Ultrathin carbon fiber bundle spreading method combining ultrasonic mechanical vibration and air blowing

Abstract

The invention belongs to the field of prepreg tapes, and relates to an ultra-thin carbon fiber bundle filament spreading method combining ultrasonic mechanical vibration and air blowing, which adopts a two-time filament spreading process, and comprises the following steps: carrying out aging treatment after the first-time filament spreading is completed, and then carrying out second-time filament spreading, each filament spreading process comprises ultrasonic filament spreading, mechanical vibration filament spreading, filament spreading through combination of air blowing and mechanical vibration, broken filament removal and carbon fiber rolling, in the ultrasonic filament spreading process, carbon fiber bundles are subjected to bundle removal, in the mechanical vibration filament spreading process, the fiber bundles are re-spread to be homogenized, and the carbon fibers are rolled up. Air blowing and mechanical vibration are combined with the filament spreading process to adjust the flexibility of the carbon fiber bundle and carry out deep spreading on the carbon fiber bundle at the same time, the broken filament removing process is used for removing broken filaments, the fiber quality after filament spreading is guaranteed, in the broken filament removing process of first filament spreading, new carbon fibers with the same amount as the removed broken filaments are supplemented to guarantee the total amount of the carbon fibers, and the carbon fiber quality is improved. And in the carbon fiber winding process, the carbon fibers are wound.

Description

Technical Field

[0001] The present invention relates to the technical field of prepreg tape production, and in particular to a method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration and air blowing. Background Art

[0002] A prepreg tape is a composite material in which a reinforcing material (such as carbon fiber and / or glass fiber) is pre-impregnated with a resin. This material can achieve a uniform resin distribution during the manufacturing process, thereby improving the performance of the final product. The thickness of an ultra-thin prepreg tape is usually between dozens of micrometers and a few millimeters. Compared with traditional prepreg tapes, it has the characteristics of being lighter and more flexible, and still exhibits excellent strength and stiffness with less material usage.

[0003] When realizing the production of ultra-thin prepreg tapes, the spreading process is crucial. However, the current traditional prepreg tape spreading methods perform poorly in terms of the spreading effect of carbon fibers, which will directly affect the subsequent material impregnation process and the strength of the final product, thereby reducing the service performance of the prepreg tape. Summary of the Invention

[0004] The technical problem to be solved by the present invention is: how to provide a method for spreading ultra-thin carbon fiber bundles, improve the spreading effect of ultra-thin carbon fiber bundles, and not affect the strength of the carbon fiber bundles.

[0005] The technical solution adopted by the present invention is: a method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration and air blowing, which adopts a two-stage spreading process. After the first-stage spreading is completed, aging treatment is carried out and then the second-stage spreading is carried out. Each spreading process includes ultrasonic spreading, mechanical vibration spreading, combined air blowing and mechanical vibration spreading, broken wire removal, and carbon fiber winding. During the ultrasonic spreading process, the carbon fiber bundles are de-bundled. During the mechanical vibration spreading process, the fiber bundles are further spread to make the fiber bundles uniform. During the combined air blowing and mechanical vibration spreading process, the flexibility of the carbon fiber bundles is adjusted while the carbon fiber bundles are deeply expanded. During the broken wire removal process, the broken wires are removed to ensure the quality of the fibers after spreading. During the broken wire removal process of the first-stage spreading, new carbon fibers with the same amount as the removed broken wires are supplemented to ensure the total amount of carbon fibers. During the carbon fiber winding process, the carbon fibers are wound.

[0006] During the ultrasonic spreading process, multiple ultrasonic guide rollers (7) with different rotation speeds are used to maximize the expansion of the carbon fiber bundles while ensuring that the carbon fiber bundles do not break.

[0007] During the mechanical vibration spreading process, first, a spreading comb assembly and a spreading roller assembly are used for beam splitting, and then spreading is completed under the action of transverse mechanical vibration and longitudinal mechanical vibration.

[0008] During the process of spreading filaments by combining air blowing and mechanical vibration, while spreading the filaments under the action of transverse mechanical vibration and longitudinal mechanical vibration, air blowing from the upper side is carried out to achieve deep filament spreading.

[0009] The broken filament removal adopts a double sponge roller removal device. When the carbon fiber bundle passes through the center of the double sponge rollers, the broken filaments in the carbon fiber bundle are adsorbed by the sponge, thereby removing the broken filaments in the carbon fiber bundle.

[0010] The winding of the carbon fiber refers to winding the carbon fiber bundle onto the driving winding roller, and the driven winding roller presses the carbon fiber bundle.

[0011] The beneficial effects of the present invention are as follows: The present invention combines the common advantages of ultrasonic filament spreading, mechanical vibration filament spreading, and air blowing filament spreading. By adopting the combined method of the three, it can not only achieve an ideal filament spreading effect but also reduce the phenomenon of fiber breakage caused by mechanical vibration filament spreading. In the subsequent processing process, broken fibers are further removed by the cotton roller, thereby providing an excellent fiber arrangement for subsequent impregnation.

[0012] The present invention adopts a design concept of multi-stage filament spreading. Compared with the traditional single filament spreading method, it can effectively disperse the fiber bundle, improve the filament spreading speed, reduce the winding and aggregation between fibers, thereby ensuring that the fibers are more uniform during the processing and ensuring the excellent performance of the prepreg tape.

[0013] The present invention not only has a good filament spreading effect, a simple structure, but also is convenient to install. This design significantly reduces material waste through an efficient filament spreading process, while saving energy consumption, thereby achieving good economic benefits.

[0014] The present invention provides a new idea for ensuring the quality of fiber filaments after filament spreading, such as controlling the ejected air flow to control the humidity of the fiber filaments, enhancing the flexibility of the fiber filaments to protect the fibers, reducing the broken filaments during mechanical vibration, and supplementing new fibers after mechanical filament spreading to further improve the quality of the fiber bundle after filament spreading.

[0015] The present invention can adjust the vibration frequency and air flow intensity according to different types of fibers and production requirements to meet the filament spreading requirements of various materials, and has good adaptability.

[0016] The filament spreading process provided by the present invention has obvious improvements in aspects such as filament widening and broken fiber rate compared with the existing process flow, so it is more reasonable than the existing traditional process. Description of the Drawings

[0017] Figure 1 It is a schematic diagram of the overall assembled structure of the present invention; Figure 2 It is a front view schematic diagram of the structure of the present invention; Figure 3 It is an enlarged view of the ultrasonic part of the present invention (the outer shell has been hidden); Figure 4 This is an enlarged view of the mechanical vibration part of the present invention; Figure 5 This is an enlarged view of the air blowing and multi-stage mechanical vibration part of the present invention; Figure 6 is This is an enlarged view of the broken wire removing and winding part of the present invention; Figure 7 This is a schematic flow chart of the present invention; Among them, 1. Ultrasonic wire spreading; 2. Mechanical vibration wire spreading; 3. Air blowing and multi-stage mechanical vibration wire spreading; 4. Broken wire removal; 5. Carbon fiber winding; 6. Ultrasonic emitter; 8. Ultrasonic box; 9. Sealing ring; 10. Wire spreading comb; 11. Driving roller of wire spreading roller; 12. Tension sensor; 13. Auxiliary roller; 14. Longitudinal concentric machine roller vibration; 15. Transverse crank guide bar mechanism vibration; 16. Driving roller of Meyer rod; 17. Air blowing rack; 18. Multi-stage mechanical vibration wire spreading; 19. Cotton roller; 20. Driving and driven rollers for winding, 71. First ultrasonic guide roller; 72. Second ultrasonic guide roller; 73. Third ultrasonic guide roller; 74. Fourth ultrasonic guide roller. Detailed implementation manners

[0018] To make the technical problems, technical solutions and advantages to be solved by the present invention clearer, the following will be described in detail with reference to the accompanying drawings and specific embodiments.

[0019] A method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration and air blowing, as Figure 7 shown, adopts a two-stage wire spreading process. After the first-stage wire spreading is completed, aging treatment is carried out and then the second-stage wire spreading is carried out. Each wire spreading process includes ultrasonic wire spreading 1, mechanical vibration wire spreading 2, air blowing and mechanical vibration combined wire spreading 3, broken wire removal 4, and carbon fiber winding 5. During the ultrasonic wire spreading process, the carbon fiber bundles are de-bundled. During the mechanical vibration wire spreading process, the fiber bundles are further unfolded to make the fiber bundles uniform. During the air blowing and mechanical vibration combined wire spreading process, while adjusting the flexibility of the carbon fiber bundles, the carbon fiber bundles are deeply expanded. During the broken wire removal process, the broken wires are removed to ensure the fiber quality after wire spreading. During the broken wire removal process in the first-stage wire spreading, new carbon fibers with the same amount as the removed broken wires are supplemented to ensure the total amount of carbon fibers. During the carbon fiber winding process, the carbon fibers are wound.

[0020] Since the thickness of ultra-thin carbon fiber bundles is usually between dozens of micrometers and several millimeters, too much external force cannot be applied during the wire spreading process, otherwise it is easy to cause broken wires or even broken bundles. By adopting a two-stage wire spreading process, after the first-stage wire spreading, aging treatment is carried out, and then the second-stage wire spreading. Compared with one-time wire spreading, not only can thinner carbon fiber bundles be obtained, but also the strength is stronger, the broken wires are fewer, and the performance is better.

[0021] During the ultrasonic fiber spreading process of the present invention, multiple ultrasonic guide rollers 7 with different rotation speeds are used to maximize the expansion of the carbon fiber bundle while ensuring that the carbon fiber bundle does not break.

[0022] In one embodiment, as Figure 3 shown, the equipment used in the ultrasonic fiber spreading process of the present invention includes an ultrasonic box body 8, an ultrasonic emitter 6 installed on the side wall of the ultrasonic box body 8, and four ultrasonic guide rollers. Four ultrasonic guide rollers are installed on the front and rear side walls in the ultrasonic box body 8. The cross-section of the four ultrasonic guide rollers is an isosceles trapezoid. Each ultrasonic guide roller is independently driven by a motor. Along the conveying direction of the carbon fiber bundle, the rotation speeds of the first ultrasonic guide roller 71, the second ultrasonic guide roller 72, the third ultrasonic guide roller 73, and the fourth ultrasonic guide roller 74 increase in sequence. When ensuring that the carbon fiber bundle does not break and meets the strength requirements, the maximum rotation speed is selected. Compared with the first ultrasonic guide roller 71, the second ultrasonic guide roller 72, the third ultrasonic guide roller 73, and the fourth ultrasonic guide roller 74 having the same speed, the thickness of the expanded carbon fiber bundle is thinner. Figure 3 , the ultrasonic emitter 6 has three and is respectively installed on the left and right side walls and the front side wall. The sealing ring 9 is to ensure that the ultrasonic medium in the ultrasonic box body 8 does not leak. These supporting devices are indispensable parts of the ultrasonic fiber spreading device, but they do not belong to the inventive points of the present invention. Those skilled in the art know how to build this device.

[0023] During the mechanical vibration fiber spreading process, first, a fiber spreading comb assembly and a fiber spreading roller assembly are used for beam splitting, and then fiber spreading is completed under the action of transverse mechanical vibration and longitudinal mechanical vibration.

[0024] In one embodiment, as Figure 1 , 2 , as shown in Figure 4, the fiber spreading comb assembly of the present invention includes a fiber spreading comb support frame, fiber spreading comb side plates, a fiber spreading comb, fiber spreading nails, and a fiber spreading comb guide roller 10. There are two fiber spreading comb side plates and two fiber spreading comb support frames respectively. Each fiber spreading comb support frame is an L-shaped support frame. The two fiber spreading comb support frames are symmetrically fixed on the support assembly and are located on both sides of the carbon fiber bundle (during the use of the fiber spreading comb assembly, the carbon fiber bundle is conveyed thereon). Each fiber spreading comb support frame fixes a fiber spreading comb side plate respectively. The two fiber spreading comb side plates are symmetrically structured. The fiber spreading comb and the fiber spreading comb guide roller 10 are fixedly installed on the two fiber spreading comb side plates in a parallel structure. A plurality of upward fiber spreading nails are installed in a parallel structure at the central position of the fiber spreading comb. The fiber spreading comb guide roller is independently driven.

[0025] In one embodiment, as Figure 1 , 2, as shown in Figures 3 and 4, the fiber spreading roller assembly includes a fiber spreading roller driving roller 11, a fiber spreading roller driven roller, a fiber spreading roller bracket, a driving roller slider (fiber spreading roller driving roller slider), a driven roller slider (fiber spreading roller driven roller slider), a top slider (fiber spreading roller top slider), a handwheel (fiber spreading roller handwheel), a tension sensor 12, a tension sensor base, an auxiliary roller base, and an auxiliary roller 13. There are two fiber spreading roller brackets, which are symmetrically installed on both sides of the carbon fiber bundle (the carbon fiber bundle being conveyed during operation). Each fiber spreading roller bracket has a rectangular through-hole, and the rectangular through-holes on the two fiber spreading roller brackets face each other. Guide rails are installed on both sides of each rectangular through-hole, and a threaded through-hole is provided at the center of the top of each rectangular through-hole. There are two driving roller sliders, and each driving roller slider has guide grooves on both sides that cooperate with the guide rails. Each driving roller slider is installed at the lower end of a rectangular through-hole through the cooperation of the guide rails and the guide grooves. The two ends of the fiber spreading roller driving roller 11 are respectively fixed on a driving roller slider. There are two handwheels, two driven roller sliders, and two top sliders. Each handwheel is connected to a top slider by a stud, and each stud passes through a threaded through-hole. The top slider is fixedly connected to the driven roller slider. Each driven roller slider and top slider have guide grooves on both sides that cooperate with the guide rails. Each driven roller slider and top slider are installed in a rectangular through-hole through the cooperation of the guide rails and the guide grooves, and the driven roller slider is located below the top slider. The two ends of the fiber spreading roller driven roller are respectively fixed on a driven roller slider. There are two tension sensor bases, which are symmetrically fixed on both sides of the support assembly. The tension sensor 12 is a tension roller with a torque sensor. The two ends of the tension roller are respectively installed on a tension sensor base. The tension roller is lower than the fiber spreading roller driving roller 11 and the auxiliary roller 13 in the horizontal direction. There are two auxiliary roller bases, which are symmetrically installed on both sides of the carbon fiber bundle (the carbon fiber bundle being conveyed during operation). The two ends of the auxiliary roller are respectively fixed on an auxiliary roller base. The fiber spreading roller brackets, the tension sensor bases, and the auxiliary roller bases are arranged in sequence along the conveying direction of the carbon fiber bundle.

[0026] In one embodiment, as Figure 1 , 2 , as shown in Figures 3 and 4, the longitudinal vibration fiber spreading assembly includes a longitudinal vibration motor, a longitudinal vibration motor base, and a longitudinally concentric vibration roller 14. Among them, there are two longitudinal vibration motor bases, which are symmetrically installed on both sides of the support assembly. The longitudinally concentric vibration roller 14 includes three vibration rollers. The two ends of the three vibration rollers are respectively installed on a longitudinal vibration motor base. The longitudinal vibration motor is installed on a longitudinal vibration motor base and is connected to the three longitudinally concentric vibration rollers to provide longitudinal vibration to the three longitudinally concentric vibration rollers. The cross-section of the three longitudinally concentric vibration rollers is such that the center connection line forms an equilateral triangle.

[0027] In one embodiment, as Figure 1 , 2, as shown in Figure 4, the transverse vibration wire spreading assembly includes a crank-slider mechanism, a cushion block, a guide sleeve device, the Meyer rod driving roller 16, the Meyer rod driven roller, and the Meyer rod base; the crank-slider mechanism is fixed to one side of the carbon fiber bundle (the carbon fiber bundle being conveyed during operation) through the cushion block. The crank-slider mechanism includes a rotating pair, a connecting rod connecting the rotating pairs, a limiting device, and a linear reciprocating guide rod. There is a limiting hole on the limiting device. The guide sleeve device includes a guide sleeve support plate and a guide sleeve hole on the guide sleeve support plate. The two ends of the linear reciprocating guide rod are respectively located in the limiting hole and the guide sleeve hole. The connecting rod connected to the linear reciprocating guide rod drives the linear reciprocating guide rod to perform linear reciprocating motion under the drive of the rotating pair. The linear reciprocating guide rod is perpendicular to the movement direction of the fiber bundle. There are two Meyer rod bases, which are symmetrically installed on both sides of the support assembly. The two ends of the Meyer rod driving roller 16 and the Meyer rod driven roller are respectively fixed to one Meyer rod base. The Meyer rod driving roller and the Meyer rod driven roller are in an up-and-down structure, and during operation, the Meyer rod driving roller rotates clockwise and the Meyer rod driven roller rotates counterclockwise.

[0028] During the process of spreading the wire by combining air blowing and mechanical vibration, while spreading the wire under the action of transverse mechanical vibration and longitudinal mechanical vibration, air blowing from the upper side is carried out to achieve deep wire spreading.

[0029] As Figure 5 shown, the devices used for the transverse mechanical vibration and longitudinal mechanical vibration involved in spreading the wire by combining air blowing and mechanical vibration are the same as those involved in the mechanical vibration wire spreading process. Compared with the devices involved in spreading the wire by combining air blowing and mechanical vibration, an air blowing device is added.

[0030] The air blowing device includes a triangular fixing block, a blowing frame support pillar, a blowing frame cross beam, a blowing frame slide bar fixing block, a blowing frame slide bar, a nozzle frame slider, a nozzle frame 17, a nozzle slide bar, a nozzle slider, and an air flow distributor. The triangular fixing block is for fixation, and other fixing methods can also be used.

[0031] Among them, the blowing rack support columns are four columns with the same height. The projections of the four blowing rack support columns on the same horizontal plane form a rectangle. The four blowing rack support columns are respectively fixed on the table board (support board) through a triangular fixing block. The blowing rack cross beams are two parallel ones. Each cross beam is a horizontal column (the cross section can be circular, rhombic, etc.). The two ends of each blowing rack cross beam are respectively fixedly connected to the top of a blowing rack support column. Each blowing rack cross beam is perpendicular to the carbon fiber bundle conveying direction. There are two parallel blowing rack sliding rods. Each blowing rack sliding rod is fixed on the two blowing rack sliding rods through a blowing rack sliding rod fixing block. The blowing rack sliding rod fixing block is just a fixing device, and it is also okay to use other existing methods for fixing. Each blowing rack sliding rod is perpendicular to the blowing rack sliding rod. There are two blowing nozzle racks 17 and two blowing nozzle rack sliders respectively. A blowing nozzle rack is fixed on each blowing rack sliding rod through a blowing nozzle rack slider. The two blowing nozzle racks are connected by a blowing nozzle sliding rod. The blowing nozzle sliding rod is perpendicular to each blowing rack sliding rod. The blowing nozzle slider is slidably connected and installed on the blowing nozzle sliding rod. The air flow distributor is installed on the blowing nozzle slider. The blowing nozzle is installed on the blowing nozzle slider or the air flow distributor.

[0032] The purpose of the air blowing device is to blow the carbon fiber bundle. The gas ejected from the nozzle is a mixture of inert gas and water vapor. It is required to keep the humidity of the air within a suitable range (the humidity of carbon fiber bundles with different components is different) to make the flexibility of the carbon fiber bundle reach the best.

[0033] The broken wire removal adopts a double sponge roller removal device. When the carbon fiber bundle passes through the center of the double sponge rollers, the broken wires in the carbon fiber bundle are adsorbed by the sponge, thereby removing the broken wires in the carbon fiber bundle.

[0034] As as shown in Figure 6 shown, the double sponge rollers for broken wire removal are two cotton rollers 19. This part can remove the broken wires generated during the mechanical vibration wire spreading process.

[0035] The carbon fiber winding refers to winding the carbon fiber bundle onto the winding driving roller, and the winding driven roller presses the carbon fiber bundle.

[0036] As as shown in Figure 6As shown, the carbon fiber winding is carried out by the cooperation of the main and driven winding rollers 20. Among them, the position of the main winding roller remains unchanged and only rotates, while the position of the driven winding roller moves upward as the coil thickness increases. There are two winding brackets, which are symmetrically installed on both sides of the carbon fiber bundle (the carbon fiber bundle being conveyed during operation). Each winding bracket has a rectangular through-hole, and the rectangular through-holes on the two winding brackets face each other. Guide rails (winding guide rails) are installed on both sides of each rectangular through-hole, and there is a threaded through-hole at the center of the top of each rectangular through-hole. There are two active roller sliders (main winding roller sliders), and each active roller slider has guide grooves (winding guide grooves) that cooperate with the guide rails. Each active roller slider is installed at the lower end of a rectangular through-hole through the cooperation of the guide rails and guide grooves. The two ends of the main winding roller are respectively fixed on an active roller slider. There are two of each of the hand wheels (winding hand wheels), driven roller sliders (driven winding roller sliders), and top sliders (winding top sliders). Each hand wheel and a top slider are connected by a stud, and each stud passes through a threaded through-hole. The top slider is elastically connected (connected by a spring) to the driven roller slider. Each driven roller slider and top slider have guide grooves that cooperate with the guide rails. Each driven roller slider and top slider are installed in a rectangular through-hole through the cooperation of the guide rails and guide grooves, and the driven roller slider is located below the top slider. The two ends of the filament spreading roller driven roller are respectively fixed on a driven roller slider.

[0037] The above are only embodiments of the present invention. Specific technical solutions and / or common knowledge such as characteristics well known in the art are not described in detail here. It should be noted that for those skilled in the art, without departing from the technical solution of the present invention, several modifications and improvements can still be made, and these should also be regarded as the protection scope of the present invention, which will not affect the implementation effect of the present invention and the practicality of the patent. The protection scope required by this application should be based on the content of its claims, and the specific implementation manners described in the specification can be used to interpret the content of the claims.

Claims

1. A method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration with air blowing, characterized in that: A double-wire spreading process is adopted. After the first wire spreading is completed, an aging treatment is carried out before the second wire spreading. Each wire spreading process includes ultrasonic wire spreading, mechanical vibration wire spreading, air blowing and mechanical vibration combined wire spreading, broken wire removal, and carbon fiber winding. During the ultrasonic wire spreading process, the carbon fiber bundles are de-bundled. During the mechanical vibration wire spreading process, the fiber bundles are re-expanded to make the fiber bundles uniform. During the air blowing and mechanical vibration combined wire spreading process, the flexibility of the carbon fiber bundles is adjusted while the carbon fiber bundles are deeply expanded. During the broken wire removal process, the broken wires are removed to ensure the fiber quality after the wire spreading. During the broken wire removal process of the first wire spreading, new carbon fibers of the same amount as the removed broken wires are added to ensure the total amount of carbon fiber. The carbon fiber winding process is wound up.

2. The method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration with air blowing according to claim 1, characterized in that: During the ultrasonic fiber spreading process, multiple ultrasonic guide rollers with differentiated rotation speeds are used to maximize the expansion of the carbon fiber bundle while ensuring that the carbon fiber bundle is not broken.

3. The method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration with air blowing according to claim 1, characterized in that: In the process of mechanical vibration fiber spreading, the fiber spreading comb assembly and the fiber spreading roller assembly are first used for bundle separation, and then the fiber spreading is completed under the action of transverse mechanical vibration and longitudinal mechanical vibration.

4. The method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration with air blowing according to claim 1, characterized in that: In the process of spreading the wire by combining air blowing with mechanical vibration, the wire is spread under the action of transverse mechanical vibration and longitudinal mechanical vibration while air blowing from the upper side is performed to perform deep wire spreading.

5. The method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration with air blowing according to claim 1, characterized in that: The broken wires are removed by a double sponge roller removal device. When the carbon fiber bundle passes through the center of the double sponge roller, the broken wires in the carbon fiber bundle are absorbed by the sponge, thereby removing the broken wires in the carbon fiber bundle.

6. The method for spreading ultra-thin carbon fiber bundles by combining ultrasonic mechanical vibration with air blowing according to claim 1, characterized in that: The carbon fiber winding refers to winding the carbon fiber bundle onto the winding active roller, and the winding driven roller presses the carbon fiber bundle.

Images