Forming method of ultrathin thermoplastic composite material

Abstract

The invention discloses a forming method of an ultrathin thermoplastic composite material. Comprising a creel, a fiber positioning device, a yarn spreading positioning observation opening, an ultrasonic yarn spreading device, a fiber width fixing roller set, an infrared preheating device, a melting and dipping device, an upper-layer sizing material unwinding device, a lower-layer sizing material unwinding device, an extruder, a rolling sizing device, an upper-layer sizing material winding device, a lower-layer sizing material winding device and a parallelism adjusting roller which are sequentially arranged. A winding mechanism; the melt impregnation system is provided with a slit runner and a slit mouth mold with an adjustable interval, and an upper-layer sizing material unwinding device and a lower-layer sizing material unwinding device which are arranged above and below the melt impregnation system ensure that the ultrathin prepreg is smoothly pulled out of the mouth mold, so that the preparation of the ultrathin prepreg is realized.

Description

Technical Field

[0001] The invention relates to the technical field of composite materials, in particular to a molding method of an ultra-thin thermoplastic composite material. Background Art

[0002] Compared with short fiber and long fiber reinforced thermoplastic composites, the mechanical properties of continuous fiber reinforced thermoplastic composites are much higher than those of short fiber and long fiber reinforced thermoplastic composites because the fibers are continuous. Due to the excellent comprehensive performance of continuous fiber reinforced thermoplastic composites, they are widely used in aerospace, equipment manufacturing, rail transportation, new energy vehicles and military industries.

[0003] Chinese invention patent CN114454513A discloses a continuous fiber reinforced thermoplastic resin-based composite material wire forming device, which includes a wire spreading preheating module, a melt impregnation module, and a cooling and winding mechanism. The forming process belongs to melt impregnation, and its difficulty lies in that when preparing ultra-thin prepregs, the fibers are prone to fluffing and it is difficult to bring the floating fibers out of the die, which will eventually lead to production interruption. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a method for preparing an ultra-thin thermoplastic composite material prepreg, the thickness of the prepreg can be highly designed, and at the same time, the problem of frequent production interruptions due to floating fibers in the preparation of prepregs by traditional powder impregnation method, solution impregnation method and melt impregnation method can be avoided.

[0005] The technical solution adopted by the present invention to solve its technical problems is: a molding method of an ultra-thin thermoplastic composite material, including a yarn frame, a fiber positioning device, a yarn spreading positioning observation port, an ultrasonic yarn spreading device, a fiber width setting roller group, an infrared preheating device, a melt impregnation system, an upper layer shaping material unwinding device, a lower layer shaping material unwinding device, an extruder, a roller shaping device, an upper layer shaping material winding device, a lower layer shaping material winding device, a parallelism adjustment roller, and a winding mechanism.

[0006] Furthermore, there are fibers on the creel; the fibers sequentially pass through a fiber positioning device, a yarn spreading positioning observation port, an ultrasonic yarn spreading device, a fiber width setting roller group, an infrared preheating device, a melt impregnation system, a roller pressing shaping device, and are wound up by a winding mechanism after passing through a parallelism adjustment roller; Further, the melt impregnation system is connected to the extruder; Furthermore, the upper shaping material unwinding device has a high temperature resistant shaping material, and the high temperature resistant shaping material sequentially passes through the upper shaping material inlet, the slit die with adjustable spacing, and the upper shaping material winding device; Furthermore, the lower-layer shaping material unwinding device has a high-temperature resistant shaping material, and the high-temperature resistant shaping material sequentially passes through the lower-layer shaping material inlet, the slit die with adjustable spacing, and the lower-layer shaping material winding device; Furthermore, after passing through the slit flow channel, the fiber is sandwiched between the upper and lower molding materials and is pulled out; Furthermore, after the prepreg is pulled out, it passes through a roller shaping device and is cooled and shaped; thereafter, the prepreg and the upper layer shaping material and the lower layer shaping material are separated and rolled up.

[0007] The beneficial effects of the present invention are as follows: the ultra-thin thermoplastic prepreg molding device of the present invention is provided with a fiber positioning device, an ultrasonic yarn spreading device, and a fiber width-fixing roller group, so that the gap between the rollers in the fiber positioning device and the fiber spreading width can be flexibly adjusted; thereby, the fiber content can be adjusted; the fiber content is highly designable; Secondly, since the upper and lower shaping material unwinding devices are provided, the well-impregnated prepreg is wrapped in the middle by the upper and lower high-temperature resistant shaping materials, and the three pass through the slit die at the same time, avoiding the phenomenon of floating fibers generated by the resin-attached fibers passing through the slit die; if floating fibers are generated, they cannot be taken out in time due to the small gap of the slit, and the accumulation of floating fibers eventually leads to the interruption of prepreg production. Therefore, the continuous production of ultra-thin prepreg can be guaranteed by providing the upper and lower shaping material unwinding devices. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 It is an overall schematic diagram.

[0009] Figure 2 It is the main cross-sectional view of the melt impregnation system.

[0010] A yarn rack (1), a fiber positioning device (2), a yarn spreading positioning observation port (3), an ultrasonic yarn spreading device (4), a fiber width setting roller group (5), an infrared preheating device (6), a melt impregnation device (7), a slit flow channel (7-1); an upper layer shaping material inlet (7-2); a lower layer shaping material inlet (7-3); a slit die with adjustable spacing (7-4), an extruder (8), an upper layer shaping material unwinding device (9), a roller shaping device (10), an upper layer shaping material winding device (11), a parallelism adjustment roller (12), a winding mechanism (13), a lower layer shaping material winding device (14), and a lower layer shaping material unwinding device (15). DETAILED DESCRIPTION

[0011] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0012] like Figure 1 and Figure 2As shown, the molding method of an ultra-thin thermoplastic composite material described in the present invention comprises a yarn frame 1, a fiber positioning device 2, a yarn spreading positioning observation port 3, an ultrasonic yarn spreading device 4, a fiber width setting roller group 5, an infrared preheating device 6, a melt impregnation device 7, an extruder 8, an upper layer shaping material unwinding device 9, a roller shaping device 10, an upper layer shaping material winding device 11, a parallelism adjustment roller 12, a winding mechanism 13, a lower layer shaping material winding device 14, and a lower layer shaping material unwinding device 15, which are arranged in sequence.

[0013] The creel 1 has fibers; the fibers sequentially pass through a fiber positioning device 2, a yarn spreading positioning observation port 3, an ultrasonic yarn spreading device 4, a fiber width setting roller group 5, an infrared preheating device 6, a melt impregnation device 7, a roller pressing and shaping device 10, and are wound up by a winding mechanism 15 after passing through a parallelism adjustment roller 12; In the specific application process: The creel 1 is used for unwinding fibers. Specifically, the fibers are one or a mixture of carbon fibers, glass fibers, aramid fibers and basalt fibers. In addition, an automatic unwinding device is installed on the creel, which can self-regulate according to the comprehensive requirements of production speed and fiber tension. The width path of the fibers is set according to the volume content of the fibers. The yarn spreading positioning observation port 3 is used to observe whether the fiber meets the design requirements; The ultrasonic yarn spreading device 4 is used to achieve fiber widening; after being widened, the fiber enters the infrared preheating device 6 for drying and removing the sizing agent.

[0014] The melt impregnation system 7 is connected to an extruder 8, and the extruder 8 provides a plasticized resin matrix to the melt impregnation system 7, wherein the resin matrix is ​​one of PP, PC, PA, PPS and PEEK plastics.

[0015] The upper shaping material unwinding device 9 and the lower shaping material unwinding device 15 are used for unwinding high temperature resistant shaping materials and are provided with a tension control system. The high temperature resistant shaping materials are PI films. The shaping materials enter the melt impregnation system 7 from the upper shaping material inlet 7-2 and the lower shaping material inlet 7-3 respectively. The fibers are impregnated through the slit flow channel 7-1 and then pass between the upper and lower shaping materials. After that, a prepreg of a certain thickness can be prepared through the slit die 7-4 with an adjustable spacing. The thickness of the prepreg can be controlled within the range of 0.05mm-0.1mm. The roller shaping device 10 will be pulled out from the slit die 7-4 for cold pressing and shaping, and then the high temperature resistant shaping material and the prepreg will be separated. The shaping material will be rolled up by the upper shaping material winding device 11 and the lower shaping material winding device 14; finally, the prepreg will be rolled up by the winding mechanism 13.

[0016] The above description is only for the preferred embodiment of the present invention, or is understood as explaining the technical principle 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 changes 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 method for forming an ultra-thin thermoplastic composite material, characterized in that: The invention comprises a yarn frame (1), a fiber positioning device (2), a yarn spreading positioning observation port (3), an ultrasonic yarn spreading device (4), a fiber width setting roller group (5), an infrared preheating device (6), a melt impregnation device (7), an upper-layer shaping material unwinding device (9), a lower-layer shaping material unwinding device (15), an extruder (8), a roller shaping device (10), an upper-layer shaping material winding device (11), a lower-layer shaping material winding device (14), a parallelism adjustment roller (12), and a winding mechanism (13), which are arranged in sequence.

2. The method for forming an ultra-thin thermoplastic composite material according to claim 1, characterized in that: The yarn rack (1) has fibers; the fibers sequentially pass through a fiber positioning device (2), a yarn spreading positioning observation port (3), an ultrasonic yarn spreading device (4), a fiber width setting roller group (5), an infrared preheating device (6), a melt impregnation device (7), a roller pressing shaping device (10), and are wound up by a winding mechanism (13) after passing through a parallelism adjustment roller (12).

3. The method for forming an ultra-thin thermoplastic composite material according to claim 1, characterized in that: The ultrasonic yarn spreading device (4) can make the fibers ultra-thin and wide, and can widen 12K carbon fibers to 25 mm, thus meeting the requirements for preparing ultra-thin prepregs.

4. The method for forming an ultra-thin thermoplastic composite material according to claim 1, characterized in that: The melt impregnation system (7) comprises a slit flow channel (7-1); an upper molding material inlet (7-2); a lower molding material inlet (7-3); and a slit die (7-4) with adjustable spacing. The thickness of the thermoplastic composite material ranges from 0.05 mm to 0.1 mm.

5. The method for forming an ultra-thin thermoplastic composite material according to claim 1, characterized in that: High temperature resistant shaping materials are placed on the upper shaping material winding device (9) and the lower shaping material winding device (15).

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