Production equipment and weaving methods for carbon fiber fabrics and carbon fiber fabrics

Abstract

This invention relates to a carbon fiber fabric production apparatus and weaving method, and to carbon fiber fabrics. The apparatus includes a yarn frame, a yarn collecting plate, a tension adjusting device, and a weaving worktable. The tension adjusting device is connected to a first heating roller and a yarn guide roller assembly. The weaving worktable is connected to a warp feed roller, a stop warp piece, heddles, a reed, a second heating roller, and a winding roller. The carbon fiber fabric production apparatus of this invention, by setting a first heating roller at the inlet of the yarn guide roller assembly, restores the yarn unfolding properties of water-soluble thermoplastic sized carbon fibers that have begun to absorb moisture after long-term storage, thereby improving the weaving performance of the fabric. By setting a second heating roller between the reed and the winding roller of the loom, the fabric thickness can be further controlled, the fabric porosity reduced, and the surface quality of the fabric improved.

Description

Technical Field

[0001] This invention relates to the technical field of high-performance fiber weaving, and more particularly to a combined production equipment and weaving method for carbon fiber fabrics sized with water-soluble thermoplastic sizing agents, specifically to a production apparatus and weaving method for carbon fiber fabrics and carbon fiber fabrics. Background Technology

[0002] In recent years, carbon fiber reinforced thermoplastic composites (CFRTPs) have been widely used in aerospace, military, automotive, and sporting goods industries due to their excellent fatigue resistance and high-temperature resistance. When using carbon fibers to reinforce thermoplastic resins, the performance of the composite material depends not only on the interfacial structure between the carbon fibers and the resin but also on the planar interwoven network within the interwoven fiber prepreg. Using water-soluble thermoplastic sizing agents can effectively improve the interfacial bonding between carbon fibers and thermoplastic resins while avoiding the use of large amounts of organic solvents. However, these sizing agents have strong hygroscopicity after film formation, especially after long-term storage, which weakens the weaving process performance and results in poor fabric appearance quality. This, in turn, affects the interlaminar shear strength and wet retention rate of subsequent composite materials, limiting the application level and scope of carbon fiber reinforced thermoplastic composites as high-performance structural materials.

[0003] Patent CN202111127369.5 discloses a motor-driven vibratory yarn spreading device and method. The device, with adjustable width, allows for smooth spreading of the carbon fiber surface; however, the spreading width is limited, and uneven spreading and gap elimination are not ideal. Patents CN202223318413.3 and CN202222280197.1, among others, propose heating operations to further optimize fiber spreading, but these address the pre-impregnation process rather than the fabric weaving process. Currently, there is no suitable solution for the weaving problems of carbon fiber fabrics sized with water-soluble thermoplastic sizing agents. Summary of the Invention

[0004] The purpose of this invention is to overcome the problems of difficulty in weaving carbon fiber fabrics sized with water-soluble thermoplastic sizing agents, high fabric porosity, and thus affecting the interlaminar shear strength and wet retention rate of subsequent composite materials. This invention provides a production apparatus, weaving method, and application for carbon fiber fabrics. The production apparatus for carbon fiber fabrics, by setting a first heating roller at the inlet of the guide roller group, restores the yarn unfolding property of water-soluble thermoplastic sized carbon fibers that have begun to absorb moisture after long-term storage, thereby improving the weaving performance of the fabric. By setting a second heating roller between the reed and the winding roller of the loom, the fabric thickness can be further controlled, the fabric porosity reduced, and the apparent quality of the fabric improved.

[0005] To achieve the above objectives, the present invention provides a production apparatus for carbon fiber fabrics. This apparatus includes a yarn frame, a yarn collecting plate, a tension adjusting device, and a weaving worktable. The yarn frame is used to convert carbon fiber bobbins into warp yarns; the yarn collecting plate is used to collect the warp yarns; the tension adjusting device is equipped with a first heating roller and a yarn guiding roller group, wherein the warp yarns are first heated by the first heating roller and then spread out by the yarn guiding roller group; the weaving worktable includes a warp feed roller, a warp stop plate, heddles, a reed, a winding roller, and a second heating roller located between the reed and the winding roller. The spread warp yarns enter the weaving worktable to participate in weaving and forming carbon fiber fabrics, wherein the carbon fiber fabrics are second-heated before being wound up by the winding roller.

[0006] A second aspect of the present invention provides a method for weaving carbon fiber fabrics, the method employing the carbon fiber fabric production apparatus described in the present invention, comprising: passing carbon fibers sequentially through a yarn frame, a yarn collecting plate, a first heating roller, a yarn guiding roller group, a warp feed roller, a stop warp plate, heddles, a reed, a second heating roller, a winding section roller, and winding.

[0007] A third aspect of the present invention provides a carbon fiber fabric woven by the weaving method described herein.

[0008] Through the above technical solution, the present invention has the following beneficial effects:

[0009] The carbon fiber fabric production apparatus of the present invention, by setting a first heating roller at the inlet of the yarn guide roller group, restores the yarn unfolding property of water-soluble thermoplastic sized carbon fibers that have begun to absorb moisture after long-term storage, thereby improving the weaving performance of the fabric. By setting a second heating roller between the reed and the winding roller of the loom, the fabric thickness can be further controlled, the fabric porosity can be reduced, and the surface quality of the fabric can be improved.

[0010] This invention provides an innovative weaving method that removes moisture adsorbed in the gaps and voids of reinforcing fibers, increases the sizing agent content, improves processability, and weaves a carbon fiber composite fabric with a more uniform thickness. This solves the current problems of difficult weaving of water-soluble thermoplastic sizing carbon fibers after moisture absorption, high fabric porosity, and thus affecting the interlaminar shear strength and wet retention rate of subsequent composite materials. Attached Figure Description

[0011] Figure 1 It is a production facility for carbon fiber fabrics. Detailed Implementation

[0012] The endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

[0013] This invention provides a production apparatus for carbon fiber fabrics, comprising: a yarn rack, a yarn collecting plate, a tension adjusting device, and a weaving worktable, wherein...

[0014] A yarn frame is used to convert carbon fiber bobbins into warp yarns.

[0015] A yarn collecting plate is used to collect the warp yarns.

[0016] The tension adjustment device is equipped with a first heating roller and a yarn guide roller group, wherein the warp yarn is first heated by the first heating roller and then spread out by the yarn guide roller group;

[0017] The weaving worktable includes a warp feed roller, a stop warp, heddles, a reed, a winding roller, and a second heating roller located between the reed and the winding roller. The unwound warp yarns enter the weaving worktable to participate in weaving and forming carbon fiber fabric. Specifically, they pass sequentially through the warp feed roller, the stop warp, the heddles, the reed, the second heating roller, and the winding roller before being wound up. The carbon fiber fabric undergoes a second heating process before being wound up by the winding roller. It should be noted that this invention does not impose any special requirements on the weaving method of the weaving worktable; existing weaving methods are sufficient, and will not be elaborated upon further in this invention.

[0018] In this invention, the winding roller refers to the roller used to wind up the woven fabric, such as the carbon fiber fabric of this invention. This invention has no special requirements for this roller and can use rollers from the prior art for winding. This invention will not elaborate further on this.

[0019] The present invention provides a first heating roller at the inlet of the yarn guide roller group, which restores the yarn unfolding property of water-soluble thermoplastic sized carbon fibers that have begun to absorb moisture after long-term storage, thereby improving the weaving performance of the fabric. At the same time, the second heating roller located between the reed and the winding roller of the loom can further control the fabric thickness, reduce the fabric porosity, and improve the appearance quality of the fabric.

[0020] In this invention, according to a preferred embodiment, the diameter difference between the first heating roller and the second heating roller is 0-15 mm. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0021] In this invention, according to a preferred embodiment, the diameter of the first heating roller is 15-25 mm, preferably 18-22 mm. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0022] In this invention, according to a preferred embodiment, the diameter of the second heating roller is 20-30 mm, preferably 23-27 mm. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved. This invention provides a weaving method for carbon fiber fabrics, the method comprising: carbon fibers sequentially passing through a yarn frame, a yarn collecting plate, a first heating roller, a yarn guiding roller group, a warp feed roller, a stop warp plate, heddles, a reed, a second heating roller, a winding roller, and winding.

[0023] According to a preferred embodiment of the present invention, the method specifically includes: S1. Hanging carbon fiber bobbins on a yarn rack to convert them into warp yarns;

[0024] S2. Gather the warp yarns pulled out in step S1 using a yarn collecting plate;

[0025] S3. After the warp yarn arranged in step S2 is pressed tightly against the first heating roller for the first heating, softened warp yarn is obtained;

[0026] S4. Use the yarn guide roller group to adjust the tension of the softened warp yarn obtained in step S3 to spread the yarn.

[0027] S5. The softened warp yarns unfolded in step S4 are wound onto the warp feed rollers of the loom and passed sequentially through the stop warp plate, heddle wires and reed to form carbon fiber fabric.

[0028] S6. Before being wound by the winding roller, the carbon fiber fabric is subjected to a second heating roller. It is understood that during the second heating, the surface of the carbon fiber fabric is kept in close contact with the second heating roller. The method of the present invention can improve the weaving performance of the fabric.

[0029] To facilitate weaving, according to a preferred embodiment of the present invention, the number of single filaments in the carbon fiber bundle is 3-24K, preferably 6-12K. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0030] According to a preferred embodiment of the present invention, the temperature difference between the first heating temperature and the second heating temperature is 160-300°C. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0031] According to a preferred embodiment of the present invention, the heating temperature of the first heating roller is 275-305°C, preferably 290-300°C. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0032] According to a preferred embodiment of the present invention, the heating temperature of the second heating roller is 85-115°C, preferably 95-105°C. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved. According to a preferred embodiment of the present invention, in step S4, the average warp tension of the unfolded yarn is 210-230 cN. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0033] According to a preferred embodiment of the present invention, the loom speed of the weaving workbench is 80-120 r / min. By adopting the aforementioned preferred embodiment, the weaving performance of the fabric can be further improved.

[0034] The present invention will be described in detail below through embodiments, but the present invention is not limited thereto.

[0035] To further evaluate the effects of the production equipment and weaving method on the fabric, the fiber spreadability, fabric thickness, and fabric porosity of the examples and comparative examples were evaluated. The specific test methods are as follows:

[0036] 1) Carbon fiber yarn unfolding test

[0037] When the width of the fiber bundle on the first guide roller along the warp traction direction of the loom remains constant during weaving, weaving is stopped, and the spread of the fiber bundle on that guide roller is measured. At the same time, the width of the fiber bundle on the first guide roller through which it passes is also measured, and these are recorded as the width of the carbon fiber bundle after spread and the width before spread, respectively. The steps are repeated for 3 tests to obtain the average width after spread. and the width of the front of the yarn The unfolding rate of the carbon fiber tow can be calculated using the following formula:

[0038]

[0039] 2) Fabric porosity test

[0040] Image-based method: First, a scanner was used to scan the fabric sample surface perpendicularly to eliminate fabric tilt issues caused by human factors. The scanner resolution was set to 600 dpi. Photoshop software was used to smooth and denoise the fabric photos. Simultaneously, equalization was performed to improve contrast and make the photos clearer. After converting the captured fabric images into grayscale images, the image changes in non-porous and porous structures were observed while adjusting the grayscale image threshold, and image segmentation was performed. A 50% threshold was set for image segmentation; grayscale images above the threshold were displayed as black, and those below the threshold were displayed as white, completing the conversion from grayscale image to binary black and white image. The area of ​​black and white regions in the binary black and white image was calculated using a program in Photoshop. Based on the calculated ratio of black to white areas, the porosity of the fabric was calculated.

[0041] 3) Fabric thickness testing

[0042] The thickness of the sample was tested in accordance with the national standard GB / T7689.1-2013 (using a presser foot diameter of 56.43 mm and a pressure of 2.0 kPa).

[0043] The following examples and comparative examples use the same carbon fiber, and the sizing agent for the carbon fiber is HBW02 from Jiangsu Hengbo Composite Materials Co., Ltd.

[0044] Example 1

[0045] The raw material used is 12K carbon fiber, and the weaving method is as follows: Carbon fiber bobbins are hung on a yarn frame and converted into warp yarns, which are then concentrated by a yarn collecting plate; the carbon fiber is wound tightly around the first heated roller (temperature: 290℃, diameter: 18mm) at the entrance of the guide roller assembly; the tension is controlled (215cN) by the guide roller assembly; the carbon fiber is then passed through the stop warp, heddles, and reed, resulting in a weaving unit area mass of 400g / m². 2 Plain weave fabric; the fabric surface is kept in close contact with the second heating roller (temperature: 95℃, diameter: 25mm) set between the reed and the winding roller of the loom, and finally the fabric is wound up (loom speed is 100r / min). It is used for the yarn unfolding test of carbon fiber, the porosity test of fabric and the thickness test of fabric. The specific implementation effect is shown in Table 2.

[0046] Example 2

[0047] Example 2 uses 12K carbon fiber as the raw material, and the weaving method is as follows: Carbon fiber bobbins are hung on a yarn rack and converted into warp yarns, which are then concentrated by a yarn collecting plate; the carbon fiber is wound tightly around the first heating roller (temperature: 295℃, diameter: 20mm) at the entrance of the guide roller group; the tension is controlled (215cN) by the guide roller group; the carbon fiber is passed through the stop warp, heddles, and reed, resulting in a weaving unit area mass of 400g / m². 2 Plain weave fabric; the fabric surface is kept in close contact with the second heating roller (temperature: 99℃, diameter: 23mm) set between the reed and the winding roller of the loom, and finally the fabric is wound up (loom speed is 100r / min). It is used for the yarn unfolding test of carbon fiber, the porosity test of fabric and the thickness test of fabric. The specific implementation effect is shown in Table 2.

[0048] Example 3

[0049] Example 3 uses 12K carbon fiber as the raw material, and the weaving method is as follows: Carbon fiber bobbins are hung on a yarn rack and converted into warp yarns, which are then concentrated by a yarn collecting plate; the carbon fiber is wound tightly around the first heating roller (temperature: 300℃, diameter: 22mm) at the entrance of the guide roller group; the tension (215cN) is controlled by the guide roller group; the carbon fiber is passed through the stop warp, heddles, and reed, resulting in a weaving unit area mass of 400g / m². 2 Plain weave fabric; the fabric surface is kept in close contact with the second heating roller (temperature: 102℃, diameter: 27mm) set between the reed and the winding roller of the loom, and finally the fabric is wound up (loom speed is 100r / min). It is applied to the yarn unfolding test of carbon fiber, the porosity test of fabric and the thickness test of fabric. The specific implementation effect is shown in Table 2.

[0050] Example 4

[0051] All are the same as in Example 1. The setting conditions of the heating roller are shown in Table 1. The difference is that the diameter of the first heating roller is 25mm, which is not within the preferred range of this application. The specific implementation effect is shown in Table 2.

[0052] Example 5

[0053] All are the same as in Example 1. The setting conditions for the heating roller are shown in Table 1. The difference is that the diameter of the second heating roller is 30mm. The specific implementation effect is shown in Table 2.

[0054] Example 6

[0055] All are the same as in Example 1. The setting conditions of the heating roller are shown in Table 1. The difference is that the temperature of the first heating roller is 275°C. The specific implementation effect is shown in Table 2.

[0056] Example 7

[0057] All are the same as in Example 1. The setting conditions for the heating roller are shown in Table 1. The difference is that the temperature of the second heating roller is 85°C. The specific implementation effect is shown in Table 2.

[0058] Comparative Example 1

[0059] All conditions are the same as in Example 1, except that the production device is only equipped with the first heating roller. The specific implementation effect is shown in Table 2.

[0060] Comparative Example 2

[0061] All conditions are the same as in Example 1, except that the production device is not equipped with any heating rollers. See Table 2 for specific implementation results.

[0062] Table 1. Setting of heating rollers during the weaving process in each embodiment

[0063]

[0064] Table 2. Specific Characteristic Indicators

[0065] Fiber unfolding rate (%) Fabric thickness (mm) Porosity (%) of the fabric Example 1 59.96 0.512 2.75 Example 2 60.84 0.511 2.74 Example 3 61.30 0.511 2.72 Example 4 57.98 0.517 2.86 Example 5 58.63 0.515 2.84 Example 6 52.38 0.561 2.98 Example 7 52.92 0.557 2.96 Comparative Example 1 49.81 0.570 3.08 Comparative Example 2 40.56 0.578 3.65

[0066] The preferred embodiments of the present invention have been described in detail above; however, the present invention is not limited thereto. Within the scope of the inventive concept, various simple modifications can be made to the technical solutions of the present invention, including combinations of various technical features in any other suitable manner. These simple modifications and combinations should also be considered as the content disclosed in the present invention and are all within the protection scope of the present invention.

Claims

1. A production apparatus for carbon fiber fabrics, characterized in that, The production facility includes: Yarn frame, used to convert water-soluble thermoplastic sized carbon fiber cone yarns into warp yarns; A yarn collecting plate is used to collect the warp yarns. The tension adjustment device is equipped with a first heating roller and a yarn guide roller group, wherein the warp yarn is first heated by the first heating roller and then spread out by the yarn guide roller group; The weaving worktable includes a reed, a winding roller, and a second heating roller located between the reed and the winding roller. The warp yarns after being unrolled enter the weaving worktable to participate in weaving and forming carbon fiber fabric. The carbon fiber fabric is subjected to a second heating before being wound up by the winding roller. The diameter of the first heating roller is 15-25mm, and the diameter of the second heating roller is 20-30mm; The temperature of the first heating is 275-305℃, and the temperature of the second heating is 85-115℃.

2. The production apparatus according to claim 1, wherein, The diameter difference between the first heating roller and the second heating roller is 0-15mm.

3. The production apparatus according to claim 1, wherein, The diameter of the first heating roller is 18-22 mm; and / or The diameter of the second heating roller is 23-27 mm.

4. A method for weaving carbon fiber fabrics, characterized in that, The weaving method includes: Water-soluble thermoplastic sized carbon fiber is passed sequentially through a yarn frame, a yarn collecting plate, a first heating roller, a yarn guiding roller group, a steel reed, a second heating roller, and a winding roller. The method specifically includes: S1. Hang the carbon fiber bobbins on the yarn rack to convert them into warp yarns; S2. Gather the warp yarns pulled out in step S1 using a yarn collecting plate; S3. After the warp yarn arranged in step S2 is pressed tightly against the first heating roller for the first heating, softened warp yarn is obtained; S4. Use the yarn guide roller group to spread the softened warp yarn obtained in step S3. S5. The softened warp yarns unfolded in step S4 are fed into the weaving workbench to participate in weaving and form carbon fiber fabric. S6. The carbon fiber fabric is subjected to a second heating roller before being wound up by the winding section roller; The diameter of the first heating roller is 15-25mm, and the diameter of the second heating roller is 20-30mm; The temperature of the first heating is 275-305℃, and the temperature of the second heating is 85-115℃.

5. The weaving method according to claim 4, wherein, The number of single filaments in carbon fiber is 3-24K.

6. The weaving method according to claim 5, wherein, The number of single filaments in carbon fiber is 6-12K.

7. The weaving method according to claim 4 or 5, wherein, The temperature difference between the first heating and the second heating is 160-300℃.

8. The weaving method according to claim 4 or 5, wherein, The temperature of the first heating is 290-300℃; and / or The second heating temperature is 95-105℃.

9. The weaving method according to claim 4 or 5, wherein, In step S4, the average warp tension of the unfolded yarn is 210-230 cN.

10. The weaving method according to claim 4 or 5, wherein, The loom speed of the weaving workbench is 80-120 r / min.

11. A carbon fiber fabric woven by the weaving method according to any one of claims 4-10.

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