Carbon fiber wire harness cutting wire and preparation method thereof

Abstract

The invention relates to the field of hard and brittle material cutting tools, in particular to a carbon fiber wire harness cutting wire which comprises a base material composed of a plurality of wire harnesses formed by twisting carbon fiber monofilaments with the surfaces coated with metal layers. And the abrasive coating coats the outer part of the base material, and abrasive particles are embedded in the abrasive coating. The carbon fibers with smaller diameter and higher tensile strength are adopted as the base material, the cutting speed higher than that of steel wires with the same diameter can be adopted, the carbon fibers with the smaller diameter can be adopted for cutting under the requirement for the same tension, the carbon fibers are low in density, the mass of the carbon fibers with the same size is far smaller than that of tungsten filaments, and the cost is greatly reduced. A metal layer with a certain thickness is arranged on the surface of the carbon fiber monofilament, and the metal layer has good plastic deformation capacity, so that the carbon fiber monofilament can be twisted into a rope bundle, the monofilament is prevented from being broken due to uneven stress, and the high strength of the carbon fiber cutting filament is kept. And abrasive particles directly participate in cutting, so that the service life of the cutting wire is effectively prolonged.

Description

Technical Field

[0001] The invention relates to the field of hard and brittle material cutting and processing tools, and in particular to a carbon fiber wire harness electroplated with composite diamond cutting wire. Background Art

[0002] Electroplated diamond wire is mainly used for cutting hard and brittle materials such as photovoltaic crystalline silicon. As an important consumable equipment for photovoltaic silicon wafers, this product can cut single crystal silicon rods into silicon wafers by adapting to customers' various types of silicon wafer cutting machines and cutting processes.

[0003] Electroplated diamond wire is mainly composed of three parts: busbar, metal nickel layer and diamond particles. The busbar is used as the bearing matrix, diamond particles are used as abrasive tools, and the metal coating is used as a binder to consolidate the diamond particles on the busbar. Diamond wire thinning is an important part of "cost reduction and efficiency improvement" in the photovoltaic industry, but at the same time, the smaller wire diameter also puts higher requirements on the busbar strength. At present, the diamond wire used in large quantities in the industry is made of high-carbon steel wire as the matrix, but the wire diameter and tensile strength of the steel wire are difficult to improve. Therefore, tungsten diamond wire may become the preferred replacement for diamond wire due to its higher strength at the same wire diameter.

[0004] However, the disadvantages of tungsten wire are: first, the price of tungsten is higher than that of iron, and the price of tungsten wire of the same length is several times that of steel wire; second, the winding length of tungsten wire is at most 100km, while steel wire can reach 300km, so the cost of transportation and use is also higher than that of steel wire; third, the current yield rate of tungsten wire mother wire (similar to the yield level of wire drawing) is also lower, which increases the cost of tungsten wire. The price of tungsten wire diamond wire is the core factor affecting its cutting economy, but tungsten wire is subject to cost and size restrictions, so it is particularly important to find new diamond wire materials with better performance and thinner wire diameter.

[0005] Carbon fiber is a microcrystalline carbon material with a carbon content of more than 90%. Its diameter is usually 6-8μm, which is one-tenth of an adult hair. It has high axial strength and low density. It is light in weight, has high breaking strength (2-7GPa), high tensile modulus (200-500GPa), good electrical conductivity, and low thermal conductivity. Carbon fiber is the preferred choice for composite material reinforcement phase due to its excellent mechanical properties: high tensile strength and elastic modulus; physical properties: low density, small thermal expansion coefficient, good electrical and thermal conductivity, and good electromagnetic shielding; chemical stability: no creep, good fatigue resistance, ultra-high temperature resistance in non-oxidizing environment, and good corrosion resistance. The specific strength and specific modulus of carbon fiber reinforced epoxy resin composite materials are the highest among existing engineering materials, so carbon fiber is expected to become the substrate for the next generation of cutting diamond wire.

[0006] However, there are the following disadvantages when using carbon fiber as cutting wire: 1. There is a certain inverse relationship between the tensile strength and diameter of carbon fiber monofilaments. The thicker the diameter, the lower the tensile strength. The diameter of the monofilament carbon fiber currently used is generally within 8μm. Because the monofilament diameter is too thin and the microscopic breaking force is too small, it cannot be directly used as a cutting wire matrix; 2. If the monofilament fibers of the multifilament single bundle are not treated, the monofilaments will interact with each other during cutting, causing the monofilaments to break, resulting in a decrease in the overall tensile strength of the cutting wire; 3. If the carbon fiber is coated with resin glue, the combination of the resin and the carbon fiber is not strong. When the force is applied during the cutting process, the monofilaments in the bundle will still move relative to each other, causing the coating to peel off. 4. Because the failure strain of carbon fiber is very small when it is stressed, it is a brittle material, and it has a high modulus and a large rebound. Therefore, carbon fiber cannot be bundled using the twisting rope process like traditional steel wire. How to effectively bundle carbon fiber without causing a decrease in fiber performance has become a problem that needs to be solved for carbon fiber cutting wire. Summary of the invention

[0007] In order to solve the defect in the prior art that carbon fibers cannot be bundled by a twisting rope process, the present invention provides a carbon fiber bundle cutting filament and a preparation method thereof.

[0008] The technical solution adopted by the present invention is as follows: a carbon fiber wire harness cutting wire, comprising

[0009] A substrate, wherein the substrate is composed of a bundle of strands formed by twisting a plurality of carbon fiber monofilaments with a metal layer coated on the surface;

[0010] The abrasive coating is coated on the outside of the substrate and has abrasive particles embedded therein.

[0011] In some embodiments, the carbon fiber monofilament is a continuous filament with a cross-sectional diameter of 0.005-0.008 mm, and the tensile strength of the carbon fiber monofilament is above 6000 MPa.

[0012] In some embodiments, the thickness of the metal layer is 0.5-1.0 μm, and the cross-sectional area of ​​the metal layer exceeds 30% of the cross-sectional area of ​​the carbon fiber monofilament.

[0013] In some embodiments, the wiring harness comprises 30 to 99 carbon fiber filaments.

[0014] In some embodiments, the metal layer is made of nickel or copper.

[0015] In some embodiments, the abrasive coating is made of nickel or copper, and the thickness of the abrasive coating is 5-10 μm.

[0016] In some embodiments, the abrasive particles are diamond particles, and the abrasive coating contains 200-1000 abrasive particles / mm.

[0017] The present invention also provides a method for preparing carbon fiber wire bundle cutting wire, firstly coating the surface of carbon fiber monofilament with a metal layer, then twisting a plurality of carbon fiber monofilaments with the surface coated with the metal layer to form a wire bundle constituting a substrate; then coating the surface of the substrate with an abrasive coating, wherein the abrasive coating has abrasive particles embedded therein.

[0018] In some embodiments, the coating method of the metal layer is electroplating; and the coating method of the abrasive coating is electroplating.

[0019] In some embodiments, the twisting process is to reversely twist multiple carbon fiber monofilaments with a metal layer on the surface to form a rope, reversely twist multiple ropes to form rope yarns, and then reversely twist multiple rope yarns to form rope strands, and twist multiple rope strands to form the wire bundle.

[0020] Beneficial effects: Compared with the prior art, the present invention uses carbon fiber with a thinner diameter and higher tensile strength as the base material, and can use a higher cutting speed than steel wire of the same diameter. Under the same tension requirement, carbon fiber with a thinner diameter can be used for cutting, and the carbon fiber has a low density. The mass of the same volume of carbon fiber is much smaller than that of tungsten wire, and the cost is greatly reduced. The surface of the carbon fiber monofilament is wrapped with a metal layer of a certain thickness. The metal layer has good plastic deformation ability, so that the carbon fiber filament can be twisted into a rope bundle to avoid rebound and looseness, avoiding the breakage of the monofilament due to uneven force, and maintaining the high strength of the carbon fiber cutting wire. The abrasive particles are fixed to the surface of the carbon fiber, and the abrasive particles are directly involved in the cutting, which effectively prolongs the service life of the cutting wire. The present invention can be applied to the fields of microelectronics industry, photovoltaic industry, etc., and has a wide range of applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic diagram of the cross-sectional structure of the cut wire of the carbon fiber harness of the present invention;

[0022] Figure 2 Schematic diagram of the structure of a carbon fiber monofilament with a metal layer coated on the surface;

[0023] Figure 3 is a schematic diagram of the substrate structure;

[0024] In the figure, 1. carbon fiber monofilament, 2. metal layer, 10. substrate, 20. abrasive coating, 21. abrasive particles. DETAILED DESCRIPTION

[0025] The present invention will be further described below in conjunction with specific implementation methods. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative changes belong to the protection scope of the present invention.

[0026] The present invention provides a carbon fiber wire harness cutting wire, such as Figures 1 to 3 As shown, its structure is as follows, including a substrate 10, such as Figure 2 and 3 As shown, the substrate 10 is composed of a bundle of strands formed by twisting a plurality of carbon fiber monofilaments 1 with a metal layer 2 coated on the surface; Figure 1 As shown, an abrasive coating 20 is coated on the outside of the substrate 10, and abrasive particles 21 are embedded in the abrasive coating 20. Since the carbon fiber monofilament 1 has a high modulus and a large rebound, the traditional steel wire twisting process will cause looseness. However, a metal layer 2 with a certain thickness and plastic deformation ability is coated on the surface of the carbon fiber monofilament 1, so that the carbon fiber monofilament 1 coated with the metal layer 2 on the surface can be twisted into a wire harness using the twisting process without looseness, avoiding the breakage of the monofilament due to uneven processing, and maintaining the high strength of the carbon fiber cutting wire. The cutting wire is a wire harness effectively combined with multiple carbon fiber monofilaments 1. When the monofilaments are combined into a wire harness, it is necessary to ensure that the tensile strength of the wire harness is not reduced. Under the same tension requirement, the cutting machine uses a thinner diameter cutting wire, and the cost of the substrate 10 is greatly reduced.

[0027] Specifically, the carbon fiber monofilament 1 can be continuous filament, the carbon fiber cross-sectional diameter is 0.005-0.008 mm, the carbon fiber monofilament 1 has a tensile strength of more than 6000 MPa, the cross-section is circular or approximately circular, and the wiring harness contains 30 to 99 carbon fiber monofilaments 1.

[0028] In one embodiment, the carbon fiber type is T1100, the tensile strength is 7000Mpa, and the cross-sectional diameter of the carbon fiber monofilament 1 is 0.006mm. Referring to the wire diameter and breaking force of tungsten wire 33μm, it can be calculated that a wire bundle composed of more than 30 carbon fibers can meet the breaking force requirements of the cutting wire.

[0029] Specifically, preferably, the thickness of the metal layer 2 is 0.5-1.0 μm, and the cross-sectional area of ​​the metal layer 2 exceeds 30% of the cross-sectional area of ​​the carbon fiber monofilament 1. The material of the metal layer 2 is preferably nickel or copper.

[0030] In one embodiment, the metal layer 2 is coated on the surface of the carbon fiber monofilament 1 by electroplating, and the metal layer 2 is made of nickel.

[0031] Specifically, in some embodiments, the abrasive coating 20 is made of nickel or copper, preferably nickel, and has a thickness of 5-10 μm. The abrasive particles 21 are diamond particles, and the abrasive coating 20 contains 200-1000 abrasive particles 21 per mm.

[0032] The present invention also provides a method for preparing carbon fiber wire harness cutting wire, which comprises the following steps: Figure 2 As shown, the surface of the carbon fiber monofilament 1 is first coated with a metal layer 2, such as Figure 3 As shown, a plurality of carbon fiber monofilaments 1 with a metal layer 2 on the surface are twisted to form a wire bundle to form a substrate 10; Figure 1 As shown, the surface of the substrate 10 is then coated with an abrasive coating 20 , wherein the abrasive coating 20 has abrasive particles 21 embedded therein.

[0033] The coating method of the metal layer 2 is preferably electroplating; the coating method of the abrasive coating 20 is preferably electroplating. In one embodiment, a nickel layer is electroplated on the surface of the carbon fiber monofilament 1 to form the metal layer 2, and a nickel-diamond composite electroplating is performed on the surface of the substrate 10 to form the abrasive coating 20, wherein the abrasive coating 20 is a nickel-plated layer and diamond particles embedded in the nickel-plated layer.

[0034] In one embodiment, the twisting process of twisting the carbon fiber monofilament 1 to form the wiring harness substrate 10 is as follows: a plurality of carbon fiber monofilaments 1 coated with a metal layer 2 on the surface are reversely twisted to form a rope, a plurality of ropes are reversely twisted to form rope yarns, and a plurality of rope yarns are reversely twisted to form rope strands, and a plurality of rope strands are twisted to form the wiring harness, and its structure is as follows Figure 3 shown.

[0035] The above contents are only for explaining the technical idea of ​​the present invention and cannot be used to limit the protection scope of the present invention. Any changes made on the basis of the technical solution in accordance with the technical idea proposed by the present invention shall fall within the protection scope of the claims of the present invention.

Claims

1. A carbon fiber wire harness cutting wire, characterized in that: include A substrate (10), wherein the substrate (10) is composed of a bundle of strands formed by twisting a plurality of carbon fiber monofilaments (1) with a metal layer (2) coated on the surface; An abrasive coating (20) is coated on the outside of the substrate (10) and has abrasive particles (21) embedded therein.

2. The carbon fiber wire harness cutting wire according to claim 1, characterized in that: The carbon fiber monofilament (1) is a continuous filament with a cross-sectional diameter of 0.005-0.008 mm. The tensile strength of the carbon fiber monofilament (1) is above 6000 MPa.

3. The carbon fiber wire harness cutting wire according to claim 1, characterized in that: The thickness of the metal layer (2) is 0.5-1.0 μm, and the cross-sectional area of ​​the metal layer (2) exceeds 30% of the cross-sectional area of ​​the carbon fiber monofilament (1).

4. The carbon fiber wire harness cutting wire according to claim 1, characterized in that: The wiring harness contains 30 to 99 carbon fiber monofilaments (1).

5. The carbon fiber wire harness cutting wire according to claim 1, characterized in that: The metal layer (2) is made of nickel or copper.

6. The carbon fiber wire harness cutting wire according to claim 1, characterized in that: The abrasive coating (20) is made of nickel or copper, and has a thickness of 5-10 μm.

7. The carbon fiber wire harness cutting wire according to claim 1, characterized in that: The abrasive particles (21) are diamond particles, and the abrasive coating (20) contains 200-1000 particles / mm of abrasive particles (21).

8. The method for preparing carbon fiber wire bundle cutting yarn according to any one of claims 1 to 7, characterized in that: First, a metal layer (2) is coated on the surface of a carbon fiber monofilament (1), and then a plurality of carbon fiber monofilaments (1) with the metal layer (2) coated on the surface are twisted to form a wire bundle to form a substrate (10); and then an abrasive coating (20) is coated on the surface of the substrate (10), wherein the abrasive coating (20) has abrasive particles (21) embedded therein.

9. The preparation method according to claim 8, characterized in that: The coating method of the metal layer (2) is electroplating; and the coating method of the abrasive coating (20) is electroplating.

10. The preparation method according to claim 8, characterized in that: The twisting process comprises: reversely twisting a plurality of carbon fiber monofilaments (1) with a metal layer (2) on the surface to form a rope, reversely twisting a plurality of ropes to form rope yarns, and then reversely twisting a plurality of rope yarns to form rope strands; and twisting a plurality of rope strands to form the wire bundle.

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