Process for producing composite material assembly through die cutting and hot press molding

Abstract

The invention discloses a process for producing a composite material assembly by using die cutting and hot press molding, and relates to the field of composite materials, the composite material assembly comprises a composite material assembly, the composite material assembly comprises a plurality of prepreg layers, and the process comprises the following steps: each prepreg layer is processed by a coiled material on a machine, the coiled material is provided with a protective film, and the model of the protective film is DSN-PR4031. Different prepreg multilayer structures are separated into coiled materials through release paper and protective films respectively, the multiple prepreg layers are nested in the release paper cut by the synchronous die cutting die, and the release paper is provided with positioning holes, so that subsequent processing and positioning are facilitated. The multi-layer prepreg die-cutting material layer adopts the structure, and the deviation of a die-cutting die needs to be ensured within + / -0.03 mm in order to control the product precision.

Description

Technical Field

[0001] The present invention relates to the field of composite materials, and particularly to a process for producing composite material components by die cutting and hot pressing molding. Background Art

[0002] When producing composite materials, especially prepreg multi-layer structures, there are problems such as the deviation of die cutting molds that are not easy to control the product accuracy, and it is not easy to attach release paper to the surface of prepreg multi-layer structures.

[0003] Therefore, it is very necessary to propose a process for producing composite material components by die cutting and hot pressing molding to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a process for producing composite material components by die cutting and hot pressing molding to solve the problems raised in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solution: A process for producing composite material components by die cutting and hot pressing molding, including a multi-layer prepreg composite component, the multi-layer prepreg composite component includes multiple prepreg layers, and includes the following steps:

[0006] Each prepreg layer is processed on a roll-fed machine. The roll contains a protective film, and the model of the protective film is DSN-PR4031;

[0007] When processing each prepreg layer, it includes:

[0008] Peel off the protective film of the upper prepreg layer. Before compounding with the lower prepreg layer, first isolate it with release paper. The release paper used is a mesh release paper with the model DSN-AB2030. Before compounding, first peel off the protective film of the lower prepreg layer. The compounding stack deviation of the multi-layer prepreg composite component 100 can be controlled within ±0.3 mm;

[0009] The roll of the prepreg layer of the first layer is at the first die cutting station. After peeling off the protective film, it is die cut by laminating release paper; enter the second station, and the roll of the prepreg layer of the second layer is laminated with release paper, and after peeling off the protective film, it is die cut; repeat the above steps to complete all die cutting processes;

[0010] After die cutting the prepreg layer of the third layer, the whole needs to be added with release paper to form a die cut part, and the die cut part is processed by a die cutting machine.

[0011] Preferably, the prepreg layer includes, from bottom to top, a first prepreg layer, a second prepreg layer, and a third prepreg layer;

[0012] The coil of the first prepreg layer is die-cut after peeling off the protective film and laminating with the release paper at the first die-cutting station; it advances to the second station, where the coil of the second prepreg layer is laminated with the release paper and die-cut after peeling off the protective film; the above steps are repeated to complete all die-cutting processes;

[0013] After die-cutting the third prepreg layer, the release paper needs to be added to the whole.

[0014] Preferably, the first release paper, the second release paper or the third release paper is laminated on the multi-layer prepreg composite component using an attaching roller;

[0015] The attaching roller includes end panels, a rubber pressing sleeve and a support shaft. There are a pair of end panels and a pair of support shafts. The pair of end panels are respectively fixedly connected to both ends of the rubber pressing sleeve, and the pair of end panels are fixedly connected by a connecting column. The connecting column is arranged in the middle of the end panel.

[0016] Preferably, a plurality of partition plates are fixedly arranged on the connecting column, the plurality of partition plates are equidistantly distributed, and a pressure regulating chamber is formed between adjacent partition plates.

[0017] Preferably, a pair of support shafts are respectively fixedly connected to the sides of the pair of end panels away from each other.

[0018] Preferably, a suction pump is fixedly installed on the side of one of the end panels. An air pipe is connected to the suction pump. The air pipe extends into the interior of the rubber pressing sleeve and passes through a plurality of pressure regulating chambers in sequence. A plurality of suction holes are arranged on the air pipe, and the plurality of suction holes respectively correspond to the plurality of pressure regulating chambers one by one.

[0019] Preferably, a solenoid valve is arranged in the suction hole.

[0020] Preferably, a pressure sensor is arranged in each pressure regulating chamber.

[0021] Preferably, positioning holes are arranged on the release paper.

[0022] Preferably, the prepreg blanks die-cut and laminated on the die-cutting machine are arranged in multiple pieces. The die-cut piece is a single-piece structure including 16 layers of prepreg composite components, and the die-cut piece is processed by cutting on the die-cutting machine multiple times.

[0023] The technical effects and advantages of the present invention:

[0024] 1. In the present invention, different prepreg multi-layer structures are separated into coils by release paper and protective film respectively. The multi-layer prepreg layers are nested in the release paper cut by the synchronous die-cutting die. The release paper is designed with positioning holes to facilitate subsequent processing and positioning. For the die-cut material layer of the multi-layer prepreg, the deviation of the die-cutting die needs to be ensured within ±0.03 mm to control the product accuracy;

[0025] 2. Multilayer prepreg layers with different structures and the protective film are processed by a die-cutting die, and are laminated layer by layer on a multi-station die-cutting machine to form a blank of a component with a special-shaped structure diagram, and then hot-pressed and formed by a finished component die. The precision of the product can be controlled. Compared with the structure details processed by post-processing procedures such as CNC and laser after hot-pressing a formed plate, the processing efficiency is increased by a hundred times, and the production cost of special-shaped structure composite materials can be greatly reduced;

[0026] 3. When the pressing force at the corresponding position is insufficient, the solenoid valve in the suction hole is opened, and the suction pump is used to fill the corresponding pressure regulating chamber with gas, increasing the pressure of the rubber pressing sleeve on the surface of the release paper at this place, which can ensure uniform pressing and make the attachment effect between the release paper and the prepreg composite component better;

[0027] 4. Just start the suction pump and the corresponding solenoid valve to inflate or inhale into the pressure regulating chamber, achieving the purpose of controlling the bonding strength according to different conditions at different positions on the surface of the release paper. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic structural diagram of the composite material component of the present invention.

[0029] Figure 2 It is a plane structure and a three-dimensional exploded view of the composite material component of the special-shaped prepreg die-cutting and hot-pressing forming of the present invention;

[0030] Figure 3 It is a first-layer die-cutting schematic diagram of the composite material component of the special-shaped prepreg die-cutting and hot-pressing forming of the present invention;

[0031] Figure 4 It is a second-layer die-cutting schematic diagram of the composite material component of the special-shaped prepreg die-cutting and hot-pressing forming of the present invention;

[0032] Figure 5 It is a third-layer die-cutting schematic diagram of the composite material component of the special-shaped prepreg die-cutting and hot-pressing forming of the present invention;

[0033] Figure 6 It is a fourth-layer die-cutting schematic diagram of the composite material component of the special-shaped prepreg die-cutting and hot-pressing forming of the present invention;

[0034] Figure 7 It is a schematic structural diagram when the attaching roller attaches the release paper of the present invention;

[0035] Figure 8 It is a schematic structural diagram of one perspective of the attaching roller of the present invention;

[0036] Figure 9 It is a schematic structural diagram of another perspective of the attaching roller of the present invention;

[0037] Figure 10Schematic diagram of the internal structure of the attachment roller of the present invention.

[0038] In the figure: 100, multi-layer prepreg composite component; 101, first prepreg layer; 102, second prepreg layer; 103, third prepreg layer; 200, die-cut part; 201, first release paper; 202, second release paper; 203, third release paper; 204, positioning hole; 3, attachment roller; 301, end panel; 302, rubber compression sleeve; 303, support shaft; 304, suction pump; 305, partition board; 306, pressure regulating chamber; 307, connecting column; 308, air pipe; 309, suction hole; 4, workbench. Detailed implementation manners

[0039] The present invention provides a process for producing composite material components by die-cutting and hot pressing.

[0040] The composite material component of the present invention includes a multi-layer prepreg structure, and different multi-layer prepreg structures are separated into coils by release paper and protective film respectively.

[0041] As Figure 1 and Figure 2 shown, in this embodiment, the multi-layer prepreg composite component 100 sequentially includes a first prepreg layer 101, a second prepreg layer 102, and a third prepreg layer 103 from bottom to top; similarly, the multi-layer prepreg composite component 100 can also be provided with N layers.

[0042] Each prepreg layer is processed on a coil on a machine. The coil is provided with a protective film, and the model of the protective film is DSN-PR4031. The compounding of each prepreg layer should include the following operations: the protective film of the upper prepreg layer is peeled off, and before being compounded with the lower prepreg layer, it is first isolated by release paper. The release paper used is a grid release paper with the model DSN-AB2030. Before compounding, the protective film of the lower prepreg layer is peeled off first, and the compounding stack deviation of the multi-layer prepreg composite component 100 can be controlled within ±0.3 mm.

[0043] Specific example: The coil of the first prepreg layer 101 is die-cut after peeling off the protective film and laminating the release paper at the first die-cutting station; entering the second station, the coil of the second prepreg layer 102 is laminated with the release paper, and die-cut after peeling off the protective film; and so on, until all die-cutting processes are completed. After die-cutting the third prepreg layer 103, a release paper needs to be added as a whole to form a die-cut part 200.

[0044] The multi-layer prepreg layers are nested in the release paper cut by a synchronous die-cutting die. The release paper is designed with positioning holes 204 to facilitate subsequent processing positioning. The multi-layer prepreg die-cut material layer adopts the above structure, and the deviation of the die-cutting die needs to be ensured within ±0.03 mm to control the product accuracy.

[0045] For the convenience of subsequent hot pressing of the mold, the prepreg blanks die-cut and laminated on the die-cutting machine are arranged in multiple pieces. In this embodiment, the die-cut piece has a structure of a single sheet containing 16 layers of prepreg composite components, and the die-cut piece 200 is processed by cutting on the die-cutting machine multiple times.

[0046] The die-cut piece tears off the release paper and attaches the forming film for hot pressing. During the specific operation, first tear off the release paper on side A and attach the forming film on side A; then tear off the release paper on side B and attach the forming film on side B. The attached forming film is then hot-pressed by the mold to obtain a heat-cured composite material blank. After trimming, polishing, or frosting and other appearance finishing, a carbon fiber composite material component is obtained.

[0047] The types of prepreg reinforcing fibers used in the composite material of the prepreg composite component include one or a mixture of multiple types among carbon fiber, glass fiber, basalt fiber, ceramic fiber, aramid fiber, PBO fiber, and PA fiber.

[0048] It should be noted that according to the number of stations of the die-cutting machine and the complexity of the product, the number of prepreg layers varies. The number of layers is greater than 2, but the number of layers is not limited.

[0049] For example: For a 26-station die-cutting machine, N can be at most 8 layers, and 9 die-cutting molds are used.

[0050] As Figures 3 to 6 shown, according to the number of layers of the prepreg composite component 100, the first release paper 201, the second release paper 202, and the third release paper 203 can be successively attached to the prepreg composite component 100.

[0051] As Figures 7 to 10 shown, the present invention also discloses a device for attaching release paper (the first release paper 201, the second release paper 202, and the third release paper 203) to the prepreg composite component 100; specifically, it includes:

[0052] The attaching roller 3, the attaching roller 3 includes end face plates 301, a rubber pressing sleeve 302 and a support shaft 303. There are a pair of end face plates 301 and a pair of support shafts 303. The pair of end face plates 301 are respectively fixedly connected to both ends of the rubber pressing sleeve 302. The pair of support shafts 303 are respectively fixedly connected to the surfaces of the pair of end face plates 301 away from each other. The pair of end face plates 301 are fixedly connected by connecting columns 307. The connecting columns 307 are arranged in the middle of the end face plates 301. And a plurality of partition plates 305 are fixedly arranged on the connecting columns 307. The plurality of partition plates 305 are equidistantly distributed. A pressure regulating chamber 306 is formed between adjacent partition plates 305. A suction pump 304 is fixedly installed on the side surface of one of the end face plates 301. An air pipe 308 is connected to the suction pump 304. The air pipe 308 extends into the interior of the rubber pressing sleeve 302 and passes through a plurality of pressure regulating chambers 306 in sequence. A plurality of suction holes 309 are arranged on the air pipe 308. The plurality of suction holes 309 respectively correspond to the plurality of pressure regulating chambers 306 one by one. Solenoid valves are arranged in the suction holes 309; A pressure sensor is also arranged in each pressure regulating chamber 306.

[0053] During operation, the prepreg composite component 100 is placed on the workbench 4. The attaching roller 3 is used to press and attach the release paper on the surface of the prepreg composite component 100. A driving mechanism such as a motor is added to the end of the support shaft 303 to drive the attaching roller 3 to roll along the length direction of the prepreg composite component 100; When the attaching roller 3 rolls on the upper surface of the prepreg composite component 100, the release paper can be attached to the upper surface of the prepreg composite component 100.

[0054] Furthermore, in the present invention, since a pressure sensor is arranged inside the pressure regulating chamber 306 and the rubber pressing sleeve 302 can elastically deform to a certain extent, the pressure sensor can monitor the pressure of the rubber pressing sleeve 302 pressing the prepreg composite component 100 in real time. If the pressing force at the corresponding position is insufficient, the solenoid valve in the suction hole 309 is opened, and the suction pump 304 is used to fill the corresponding pressure regulating chamber 306 with gas, increasing the pressure of the rubber pressing sleeve 302 on the surface of the release paper at this place, which can ensure uniform pressing and make the attaching effect between the release paper and the prepreg composite component 100 better.

[0055] In another embodiment, it is also possible to punch air into the corresponding pressure regulating chamber 306 by opening the solenoid valve in the suction hole 309, and the corresponding pressure sensor monitors the gas pressure in the pressure regulating chamber 306; If the gas pressure in one of the pressure regulating chambers 306 is abnormal (different from that of other groups of pressure sensors), it proves that the bonding position here may have insufficient bonding. Starting the suction pump 304 and the corresponding solenoid valve to inflate or suck air into the pressure regulating chamber 306 can achieve the purpose of controlling the bonding strength according to different conditions at different positions on the surface of the release paper.

[0056] It will be understood that the above-described embodiments are merely exemplary embodiments adopted to illustrate the principles of the present invention, and the present invention is not limited thereto. For those of ordinary skill in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also regarded as the protection scope of the present invention.

Claims

1. A process for producing a composite material component by die cutting and hot pressing, comprising a multi-layer prepreg composite component (100), wherein the multi-layer prepreg composite component (100) comprises a plurality of prepreg layers, characterized in that: The following steps are involved: Each prepreg layer is machined on a coil with a protective film; The processing of each prepreg layer includes: The protective film of the upper prepreg layer is peeled off, and the release paper is used to separate the upper prepreg layer before laminating with the lower prepreg layer. The protective film of the lower prepreg layer is peeled off before laminating, and the composite stacking deviation of the multi-layer prepreg composite assembly (100) is controlled within ±0.3 mm; The coil of the first layer of prepreg layer is placed at the first die-cutting station, and after the protective film is peeled off, it is attached to the release paper for die-cutting; it enters the second station, and the coil of the second layer of prepreg layer is attached to the release paper, and after the protective film is peeled off, it is die-cut; Repeat the above steps to complete all die-cutting processes; After the third prepreg layer is die-cut, a release paper is added to the whole to form a die-cut piece (200), and the die-cut piece (200) is processed using a die-cutting machine.

2. A process for producing composite material components by die cutting and hot pressing according to claim 1, characterized in that: The prepreg layer comprises, from bottom to top, a first prepreg layer (101), a second prepreg layer (102), and a third prepreg layer (103); The coil of the first prepreg layer (101) is placed at the first die-cutting station, and after the protective film is peeled off, it is attached to the release paper for die-cutting; it enters the second station, and the coil of the second prepreg layer (102) is attached to the release paper, and after the protective film is peeled off, it is die-cut; Repeat the above steps to complete all die-cutting processes; After the third prepreg layer (103) is die-cut, a release paper needs to be added to the whole.

3. A process for producing composite material components by die cutting and hot pressing according to claim 1, characterized in that: The first release paper 201, the second release paper 202 or the third release paper 203 is laminated on the multilayer prepreg composite assembly (100) using an attaching roller (3); The attachment roller (3) comprises an end panel (301), a rubber pressure sleeve (302) and a support shaft (303); the end panel (301) and the support shaft (303) are each provided in a pair; the pair of end panels (301) are respectively fixedly connected to the two ends of the rubber pressure sleeve (302); the pair of end panels (301) are fixedly connected via a connecting column (307); and the connecting column (307) is provided in the middle of the end panel (301).

4. A process for producing composite material components by die cutting and hot pressing according to claim 3, characterized in that: A plurality of partitions (305) are fixedly arranged on the connecting column (307), the plurality of partitions (305) are distributed at equal distances, and a pressure regulating chamber (306) is formed between adjacent partitions (305).

5. A process for producing composite material components by die cutting and hot pressing according to claim 4, characterized in that: A pair of support shafts (303) are respectively fixedly connected to the sides of a pair of end panels (301) that are away from each other.

6. A process for producing composite material components by die cutting and hot pressing according to claim 5, characterized in that: A suction pump (304) is fixedly mounted on the side of one of the end panels (301), and an air pipe (308) is connected to the suction pump (304). The air pipe (308) extends into the interior of the rubber compression sleeve (302) and passes through a plurality of pressure regulating chambers (306) in sequence. A plurality of suction holes (309) are provided on the air pipe (308), and the plurality of suction holes (309) correspond one-to-one to the plurality of pressure regulating chambers (306), respectively.

7. A process for producing composite material components by die cutting and hot pressing according to claim 6, characterized in that: A solenoid valve is provided in the suction hole (309).

8. A process for producing composite material components by die cutting and hot pressing according to claim 7, characterized in that: A pressure sensor is provided in each pressure regulating chamber (306).

9. A process for producing composite material components by die cutting and hot pressing according to claim 1, characterized in that: The release paper is provided with a positioning hole (204).

10. A process for producing composite material components by die cutting and hot pressing according to claim 9, characterized in that: The prepreg blanks die-cut and composited on the die-cutting machine are arranged in multiple pieces, and the die-cut piece (200) is a structure that includes 16 layers of prepreg composite components in a single piece. The die-cut piece (200) is cut and processed multiple times using the die-cutting machine.

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