A device for correcting the deviation of continuous fiber reinforced resin prepreg yarn

Abstract

The application belongs to the field of composite material additive manufacturing, and discloses a deviation rectifying device for preparing continuous fiber reinforced resin prepreg yarn, which comprises a deviation rectifying module and a tension adjusting module. In view of the problem of fiber eccentricity in the prepreg yarn caused by the large angle between the dry yarn and the central axis during the preparation of the continuous fiber prepreg yarn, a yarn unwinding device is designed, in which the raw material roller and the dry yarn are reversely followed, so that the angle between the fiber dry yarn and the central axis of the device is less than 20°. In view of the problem that the fiber yarn is pulled off due to excessive tension or the fiber / resin impregnation is insufficient due to too small tension during the yarn preparation process, a tension adjusting device with tension feedback is designed to quantitatively adjust the tension during the yarn preparation process, so that the tension is controllable. Through the cooperation of the deviation rectifying module and the tension adjusting module, the angle between the fiber dry yarn and the device axis is controlled within a small range, and at the same time, the quantitative adjustment of the fiber yarn tension is realized, so that the uniformity of the fiber distribution in the prepared prepreg yarn and the mechanical properties are finally improved.

Description

Technical Field

[0001] The invention belongs to the field of composite material additive manufacturing and relates to a deviation-correcting device for preparing continuous fiber-reinforced resin prepreg yarns. Background Art

[0002] Continuous fiber-reinforced resin additive manufacturing (AM) technology has been widely used in the automotive and sporting goods industries in recent years due to its high flexibility and the absence of mold manufacturing requirements. Continuous fiber prepregs are an important raw material for continuous fiber-reinforced resin 3D printing. The degree of fiber / resin impregnation determines the interfacial bonding properties of the printed component, and the uniformity of the fiber distribution within the prepreg determines the smoothness of the printing process. For example, uneven fiber distribution can lead to uneven deposition, clogging, and poor interlayer bonding during the printing process. However, existing continuous fiber prepreg preparation methods mostly use an impregnation mold to ensure the degree of fiber / resin impregnation and fiber distribution uniformity. However, this does not take into account that during the spinning process, the dry fiber filaments on the raw material roll are not always wound around the center of the raw material roll. Therefore, as the spinning process progresses, the dry fiber filaments on the raw material roll will deviate significantly from the axis, resulting in fiber eccentricity in the prepared prepreg. This can also cause unstable tension during the spinning process, thus affecting the degree of fiber / resin impregnation. Therefore, it is necessary to develop a fiber correction device with tension control function to always ensure that the angle between the fiber dry yarn and the axis is in a small range during the silk making process, so as to solve the problems of fiber eccentricity in prepreg yarn and sudden changes in tension during the silk making process.

[0003] To increase the degree of fiber resin / impregnation, patent CN111186138A uses a tensioning roller to increase the pretension during fiber filament preparation. This increases the external force applied to the fiber filaments during impregnation in the flow channel by increasing the tension. However, in its pursuit of increased tension, this patent overlooks the fact that during the filament production process, the dry filaments are not concentrated on the central axis of the fiber roller during unwinding. This leads to a large deviation between the dry filaments and the impregnation axis, resulting in uneven fiber distribution in the prepared prepreg. Patent CN114179251A improves the fiber dry filament feeding module based on the above patent, using a motor-driven rubber wheel friction method to ensure that the fiber filaments are in the axial position. However, this ignores the strong wear resistance of fibers. When the dry filaments rub against the rubber wheels for a long time, a gap will be worn between the rubber wheels, making the tension adjustment mechanism ineffective. Therefore, it is necessary to comprehensively consider the requirements of continuous fiber prepreg performance for tension adjustment, as well as the requirements of fiber filament distribution uniformity for dry filament unwinding tension stability and the angle between the fiber dry filaments and the axis, to develop a deviation correction device that can adjust the tension in real time and ensure a small angle between the fiber dry filaments and the central axis. Summary of the Invention

[0004] The present invention provides a deviation-correcting device for preparing continuous fiber-reinforced resin prepreg yarns, which mainly comprises a raw material roller and a reeling device that moves in opposite directions with the fiber dry yarns. When the fiber dry yarns on the raw material roller deviate upward, they will hit the upper limit switch, and the raw material roller will move downward, and vice versa. By controlling the spacing between the left and right limit switches, the angle between the fiber dry yarns and the central axis is kept in a smaller range, thereby solving the problem of fiber eccentricity in the prepared prepreg yarns. In addition, a tension adjustment device with tension feedback is designed to quantitatively adjust the tension in the yarn-making process, thereby solving the problem of fiber yarns being broken due to excessive tension or insufficient fiber / resin impregnation due to too little tension, thereby significantly improving the mechanical properties of the prepreg yarns.

[0005] The technical solution of the present invention:

[0006] A deviation-correcting device for preparing continuous fiber-reinforced thermoplastic resin prepreg yarns comprises a deviation-correcting module A and a tension-adjusting module B. A raw material roller A9 in the deviation-correcting module A swings back and forth between two limit switches to achieve the deviation-correcting function. The tension-adjusting module B cooperates with the tension roller via a tension sensor B13 to achieve accurate adjustment of the tension during the prepreg preparation process.

[0007] The correction module A includes a bracket A1, a linear module A2, a slider A3, a connecting plate A4, an upper positioning block A5, an upper support plate A6, an upper damper A7, an upper support shaft A8, a raw material roller A9, a lower support shaft A10, a motor A11, a lower positioning block A12, a lower support plate A13, a lower damper A14, a base A15, an upper moving block A16, an upper limit switch A17, an upper limit shaft A18, a lower moving block A19, a lower limit switch A20, a lower limit shaft A21 and a base plate A22; The linear module A2 is fixed on the bracket A1, the slider A3 is fixed on the linear module A2 and can move up and down, and the connecting plate A4 is fixed on the slider A3 to maintain the same linear motion as the slider A3; the upper positioning block A5 is fixed on the upper end of the connecting plate A4, and the upper support plate A6 is fixed on the lower end of the upper positioning block A5 to support the raw material roller A9; one end of the upper damper A7 is connected to the upper support plate A6, and the other end is connected to the upper support shaft A8. By adjusting the resistance of the upper damper A7, the torque of the raw material roller A9 can be controlled. The upper end of the raw material roller A9 is connected to the upper support shaft A8, and the lower end is connected to the lower support shaft A10; the motor A11 is fixed to the lower end of the linear module A2, and the movement direction of the slider A3 can be adjusted by controlling the rotation direction of the motor A11; the lower positioning block A12 is fixed on the connecting plate A4, and the lower support plate A13 is fixed to the upper end of the lower positioning block A12 to support the raw material roller A9; one end of the lower damper A14 is connected to the lower support plate A13, and the other end is connected to the lower support shaft A10, and the damper A14 can be adjusted by adjusting the damping force. The torque of the raw material roller A9 is controlled by the force; the base A15 is fixed on the bottom plate A22, and the upper moving block A16 is fixed in the upper rectangular groove of the base A15 and can move up and down; the upper limit switch A17 is fixed on the upper moving block A16, and the upper limit shaft A18 is fixed on the upper limit switch A17; the lower moving block A19 is fixed in the lower rectangular groove of the base A15 and can move up and down; the lower limit switch A20 is fixed on the lower moving block A19, and the lower limit shaft A21 is welded to the lower limit switch A20;

[0008] The tension adjustment module B includes an optical axis module B1, a roller bracket B2, a ceramic ring bracket B3, a right ceramic ring B4, a left ceramic ring B5, a first tension roller B6, an upper fixed shaft B7, a screw B8, a second tension roller B9, a lower fixed shaft B10, an optical axis slider B11, a tension sensor bracket B12 and a tension sensor B13; the optical axis module B1 is fixed on the base plate A22, the roller bracket B2 is fixed on the right end of the optical axis module B1, the ceramic ring bracket B3 is fixed on the roller bracket B2, the right ceramic ring B4 and the left ceramic ring B5 are fixed on the bottom plate A22, and the tension adjustment module B includes an optical axis module B1, a roller bracket B2, a ceramic ring bracket B3, a right ceramic ring B4 and a left ceramic ring B5. Ying is installed on both sides of the ceramic ring bracket B3, the first tension roller B6 is fixed to the front end of the roller bracket B2 by the upper fixed shaft B7, the optical axis slider B11 is installed on the optical axis module B1 through clearance fit, and the screw B8 controls the movement of the optical axis slider B11 by tightening it. The second tension roller B9 is fixed to the front end of the optical axis slider B11 by the lower fixed shaft B10 through a threaded connection, the tension sensor bracket B12 is fixed on the base plate A22, and the tension sensor B13 is fixed to the tension sensor bracket B12 by screws, which can test the tension changes in real time.

[0009] The raw material roller A9 moves up and down with the rotation of the motor A11. When the raw material roller A9 moves upward, if the dry fiber filaments thereon hit the upper limit shaft A18, it will trigger the designation and feedback to the motor A11, the motor A11 will rotate in the opposite direction, and the raw material roller A9 moves downward; similarly, when the dry fiber filaments hit the lower limit shaft A21 again, it will trigger the instruction feedback to the motor A11 to make the motor A11 rotate in the opposite direction, thereby realizing the upward movement of the raw material roller A9; in this way, it is ensured that the dry fiber filaments are always between the upper limit switch A17 and the lower limit switch A20, thereby ensuring that the dry fiber filaments on the raw material roller A9 maintain a small angle with the axis.

[0010] During the silk-making process, in order to avoid the problem of the dry silk becoming loose during the unwinding process due to the rear-end silk-making drag force being much greater than the damper resistance, and also to avoid the problem of the fiber being tightened and damaged due to the drag force being much smaller than the damper resistance, the drag force F1, the damper resistance F2 and the fiber's own tension F3 need to satisfy the following conditions: 0.5F3≤F1-F2≤1.5F3.

[0011] When the fiber dry filaments enter the right ceramic ring B4, there will be a certain angle between them and the axis of the right ceramic ring B4. Therefore, the inner surface roughness of the right ceramic ring B4 needs to be Ra1.6 to avoid scratching the fiber dry filaments. At the same time, the entrance of the right ceramic ring B4 needs to be made into a bell mouth to reduce the friction of the fiber dry filaments when entering the right ceramic ring B4. In addition, the lower end of the inner diameter of the right ceramic ring B4 needs to be flush with the upper surface of the first tension roller B6 to ensure that the wire material bypasses the first tension roller B6.

[0012] The distance between the upper limit switch A17 and the lower limit switch A20 is adjustable to ensure constant tension during the silk making process. The distance L1 between the upper limit switch A17 and the lower limit switch A20, the length L2 of the raw material roller A9, and the distance L3 from the center of the raw material roller A9 to any limit switch must meet the following conditions:

[0013] .

[0014] The tension sensor B13 has a small force measurement range, so it can accurately measure the changes in tension during the silk making process. The second tension roller B9 slides up and down driven by the optical axis slider B11, and adjusts the position of the optical axis slider B11 according to the tension value measured by the tension sensor B13, thereby achieving tension adjustment.

[0015] The beneficial effects of the present invention are as follows: through the coordinated work of the deviation correction module and the tension adjustment module, the problem of tension fluctuation in the silk-making process caused by unstable unwinding of fiber dry yarn during the preparation of prepreg yarn is improved, and the problem of unstable size and performance of prepreg yarn caused by unstable tension is solved. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic diagram of the overall structure of a deviation-correcting device for preparing continuous fiber-reinforced thermoplastic resin prepreg yarns according to the present invention, which is suitable for tension adjustment and deviation correction during the preparation process of continuous fiber-reinforced thermoplastic resin prepreg yarns;

[0017] Figure 2 This is a schematic diagram of the structure of a correction module of a correction device for preparing continuous fiber reinforced thermoplastic resin prepreg yarns according to the present invention from one perspective, which is used for correcting the dry yarn in the preparation of prepreg yarns;

[0018] Figure 3 This is a schematic diagram of a tension adjustment module of a deviation correction device for preparing continuous fiber reinforced thermoplastic resin prepreg yarns according to the present invention, which is used for deviation correction of dry yarns in the preparation of prepreg yarns;

[0019] Figure 4 This is a schematic diagram of the structure of a correction module of a correction device for preparing continuous fiber reinforced thermoplastic resin prepreg yarns according to the present invention from one perspective, which is used for correcting the dry yarn in the preparation of prepreg yarns;

[0020] Figure 5 The arrangement and stress conditions of dry fiber yarns in a deviation-correcting device prepared from a continuous fiber-reinforced thermoplastic resin prepreg according to the present invention;

[0021] Figure 6 A schematic diagram of the distance between the dry fiber and the limit switch in a deviation-correcting device prepared from a continuous fiber-reinforced thermoplastic resin prepreg according to the present invention;

[0022] In the figure: A correction module, A1 bracket, A2 linear module, A3 slider, A4 connecting plate, A5 upper positioning block, A6 upper support plate, A7 upper damper, A8 upper support shaft, A9 raw material roller, A10 lower support shaft A11 motor, A12 lower positioning block, A13 lower support plate, A14 lower damper, A15 base, A16 upper moving block, A17 upper limit switch, A18 upper limit shaft, A19 lower moving block, A20 lower limit switch, A21 lower limit shaft, A22 bottom plate, B tension adjustment module, B1 optical axis module, B2 roller bracket, B3 ceramic ring bracket, B4 right ceramic ring, B5 left ceramic ring, B6 first tension roller, B7 upper fixed shaft, B8 screw, B9 second tension roller, B10 lower fixed shaft, B11 optical axis slider. DETAILED DESCRIPTION

[0023] The specific implementation of the present invention is further described below in conjunction with the accompanying drawings and technical solutions.

[0024] Example 1

[0025] Taking the preparation of continuous fiber reinforced thermoplastic resin prepreg as an example, 1K continuous fiber dry yarn is selected. According to the material properties, appropriate process parameters are selected to carry out this example: the resistance provided by the damper is F2, and the fiber dry yarn breaking force is 150N.

[0026] A deviation-correcting device for preparing continuous fiber prepreg yarn with a tension-adjusting function, comprising a deviation-correcting module and a tension-adjusting module;

[0027] The correction module A includes a bracket A1, a linear module A2, a slider A3, a connecting plate A4, an upper positioning block A5, an upper support plate A6, an upper damper A7, an upper support shaft A8, a raw material roller A9, a lower support shaft A10, a motor A11, a lower positioning block A12, a lower support plate A13, a lower damper A14, a base A15, an upper moving block A16, an upper limit switch A17, an upper limit shaft A18, a lower moving block A19, and a lower limit switch A20; the linear module A2 is fixed to the bracket A1 by screws The slider A3 is fixed on the linear module A2 and can move up and down. The connecting plate A4 is fixed on the slider A3 to keep the same linear motion as the slider A3. The upper positioning block A5 is fixed to the upper end of the connecting plate A4 by screws. The upper support plate A6 is fixed to the lower end of the upper positioning block A5 to support the raw material roller A9. One end of the upper damper A7 is connected to the upper support plate A6, and the other end is connected to the upper support shaft A8. The torque of the raw material roller A9 can be controlled by adjusting the resistance of the upper damper A7. The upper end of the raw material roller A9 is connected to the upper support plate A6. The lower end of the lower damper A14 is connected to the lower support shaft A13, and the lower end of the lower damper A14 is connected to the lower support shaft A10. The motor A11 is fixed to the lower end of the linear module A2. The movement direction of the slider A3 can be adjusted by controlling the rotation direction of the motor. The lower positioning block A12 is fixed to the lower end of the connecting plate A4 by screws. The lower support plate A13 is fixed to the upper end of the lower positioning block A12 to support the raw material roller A9. One end of the lower damper A14 is connected to the lower support plate A13, and the other end is connected to the lower support shaft A10. The resistance of the lower damper A14 can be adjusted to achieve the effect of adjusting the raw material roller. A9 torque control, base A15 is fixed on bottom plate A22, upper moving block A16 is fixed in the upper rectangular groove of base A15 by screws and can move up and down, upper limit switch A17 is fixed on upper moving block A16 by screws, upper limit shaft A18 is welded on upper limit switch A17, lower moving block A19 is fixed in the lower rectangular groove of base A15 by screws and can move up and down, lower limit switch A20 is fixed on lower moving block A19, lower limit shaft A21 is welded on lower limit switch A20.

[0028] The tension adjustment module B includes an optical axis module B1, a roller bracket B2, a ceramic ring bracket B3, a right ceramic ring B4, a left ceramic ring B5, a first tension roller B6, an upper fixed shaft B7, a screw B8, a second tension roller B9, a lower fixed shaft B10, and an optical axis slider B11; the optical axis module B1 is fixed on the base plate A22, the roller bracket B2 is fixed to the right end of the optical axis module B1 by screws, the ceramic ring bracket B3 is fixed to the roller bracket B2, and the right ceramic ring B4 and the left ceramic ring B5 are interference-mounted on both sides of the ceramic ring bracket B3. On the side, the first tension roller B6 is fixed to the front end of the roller bracket B2 by the upper fixed shaft B7 through a threaded connection, the optical axis slider B11 is installed on the optical axis module B1 through clearance fit, and the screw B8 can control the movement of the optical axis slider B11 by loosening or tightening it. The second tension roller B9 is fixed to the front end of the optical axis slider B11 by the lower fixed shaft B10 through a threaded connection, the tension sensor bracket B12 is fixed on the base plate A22, and the tension sensor B13 is fixed to the tension sensor bracket B12 by screws, which can test the tension changes in real time.

[0029] Before the experiment, the two limit switches were adjusted to an appropriate distance, ensuring that the angle between the fiber strands at all locations on the raw material roller and the limit axis on the limit switches was less than 10°. The fiber strands were then passed through two ceramic rings, the top of the first tension roller, the bottom of the second tension roller, the top of the right wheel of the tension tester, the bottom of the middle wheel of the tension tester, and the top of the left wheel of the tension tester. The strands were then arranged. During silk production, after connecting to the subsequent winding device, the tension can be directly read using a tension sensor. By comparing the difference between the drag force F3 and the damper resistance F2 with the fiber breaking force, the second tension roller is moved up or down. If F3-F2 < 75N, the second tension roller is moved downward to increase the fiber tension. If F3-F2 > 225N, the second tension roller is adjusted downward to reduce the fiber tension.

[0030] The present invention designs a dry fiber roller follow-up unwinding device, which enables the fiber dry fibers on the dry fiber roller to always move between two limit switches, ensuring that the dry fibers are always in the axial position during the preparation process, solving the problem of unstable tension in the silk-making process; in addition, a tension adjustment device with tension feedback is designed to quantitatively adjust the tension in the silk-making process, solving the problem of fiber fibers being broken due to excessive tension or insufficient fiber / resin impregnation due to too little tension, thereby significantly improving the mechanical properties of the prepreg.

Claims

1. A deviation-correcting device for preparing continuous fiber-reinforced resin prepreg, characterized in that: The deviation correction device includes a deviation correction module (A) and a tension adjustment module (B); The correction module (A) includes a bracket (A1), a linear module (A2), a slider (A3), a connecting plate (A4), an upper positioning block (A5), an upper support plate (A6), an upper damper (A7), an upper support shaft (A8), a raw material roller (A9), a lower support shaft (A10), a motor (A11), a lower positioning block (A12), a lower support plate (A13), a lower damper (A14), a base (A15), an upper moving block (A16), an upper limit switch (A17), an upper limit shaft (A18), a lower moving block (A19), a lower limit switch (A20), and a lower limit shaft (A21 ) and base plate (A22); the linear module (A2) is fixed on the bracket (A1), the slider (A3) is fixed on the linear module (A2) and can move up and down, the connecting plate (A4) is fixed on the slider (A3) and maintains the same linear motion as the slider (A3); the upper positioning block (A5) is fixed on the upper end of the connecting plate (A4), and the upper support plate (A6) is fixed on the lower end of the upper positioning block (A5) to support the raw material roller (A9); one end of the upper damper (A7) is connected to the upper support plate (A6), and the other end is connected to the upper support shaft (A8). By adjusting the resistance of the upper damper (A7), the raw material roller can be adjusted. (A9) torque control; the upper end of the raw material roller (A9) is connected to the upper support shaft (A8), and the lower end is connected to the lower support shaft (A10); the motor (A11) is fixed to the lower end of the linear module (A2), and the movement direction of the slider (A3) can be adjusted by controlling the rotation direction of the motor (A11); the lower positioning block (A12) is fixed on the connecting plate (A4), and the lower support plate (A13) is fixed on the upper end of the lower positioning block (A12) to support the raw material roller (A9); one end of the lower damper (A14) is connected to the lower support plate (A13), and the other end is connected to the lower support shaft (A10). By adjusting the lower damper ( The torque of the raw material roller (A9) is controlled by the resistance of the roller (A14); the base (A15) is fixed on the bottom plate (A22); the upper moving block (A16) is fixed in the upper rectangular groove of the base (A15) and can move up and down; the upper limit switch (A17) is fixed on the upper moving block (A16); the upper limit shaft (A18) is fixed on the upper limit switch (A17); the lower moving block (A19) is fixed in the lower rectangular groove of the base (A15) and can move up and down; the lower limit switch (A20) is fixed on the lower moving block (A19), and the lower limit shaft (A21) is welded to the lower limit switch (A20); The tension adjustment module (B) comprises an optical axis module (B1), a roller bracket (B2), a ceramic ring bracket (B3), a right ceramic ring (B4), a left ceramic ring (B5), a first tension roller (B6), an upper fixed shaft (B7), a screw (B8), a second tension roller (B9), a lower fixed shaft (B10), an optical axis slider (B11), a tension sensor bracket (B12) and a tension sensor (B13); the optical axis module (B1) is fixed on the base plate (A22), the roller bracket (B2) is fixed on the right end of the optical axis module (B1), the ceramic ring bracket (B3) is fixed on the roller bracket (B2), the right ceramic ring (B4) and the left ceramic ring (B5) are fixed on the bottom plate (A22), and the second tension roller (B9) and the lower fixed shaft (B10) are fixed on the bottom plate (A22). The ceramic ring (B5) is interference-fitted on both sides of the ceramic ring bracket (B3). The first tension roller (B6) is fixed to the front end of the roller bracket (B2) by the upper fixed shaft (B7). The optical axis slider (B11) is installed on the optical axis module (B1) through clearance fit. The screw (B8) controls the movement of the optical axis slider (B11) by tightening it. The second tension roller (B9) is fixed to the front end of the optical axis slider (B11) by the lower fixed shaft (B10) through threaded connection. The tension sensor bracket (B12) is fixed to the base plate (A22). The tension sensor (B13) is fixed to the tension sensor bracket (B12) by screws, which can test the tension change in real time. The distance between the upper limit switch (A17) and the lower limit switch (A20) is adjustable to ensure constant tension during the silk making process. The distance L1 between the upper limit switch (A17) and the lower limit switch (A20), the length L2 of the raw material roller (A9) and the distance L3 from the center of the raw material roller (A9) to any limit switch must meet the following requirements: .

2. The correction device according to claim 1, characterized in that: The raw material roller (A9) moves up and down as the motor (A11) rotates. When the raw material roller (A9) moves upward, if the dry fiber filaments thereon hit the upper limit shaft (A18), it will trigger a command and feedback to the motor (A11), the motor (A11) rotates in the opposite direction, and the raw material roller (A9) moves downward. Similarly, when the dry fiber filaments hit the lower limit shaft (A21) again, it will trigger a command feedback to the motor (A11) to make the motor (A11) rotate in the opposite direction, thereby realizing the upward movement of the raw material roller (A9).

3. The deviation correcting device according to claim 1, characterized in that: The drag force F1, the damper resistance F2 and the fiber's own tension F3 need to satisfy the following relationship: 0.5F3≤F1-F2≤1.5F3.

4. The deviation correction device according to claim 2, characterized in that: When the fiber dry filaments enter the right ceramic ring (B4), they will have a certain angle with the axis of the right ceramic ring (B4). The inner surface roughness of the right ceramic ring (B4) needs to be Ra1.

6. At the same time, the entrance of the right ceramic ring (B4) needs to be made into a bell mouth to reduce the friction of the fiber dry filaments when entering the right ceramic ring (B4); in addition, the lower end of the inner diameter of the right ceramic ring (B4) needs to be flush with the upper surface of the first tension roller (B6) to ensure that the wire material bypasses the first tension roller (B6).

5. The deviation correcting device according to claim 1, characterized in that: The tension sensor (B13) is used to accurately measure the change in tension during the silk making process. The second tension roller (B9) slides up and down under the drive of the optical axis slider (B11), and the position of the optical axis slider (B11) is adjusted according to the tension value measured by the tension sensor (B13), thereby achieving tension adjustment.

Images