding, the composite material shaped product is obtained.

10. The carbon fiber thermoplastic composite molding process as described in claim 9, characterized in that, While the prepreg fabric is in the preforming cavity of the preforming assembly, the female mold and the pre-pressing male mold are heated. After the laminated prepreg fabric is stamped in the stamping assembly, the female mold is cooled.

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