Continuous fiber fabric reinforced thermoplastic composite board as well as preparation device and preparation method thereof

Abstract

The embodiment of the invention provides a continuous fiber fabric reinforced thermoplastic composite board and a preparation device and method thereof, and the preparation device comprises a continuous fiber fabric providing unit which is used for providing a continuous fiber fabric; the resin infiltration unit is suitable for receiving the continuous fiber fabric provided by the continuous fiber fabric providing unit and infiltrating the continuous fiber fabric with thermoplastic resin, and the resin infiltration unit comprises a resin providing device suitable for coating one or two surfaces of the continuous fiber fabric with the thermoplastic resin; the pressing device is suitable for pressing the thermoplastic resin and the continuous fiber fabric; and the heating device is suitable for heating the thermoplastic resin in the pressing process. The composite board prepared by the preparation device has good mechanical properties and smoothness.

Description

Technical Field

[0001] The present disclosure relates to the field of fiber composite materials, and particularly to a continuous fiber fabric reinforced thermoplastic composite board, and a preparation device and a preparation method thereof. Background Art

[0002] Continuous fiber reinforced thermoplastic composites have been favored by the composite material industry due to their low material cost, manufacturing cost, excellent comprehensive performance, and complete recyclability. With the continuous development of the manufacturing technology of continuous fiber reinforced thermoplastic composites and the application of downstream products, the application of continuous fiber reinforced thermoplastic composites in the fields of automobiles, sports equipment, construction, transportation, industry, medical treatment, boats, etc. has been gradually expanded.

[0003] Continuous fiber fabrics are often used in thermoplastic composites due to their good processability. However, the thermoplastic resin matrix is a high molecular weight polymer with a large melt viscosity and low fluidity. Therefore, there is a problem of poor infiltration effect when the thermoplastic resin infiltrates the continuous fiber fabric, which in turn affects the performance of the final continuous fiber reinforced thermoplastic composite.

[0004] One way to improve the resin infiltration effect is to increase the infiltration pressure of the equipment. However, too high pressure will affect the regularity of the fibers and even cause fiber breakage. Another way is to modify the thermoplastic resin, and the process is relatively complicated.

[0005] Continuous fiber fabric reinforced thermoplastic composites can usually be prepared using a press. The press laminates and molds the thermoplastic resin film and the fiber fabric, including two processes of thermal composite and cooling. It is a batch production, with complex processes, low production efficiency, and high energy consumption. And the fluidity of the thermoplastic resin film will affect the effect of resin infiltration of the continuous fiber fabric. At the same time, due to the size limitation of the press, it is impossible to produce ultra-large composite boards.

[0006] Continuous fiber fabric reinforced thermoplastic composites can usually be prepared using a continuous Teflon belt machine and a continuous Teflon steel belt machine. This process requires continuous composite of the thermoplastic resin film and the fiber fabric. Poor fluidity of the thermoplastic resin film will lead to poor resin wettability. In addition, due to the uncontrollable surface quality of the Teflon belt and steel belt, the surface of the composite board cannot meet the requirements of higher appearance products. At the same time, the production heating section is long, the composite speed is slow, and the energy consumption is high.

[0007] Therefore, it is necessary to develop a new continuous fiber fabric reinforced thermoplastic composite board, and a preparation device and a preparation method thereof. Summary of the Invention

[0008] To solve the above technical problems, an embodiment of the present disclosure provides a device for preparing a continuous fiber fabric reinforced thermoplastic composite plate. The preparation device includes: a continuous fiber fabric providing unit for providing a continuous fiber fabric; a resin infiltration unit adapted to receive the continuous fiber fabric provided by the continuous fiber fabric providing unit and infiltrate the continuous fiber fabric with a thermoplastic resin. The resin infiltration unit includes: a resin providing device adapted to coat the thermoplastic resin on one or both sides of the continuous fiber fabric; a pressing device adapted to press the thermoplastic resin and the continuous fiber fabric; and a heating device adapted to heat the thermoplastic resin during the pressing process.

[0009] In some embodiments, the continuous fiber fabric providing unit includes: a transition flattening device for transporting and flattening the continuous fiber fabric so that the fiber directions of the continuous fiber fabric entering the resin infiltration unit are regular. The transition flattening device includes: a pre-traction roller assembly including at least two pre-traction rollers adapted to cooperate to traction the continuous fiber fabric from both sides of the continuous fiber fabric; and a flattening roller assembly including at least one flattening roller for flattening the continuous fiber fabric.

[0010] In some embodiments, the continuous fiber fabric providing unit further includes: a pretreatment device adapted to infiltrate the continuous fiber fabric with an infiltrant before the continuous fiber fabric is transported into the transition flattening device.

[0011] In some embodiments, the continuous fiber fabric providing unit further includes: an infiltrant activation device adapted to provide heat to the continuous fiber fabric treated by the pretreatment device so that the infiltrant infiltrated into the continuous fiber fabric is activated.

[0012] In some embodiments, the infiltrant activation device includes: an infrared oven.

[0013] In some embodiments, the pressing device includes at least two pressing rollers.

[0014] In some embodiments, the material of the pressing roller is metal, and the inside of the pressing roller is adapted to pass hot oil or steam to maintain the temperature of the pressing roller.

[0015] In some embodiments, the heating device is an oven, and the pressing device is located inside the oven.

[0016] In some embodiments, the heating device is an infrared oven.

[0017] In some embodiments, the preparation device further comprises: a cooling unit, configured to receive the continuous fiber fabric that has passed through the resin impregnation unit and cool the thermoplastic resin impregnated in the continuous fiber fabric.

[0018] In some embodiments, the cooling unit comprises: at least a pair of cooling rollers, and the at least a pair of cooling rollers are adapted to cooperate with each other to extrude and cool the thermoplastic resin from both sides of the continuous fiber fabric.

[0019] In some embodiments, the positions of the cooling rollers are adjustable.

[0020] In some embodiments, the cooling unit further comprises: an air cooling device or a water cooling device, adapted to further cool the continuous fiber fabric impregnated with the thermoplastic resin cooled by the cooling rollers.

[0021] In some embodiments, the resin supply device comprises: a first coating device and a second coating device, adapted to coat the thermoplastic resin on both sides of the continuous fiber fabric.

[0022] In some embodiments, the first coating device and the second coating device respectively comprise: a double-layer coextrusion die head, adapted to coat two layers of thermoplastic resin on both sides of the continuous fiber fabric respectively.

[0023] In some embodiments, the continuous fiber fabric supply unit further comprises: at least one transition roller, and one of the transition rollers is used to change the transmission direction of the continuous fiber fabric from a horizontal direction to a vertical direction; the first coating device and the second coating device are relatively arranged on both sides of the continuous fiber fabric, and are adapted to coat the thermoplastic resin on both sides of the continuous fiber fabric when the continuous fiber fabric passes through in the vertical direction.

[0024] In some embodiments, the pressing device comprises three pressing rollers, and the connecting lines of the roller axes of the cross-sections of the three pressing rollers form a right angle, so that the continuous fiber fabric transmitted in the vertical direction is changed to be transmitted in the horizontal direction after passing through the three pressing rollers.

[0025] In some embodiments, the preparation device further includes: a flipping unit adapted to flip the continuously-fibered fabric being horizontally transported, so as to displace the orientations of both sides of the continuously-fibered fabric, and continue to transport it in the horizontal direction; the first coating device is disposed before the flipping unit and is adapted to coat one side of the continuously-fibered fabric before flipping with a thermoplastic resin; the second coating device is disposed after the flipping unit and is adapted to coat the other side of the continuously-fibered fabric after flipping with a thermoplastic resin; the pressing device includes: a first pressing roller assembly and a second pressing roller assembly, the first pressing roller assembly and the second pressing roller assembly each include at least two pressing rollers, the first pressing roller assembly is disposed between the first coating device and the flipping unit and is adapted to press the thermoplastic resin coated on one side of the continuously-fibered fabric against the continuously-fibered fabric; the second pressing roller assembly is disposed after the second coating device and is adapted to press the thermoplastic resin coated on the other side of the continuously-fibered fabric against the continuously-fibered fabric; the heating device includes: a first heating device adapted to heat the thermoplastic resin when the first pressing roller assembly performs pressing; a second heating device adapted to heat the thermoplastic resin when the second pressing roller assembly performs pressing.

[0026] In some embodiments, the flipping unit includes two flipping rollers adapted to horizontally flip the continuously-fibered fabric being horizontally transported through the first coating device and then continue to transport it horizontally to the second coating device.

[0027] In some embodiments, the first pressing roller assembly includes: three pressing rollers arranged horizontally; the second pressing roller assembly includes: three pressing rollers arranged horizontally.

[0028] An embodiment of the present disclosure further provides a method for preparing a continuously-fibered fabric reinforced thermoplastic composite board, using any of the above preparation devices to prepare a continuously-fibered fabric reinforced thermoplastic composite board, the preparation method including the following steps: S1: providing a continuously-fibered fabric through a continuously-fibered fabric providing unit; S2: coating the thermoplastic resin on both sides of the continuously-fibered fabric through a resin providing device, pressing the coated thermoplastic resin and the continuously-fibered fabric by a pressing device, and heating the thermoplastic resin during the pressing process through the heating device.

[0029] In some embodiments, the preparation method includes the following steps: S3: quickly cooling and shaping the thermoplastic resin by a cooling roller, and further cooling the thermoplastic resin by an air-cooling or water-cooling device to remove stress.

[0030] In some embodiments, the temperature for heating the thermoplastic resin during the pressing process is 100°C to 200°C.

[0031] In some embodiments, the temperature of each pressing roller of the pressing device is 100°C to 300°C.

[0032] In some embodiments, S1 includes: S11: Pretreating the continuous fiber fabric, where the pretreatment includes: impregnating the continuous fiber fabric with an impregnating agent.

[0033] In some embodiments, the impregnating agent includes at least one of a silane coupling agent, a film-forming agent, a crosslinking agent, a compatibilizer, and an antistatic agent.

[0034] In some embodiments, S1 further includes: S12: After pretreating the continuous fiber fabric, heating to activate the impregnating agent impregnated in the continuous fiber fabric, where the heating temperature is 20°C to 450°C.

[0035] In some embodiments, S1 includes: S13: Traction and flattening the continuous fiber fabric through a pre-traction roller assembly and a flattening roller assembly to make the fiber directions of the continuous fiber fabric regular, where the rotation speed of the pre-traction roller in the pre-traction roller assembly is 1 to 2 mm / min, and the rotation speed of the flattening roller in the flattening roller assembly is 1 to 2 mm / min.

[0036] In some embodiments, in S2, coating the thermoplastic resin on both sides of the continuous fiber fabric includes: coating the thermoplastic resin on both sides of the continuously vertically transported continuous fiber fabric simultaneously through a first coating device and a second coating device, or coating it on both sides of the continuously horizontally transported continuous fiber fabric successively.

[0037] In some embodiments, the continuous fiber fabric includes: a continuous glass fiber fabric, a continuous carbon fiber fabric, a continuous aramid fiber fabric, a continuous alumina fiber fabric, a continuous polyester fiber fabric, or a continuous glass fiber polyester fiber woven fabric; the thermoplastic resin includes at least one of a polypropylene resin, a polyethylene resin, a polyvinyl chloride resin, a polyethylene terephthalate resin, a nylon resin, a polyoxymethylene resin, a polycarbonate resin, and a polyphenylene sulfide resin.

[0038] An embodiment of the present disclosure also provides a continuous fiber fabric reinforced thermoplastic composite board prepared according to any of the above preparation methods.

[0039] Compared with the prior art, the technical solution of the embodiment of the present disclosure has the following beneficial effects:

[0040] The preparation device of the continuous fiber fabric reinforced thermoplastic composite board according to the embodiments of the present disclosure, the resin infiltration unit includes a heating device, which is adapted to heat the thermoplastic resin during the pressing process of the continuous fiber fabric coated with the thermoplastic resin, so as to improve the fluidity of the thermoplastic resin, and further improve the wettability of the thermoplastic resin to the continuous fiber fabric, and improve the mechanical strength of the composite board.

[0041] Further, the pressing is performed by a pressing roller, and the continuous fiber fabric is only under pressure when it contacts the pressing roller, avoiding being under pressure for a long time during the pressing process, which is beneficial to maintaining the regularity of the continuous fiber fabric and the full pressing and infiltration of the thermoplastic resin in the continuous fiber fabric.

[0042] Further, the continuous fiber fabric providing unit according to the embodiments of the present disclosure pre-traces and flattens the continuous fiber fabric through a transition flattening device, so that the fiber directions of the continuous fiber fabric entering the resin infiltration unit are regular, which is more conducive to the thermoplastic resin infiltrating the continuous fiber fabric.

[0043] Further, the thermoplastic resin infiltrated in the continuous fiber fabric after pressing is quickly cooled and shaped by the cooling roller according to the embodiments of the present disclosure. At the same time, the internal stress is further removed by cooling through a water cooling device or an air cooling device. The prepared composite board has no warping problem, and the flatness of the surface of the composite board is excellent, meeting the A-level surface standard.

[0044] Further, the first coating device and the second coating device according to the embodiments of the present disclosure are relatively arranged on both sides of the continuous fiber fabric, and are adapted to uniformly coat the thermoplastic resin on both sides of the continuous fiber fabric when the continuous fiber fabric passes in the vertical direction, so as to facilitate the subsequent pressing device to press and uniformly infiltrate the thermoplastic resin and the continuous fiber fabric.

[0045] Furthermore, the first coating device and the second coating device according to the embodiments of the present disclosure are respectively arranged before and after the flipping unit, and coat the thermoplastic resin on both sides of the horizontally transported continuous fiber fabric respectively. This coating is not affected by gravity, so that the thermoplastic resin is coated on both sides of the continuous fiber fabric successively. The uniformly coated thermoplastic resin is beneficial for the pressing device to press and uniformly infiltrate the thermoplastic resin and the continuous fiber fabric.

[0046] Further, the pretreatment device and the sizing agent activation device according to the embodiments of the present disclosure improve the interfacial adhesion between the continuous fiber fabric and the thermoplastic resin by infiltrating the continuous fiber fabric with a sizing agent and activating the sizing agent, and further improve the mechanical strength of the composite board. In addition, infiltrating and heating and activating the sizing agent on the continuous fiber fabric has lower production cost and operation convenience compared with modifying the thermoplastic resin.

[0047] Furthermore, the resin providing device of the embodiments of the present disclosure includes a double-layer co-extrusion die head, which is adapted to coat two layers of thermoplastic resin on one or both sides of the continuous fiber fabric. The two layers of thermoplastic resin are laminated on the surface of the continuous fiber fabric and have different compositions. By adjusting the mechanical properties, wear resistance, and interfacial adhesion between the thermoplastic resin and the continuous fiber fabric with the double-layer thermoplastic resin of different compositions, the overall performance of the composite board can be improved. Description of the Drawings

[0048] Other features and advantages of the present disclosure will be better understood through the following alternative embodiments described in detail in conjunction with the drawings, where the same reference numerals represent the same or similar components, and in which:

[0049] Figure 1 FIG. shows a schematic diagram of an embodiment of a preparation device for a continuous fiber fabric reinforced thermoplastic composite board according to an embodiment of the present disclosure;

[0050] Figure 2 FIG. shows a schematic diagram of another embodiment of a preparation device for a continuous fiber fabric reinforced thermoplastic composite board according to an embodiment of the present disclosure. Detailed Embodiments

[0051] The embodiments of the present disclosure will be described in detail below. The examples of the embodiments are shown in the drawings. In the drawings, the same or similar reference numerals represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the drawings are exemplary and are only used to explain the present disclosure and should not be construed as a limitation of the present disclosure.

[0052] Unless otherwise defined, the technical terms or scientific terms used herein should have the ordinary meaning as understood by those of ordinary skill in the art to which the present disclosure belongs. In the description of the present disclosure, it should be understood that the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present disclosure and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation of the present disclosure.

[0053] The embodiments of the present disclosure provide a preparation device for a continuous fiber fabric reinforced thermoplastic composite board, which will be elaborated in detail below in conjunction with the drawings.

[0054] Figure 1 FIG. shows a schematic diagram of an embodiment of a preparation device for a continuous fiber fabric reinforced thermoplastic composite board according to an embodiment of the present disclosure. Refer to Figure 1, the preparation device of the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiments of the present disclosure includes:

[0055] A continuous fiber fabric providing unit 1 for providing a flat continuous fiber fabric;

[0056] A resin infiltration unit 2 adapted to receive the continuous fiber fabric provided by the continuous fiber fabric providing unit 1 and infiltrate the continuous fiber fabric with a thermoplastic resin. The resin infiltration unit 2 includes:

[0057] A resin providing device 201 adapted to coat the thermoplastic resin on one or both sides of the continuous fiber fabric;

[0058] A pressing device 202 adapted to press the thermoplastic resin coated on the continuous fiber fabric with the continuous fiber fabric;

[0059] A heating device 203 adapted to heat the thermoplastic resin during the pressing process.

[0060] In some embodiments, for the preparation device of the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiments of the present disclosure, the continuous fiber fabric providing unit 1 includes a transition flattening device 101 for transporting and flattening the continuous fiber fabric so that the fiber directions of the continuous fiber fabric entering the resin infiltration unit 2 are regular.

[0061] The transition flattening device 101 includes a pre-traction roller assembly 1011 for providing traction to the continuous fiber fabric. The pre-traction roller assembly 1011 includes at least two pre-traction rollers, which are relatively arranged on both sides of the continuous fiber fabric and are adapted to cooperate to traction the continuous fiber fabric from both sides of the continuous fiber fabric. Due to the traction of the pre-traction rollers on the continuous fiber fabric, the continuous fiber fabric is gradually subjected to traction force, rather than suddenly being subjected to a large traction force resulting in a change in the fiber direction, thereby avoiding the problem that the fiber directions change during the traction of the continuous fiber fabric, resulting in irregular fiber arrangement, and further avoiding problems such as poor infiltration effect of the subsequent thermoplastic resin and uneven surface of the composite plate formed after the infiltration of the thermoplastic resin.

[0062] The transition flattening device 101 further includes a flattening roller assembly 1012 including at least one flattening roller for flattening the continuous fiber fabric. The flattening roller assembly 1012 is beneficial to further regularize the fiber directions of the continuous fiber fabric and at the same time flatten the surface of the continuous fiber fabric.

[0063] In some embodiments, the flattening roller assembly 1012 is arranged behind the pre-traction roller assembly 1011, that is, first the continuous fiber fabric is pre-tracted by the pre-traction roller assembly 1011, and then the continuous fiber fabric is flattened by the flattening roller assembly 1012.

[0064] In some embodiments, to make the traction force on the continuous fiber fabric more uniform, the pre-traction roller assembly 1011 may include multiple groups of pre-traction rollers with a certain spacing, and each group of pre-traction rollers includes at least two pre-traction rollers.

[0065] In some embodiments, the continuous fiber fabric providing unit 1 further includes: at least one transition roller 104, and one of the transition rollers 104 is disposed after the pre-traction roller assembly 1011 for changing the transmission direction of the continuous fiber fabric from the horizontal direction to the vertical direction.

[0066] In some embodiments, referring to Figure 1 , the transition roller 104 disposed after the pre-traction roller assembly 1011 and the flattening roller assembly 1012 are disposed on opposite sides of the continuous fiber fabric, and are adapted to cooperate with each other to flatten both sides of the continuous fiber fabric. At the same time, the continuous fiber fabric undergoes a 90° turn when passing through the transition roller 104, changing from horizontal transmission to vertical transmission.

[0067] In some embodiments of the preparation device for the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiments of the present disclosure, the continuous fiber fabric providing unit 1 further includes: a pretreatment device 102, which is adapted to perform an infiltration treatment on the continuous fiber fabric through an infiltrant before the continuous fiber fabric is transmitted into the transition flattening device 101.

[0068] In some embodiments, the pretreatment device 102 includes an infiltration tank (not shown in the figure), and the infiltration tank stores an infiltrant. When performing an infiltration treatment on the continuous fiber fabric, the continuous fiber fabric is immersed in the infiltration tank for infiltration, so that the infiltrant infiltrates into the continuous fiber fabric.

[0069] In some embodiments, the infiltrant is selected and proportioned according to the type of thermoplastic resin. The infiltrant can be a single substance or multiple substances, or a solution of a single substance or a mixed solution of multiple substances. In some embodiments, the infiltrant includes at least one of a silane coupling agent, a film-forming agent, a cross-linking agent, a compatibilizer, and an antistatic agent. In some embodiments, the infiltrant is a water-soluble infiltrant, exists in the form of an aqueous solution, and the mass fraction of the infiltrant in the aqueous solution is 5% - 10%. The infiltrant includes: 5% - 10% of a silane coupling agent, 30% - 70% of a film-forming agent, 5% - 20% of a cross-linking agent, 1% - 10% of a compatibilizer, and 2% - 5% of an antistatic agent.

[0070] In some embodiments, the pretreatment device 102 further includes a drying device for drying the continuous fiber fabric infiltrated with the infiltrant to evaporate the moisture, which is more conducive to winding or subsequent flattening and infiltration with thermoplastic resin, etc.

[0071] In some embodiments, the continuous fiber fabric providing unit 1 further includes an unwinding device 105, which is configured to receive the continuous fiber fabric processed by the pretreatment device 102, wind and store it, and is adapted to actively unwind to transfer the continuous fiber fabric to the transition flattening device 101.

[0072] In the preparation device of the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiments of the present disclosure, in some embodiments, the continuous fiber fabric providing unit 1 further includes: a sizing agent activation device 103, which is adapted to provide heat to the continuous fiber fabric processed by the pretreatment device 102 so that the sizing agent infiltrated in the continuous fiber fabric is activated, and the activated sizing agent is more conducive to the infiltration of the thermoplastic resin into the continuous fiber fabric.

[0073] In some embodiments, the sizing agent activation device 103 includes: an infrared oven. In some embodiments, the infrared oven is adapted to provide a temperature environment of 20°C to 450°C to activate the sizing agent.

[0074] In some embodiments, the sizing agent activation device 103 is disposed on the path where the continuous fiber fabric is transmitted in the vertical direction, as Figure 1 shown; in some other embodiments, the sizing agent activation device 103 is disposed on the path where the continuous fiber fabric is transmitted in the horizontal direction; there is no limitation here.

[0075] In the preparation device of the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiments of the present disclosure, in some embodiments, the resin providing device 201 includes: a first coating device 2011 and a second coating device 2012, which are adapted to coat the thermoplastic resin on both sides of the continuous fiber fabric.

[0076] Referring to Figure 1 , the first coating device 2011 and the second coating device 2012 are oppositely disposed on both sides of the continuous fiber fabric, and are adapted to coat the thermoplastic resin on both sides of the continuous fiber fabric when the continuous fiber fabric passes through in the vertical direction.

[0077] In some embodiments, the first coating device 2011 includes an extrusion die head, the second coating device 2012 includes an extrusion die head, and the extrusion die heads of the first coating device 2011 and the second coating device 2012 are disposed at the same height to coat the thermoplastic resin on two surfaces of the continuous fiber fabric at the same height.

[0078] The width of the extrusion orifice of the extrusion die head corresponds to the width of the continuous fiber fabric, so as to facilitate the extrusion die head to uniformly coat the thermoplastic resin on two surfaces of the continuous fiber fabric, and further facilitate the subsequent uniform infiltration of the thermoplastic resin into the continuous fiber fabric.

[0079] In some embodiments, the first coating device 2011 is an extruder, and the second coating device 2012 is an extruder.

[0080] In some embodiments, the extrusion dies of the first coating device 2011 and the second coating device 2012 are double-layer co-extrusion dies, which are suitable for coating two layers of thermoplastic resin on the surface of a continuous fiber fabric. The two layers of thermoplastic resin are stacked on the surface of the continuous fiber fabric and have different compositions. The mechanical properties, wear resistance, and interfacial adhesion between the thermoplastic resin and the continuous fiber fabric of the composite board are adjusted through the double-layer thermoplastic resin with different compositions, thereby improving the overall performance of the prepared composite board.

[0081] In the preparation device of the continuous fiber fabric reinforced thermoplastic composite board according to the embodiments of the present disclosure, in some embodiments, the heating device 203 of the resin infiltration unit 2 is an oven, and the pressing device 202 of the resin infiltration unit 2 is located in the oven and is suitable for receiving the continuous fiber fabric coated with thermoplastic resin by the resin supply device 201 and performing pressing. In some embodiments, the heating device 203 of the resin infiltration unit 2 is an infrared oven and is arranged below the pressing device 202.

[0082] Since the pressing device 202 is arranged in the oven, it is in the temperature environment set by the oven. During the pressing process of the continuous fiber fabric coated with thermoplastic resin, the oven temperature is set to heat the thermoplastic resin, which improves the fluidity of the thermoplastic resin, and further improves the wettability of the thermoplastic resin to the continuous fiber fabric. Moreover, the thermoplastic resin with good fluidity is not easy to damage the fiber directions of the continuous fiber fabric and maintains the regularity of each fiber direction during infiltration, improving the mechanical strength of the prepared composite board from both the aspects of fiber regularity and resin wettability.

[0083] In some embodiments, the heating device 203 is suitable for providing a temperature environment of 100°C to 200°C to improve the fluidity of the thermoplastic resin during the pressing process.

[0084] In the preparation device of the continuous fiber fabric reinforced thermoplastic composite board according to the embodiments of the present disclosure, in some embodiments, the pressing device 202 includes at least two pressing rollers.

[0085] Continue to refer to Figure 1 , the pressing device 202 of the resin infiltration unit 2 includes three pressing rollers (2021, 2022, 2023), wherein one pressing roller 2022 and the other two pressing rollers (2021, 2023) are respectively arranged opposite to both sides of the continuous fiber fabric and are suitable for cooperating with each other to press the thermoplastic resin infiltrated in the continuous fiber fabric and the continuous fiber fabric.

[0086] The material of the pressing roller can be selected as needed. Each pressing roller of the pressing device 202 can be of the same or different materials. In some embodiments, the materials of the pressing roller are: rubber, silica gel, fluororubber, metal, etc. In some embodiments, the material of the pressing roller is steel.

[0087] In some embodiments, the material of the pressing roller is high-strength steel; in some embodiments, hot oil or steam is suitable for being introduced into the pressing roller to maintain the temperature of the pressing roller, so that the thermoplastic resin is heated to enhance its fluidity.

[0088] In some embodiments, the temperature of the pressing roller is 100°C to 300°C.

[0089] In some embodiments, the connecting lines of the roller axes of the cross-sections of the three pressing rollers (2021, 2022, 2023) are at right angles, that is, the included angle between the connecting line of the roller axes of the cross-sections of the pressing roller 2022 and the pressing roller 2021 and the connecting line of the roller axes of the cross-sections of the pressing roller 2022 and the pressing roller 2023 is a right angle. Thus, the continuous fiber fabric transmitted in the vertical direction is changed to be transmitted in the horizontal direction after passing through the three pressing rollers (2021, 2022, 2023). The pressing device 202 simultaneously functions to press the continuous fiber fabric and change the transmission direction of the continuous fiber fabric.

[0090] Continue to refer to Figure 1 , the continuous fiber fabric is initially transmitted in the horizontal direction. After passing through the transition roller 104, the transmission direction is changed to the vertical direction. The resin supply device 201 is suitable for uniformly coating the two sides of the continuous fiber fabric transmitted in the vertical direction with the thermoplastic resin, and then the pressing device 202 presses the continuous fiber fabric and simultaneously changes its transmission direction to the horizontal direction.

[0091] The continuous fiber fabric transmitted in the horizontal direction is beneficial for leveling. When coating the continuous fiber fabric transmitted in the vertical direction with the thermoplastic resin, the transmission direction of the thermoplastic resin is consistent with the direction of gravity. At the same time, by coordinating the adjustment of the transmission speed and the extrusion pressure of the thermoplastic resin, the thermoplastic resin is uniformly coated on the two sides of the continuous fiber fabric at the same time. Then, subsequently, the thermoplastic resin and the continuous fiber fabric are pressed through the pressing device, so as to realize the uniform infiltration of the thermoplastic resin into the continuous fiber fabric. For the conventional preparation device for coating the continuous fiber fabric transmitted in the horizontal direction with the thermoplastic resin, the thermoplastic resin is greatly affected by gravity, which will cause the problem of uneven distribution of the thermoplastic resin and affect the infiltration effect. Compared with the conventional preparation device for coating the continuous fiber fabric transmitted in the horizontal direction with the thermoplastic resin, the preparation device of the embodiments of the present disclosure coats the thermoplastic resin when the continuous fiber fabric is transmitted in the vertical direction, which can eliminate the influence of gravity on the distribution of the thermoplastic resin and uniformly coat the thermoplastic resin on the surface of the continuous fiber fabric.

[0092] The preparation device of the continuous fiber fabric reinforced thermoplastic composite board according to the embodiments of the present disclosure. In some embodiments, the preparation device further includes: a cooling unit 3, configured to receive the continuous fiber fabric that has passed through the resin infiltration unit 2 and cool the thermoplastic resin infiltrated in the continuous fiber fabric.

[0093] Continuing to refer to Figure 1 , the cooling unit 3 includes at least a pair of cooling rollers 301, and each pair of cooling rollers 301 is adapted to cooperate to cool the thermoplastic resin from both sides of the continuous fiber fabric. The continuous fiber fabric passing through the cooling rollers is rapidly cooled, and the thermoplastic resin infiltrated in the continuous fiber fabric is quickly shaped, thereby ensuring the flatness of its surface.

[0094] In some embodiments, the position of the cooling roller 301 is adjustable to change the distance between the cooling roller 301 and the pressing device 202, and to adjust the time for the thermoplastic resin to reach the cooling roller 301 after passing through the pressing device 202 in coordination with the traction speed of the continuous fiber fabric, so as to avoid problems such as warping caused by too long a natural cooling time of the thermoplastic resin due to too long a distance. That is, through the position adjustment of the cooling roller 301, the thermoplastic resin infiltrated in the continuous fiber fabric after passing through the pressing device 202 is quickly cooled and shaped by being extruded by the cooling roller 301 while maintaining fluidity (at a certain temperature) to form a flat composite board surface and avoid problems such as warping.

[0095] To quickly cool the thermoplastic resin infiltrated in the continuous fiber fabric, in some embodiments, the temperature of the cooling roller 301 of the cooling unit 3 is -10°C to 10°C. In some embodiments, coolant is introduced into the cooling roller 301 to ensure the temperature of the cooling roller 301.

[0096] In some embodiments, the cooling unit 3 further includes a water cooling device 302, which is arranged behind the cooling roller 301 and is used to further cool the continuous fiber fabric infiltrated with thermoplastic resin that has been cooled by the cooling roller 301 to remove internal stress and avoid problems such as warping or unevenness caused by internal stress over time.

[0097] In some embodiments, the water cooling device 302 is a cooling water tank, and the temperature of the cooling water in the cooling water tank is 0°C to 10°C.

[0098] In some embodiments, the cooling unit 3 further includes an air cooling device ( Figure 1 not shown), which is arranged behind the cooling roller 301 and is used to further cool the continuous fiber fabric infiltrated with thermoplastic resin that has been cooled by the cooling roller 301 to remove internal stress and avoid problems such as warping or unevenness caused by internal stress over time.

[0099] After passing through the cooling unit 3, the continuous fiber fabric reinforced thermoplastic composite board has been prepared, and subsequent cutting and winding can be carried out according to needs.

[0100] The preparation device for a continuous fiber fabric reinforced thermoplastic composite plate according to an embodiment of the present disclosure. In some embodiments, the preparation device further includes: a traction unit 4 for providing traction force for the continuous production of the composite plate.

[0101] In some embodiments, the traction unit 4 includes a traction device 401 which includes at least two traction rollers. The two traction rollers are oppositely arranged on both sides of the continuous fiber fabric and are adapted to cooperate with each other to provide traction force for the continuous fiber fabric.

[0102] In some embodiments, the traction unit 4 further includes a winding device 402 for winding the continuous fiber fabric reinforced thermoplastic composite plate.

[0103] The preparation device for a continuous fiber fabric reinforced thermoplastic composite plate according to an embodiment of the present disclosure. In some embodiments, the continuous fiber fabric is a continuous glass fiber fabric, a continuous carbon fiber fabric, a continuous aramid fiber fabric, a continuous alumina fiber fabric, a continuous polyester fiber fabric, or a continuous glass fiber polyester fiber mixed woven fabric.

[0104] In some embodiments, the thermoplastic resin includes at least one of: polypropylene resin, polyethylene resin, polyvinyl chloride resin, polyethylene terephthalate resin, nylon resin, polyoxymethylene resin, polycarbonate resin, polyphenylene sulfide resin.

[0105] In some embodiments, the thermoplastic resin provided by the resin supply device 201 is a thermoplastic resin modified with an additive. The additive includes at least one of: a compatibilizer, an antioxidant, a heat resistant agent, a masterbatch.

[0106] Figure 2 It shows a schematic diagram of another embodiment of the preparation device for a continuous fiber fabric reinforced thermoplastic composite plate according to an embodiment of the present disclosure. Figure 2 And Figure 1 For different embodiments, the difference is that Figure 2 In the embodiment of, the resin infiltration unit and the cooling unit infiltrate and cool the thermoplastic resin on the two surfaces of the continuous fiber fabric transported in the horizontal direction successively. The continuous fiber fabric passes through a flipping unit for horizontal flipping so that different surfaces of the continuous fiber fabric face upward for the infiltration of the thermoplastic resin.

[0107] Figure 2 In the embodiment of, the pretreatment device 12, the sizing agent activation device 13, the unwinding device 14, the traction device 41, the winding device 42 and Figure 1 The pretreatment device 102, the sizing agent activation device 103, the unwinding device 105, the traction device 401, the winding device 402 in are the same or similar, and will not be described in detail here.

[0108] Reference Figure 2 , the pre-traction roller assembly 111 includes two pairs of pre-traction rollers for traction of the continuous fiber fabric for transmission to the flattening roller assembly 112 for flattening.

[0109] The resin supply device includes: a first coating device 211 and a second coating device 212 adapted to sequentially coat the corresponding positions on both sides of the continuous fiber fabric with the thermoplastic resin. In some embodiments, the first coating device 211 includes an extrusion die head adapted to extrude the thermoplastic resin to coat the first side of the continuous fiber fabric when the continuous fiber fabric passes horizontally; in some embodiments, the second coating device 212 includes an extrusion die head adapted to extrude the thermoplastic resin to coat the second side of the continuous fiber fabric when the continuous fiber fabric passes horizontally, the second side having an opposite orientation to the first side.

[0110] In some embodiments, the extrusion die head of the first coating device 211 is disposed above the first pressing roller assembly 221, and the extrusion die head of the second coating device 212 is disposed above the second pressing roller assembly 222, and the extrusion orifice of the extrusion die head is disposed between the two pressing rollers, so that the extruded thermoplastic resin is pressed by the pressing rollers in the first time to infiltrate the continuous fiber fabric.

[0111] In some embodiments, the preparation device of the continuous fiber reinforced thermoplastic composite plate further includes: a flipping unit 5 adapted to flip the horizontally transmitted continuous fiber fabric, so that the orientations of both sides of the continuous fiber fabric are replaced, and continue to be transmitted in the horizontal direction, and the coating is completed when the side of the continuous fiber fabric that needs to be coated with the thermoplastic resin faces upward.

[0112] In some embodiments, the flipping unit 5 includes two flipping rollers (51, 52) adapted to horizontally flip the continuously fiber fabric transmitted in the horizontal direction and then continue to be transmitted in the horizontal direction. In some embodiments, the flipping roller 52 is disposed directly below the flipping roller 51.

[0113] In some embodiments, the pressing device includes: a first pressing roller assembly 221 and a second pressing roller assembly 222. The first pressing roller assembly 221 and the second pressing roller assembly 222 each include at least two pressing rollers. The first pressing roller assembly 221 is disposed between the first coating device 211 and the flipping unit 5 and is adapted to press the thermoplastic resin coated on the first side of the continuous fiber fabric against the continuous fiber fabric; the second pressing roller assembly 222 is disposed after the second coating device and is adapted to press the thermoplastic resin coated on the second side of the continuous fiber fabric against the continuous fiber fabric.

[0114] In some embodiments, the first pressing roller assembly 221 includes: three pressing rollers (2211, 2212, 2213) arranged horizontally; in some embodiments, the first pressing roller 2211 that the continuous fiber fabric first passes through is a silica gel roller, and the other two pressing rollers (2212, 2213) arranged horizontally with the silica gel roller are steel rollers.

[0115] In some embodiments, the second pressing roller assembly 222 includes: three pressing rollers (2221, 2222, 2223) arranged horizontally; in some embodiments, the first pressing roller 2221 that the continuous fiber fabric first passes through is a silica gel roller, and the other two pressing rollers (2222, 2233) arranged horizontally with the silica gel roller are steel rollers.

[0116] In some embodiments, the heating device includes: a first heating device 231, adapted to heat the thermoplastic resin when the first pressing roller assembly 221 performs pressing; a second heating device 232, adapted to heat the thermoplastic resin when the second pressing roller assembly 222 performs pressing.

[0117] In some embodiments, the first heating device 231 is an infrared oven, disposed below the first pressing roller assembly 221, so that when the continuous fiber fabric passes through the first pressing roller assembly 221, its first side faces the infrared oven, which is beneficial to heating the thermoplastic resin; in some embodiments, the first heating device 231 is a high-temperature oven, and at least one pressing roller of the first pressing roller assembly 221 is disposed in the high-temperature oven.

[0118] In some embodiments, the second heating device 232 is an infrared oven, disposed below the second pressing roller assembly 222, so that when the continuous fiber fabric passes through the second pressing roller assembly 222, its second side faces the infrared oven, which is beneficial to heating the thermoplastic resin; in some embodiments, the second heating device 232 is a high-temperature oven, and at least one pressing roller of the second pressing roller assembly 222 is disposed in the high-temperature oven.

[0119] During the process of pressing the continuous fiber fabric and the thermoplastic resin, the first heating device 231 and the second heating device 232 are respectively used for heating to improve the fluidity of the thermoplastic resin, thereby improving the infiltration effect.

[0120] Continue to refer to Figure 2, The three pressing rollers (2211, 2212, 2213) of the first pressing roller assembly 221 are horizontally arranged. In some embodiments, the first heating device 231 heats the pressing roller 2212 located between the two pressing rollers (2212, 2213) during the pressing process. Further, the first heating device 231 is located below the pressing roller 2212 and the pressing roller 2213, or the pressing roller 2212 and the pressing roller 2213 are located within the first heating device 231. The first heating device 231 heats the thermoplastic resin coated on the continuous fiber fabric passing through the pressing roller 2212 and the pressing roller 2213 to keep the thermoplastic resin at a certain temperature during the pressing process, so that the thermoplastic resin passing through the pressing roller 2213 maintains its temperature and fluidity and is rapidly cooled and shaped after entering the cooling unit, forming a flat surface of the composite board and preventing warping.

[0121] The three pressing rollers (2221, 2222, 2223) of the second pressing roller assembly 222 are horizontally arranged. In some embodiments, the second heating device 232 heats the pressing roller 2222 in the middle during the pressing process. Further, the second heating device 232 is located below the pressing roller 2222 and the pressing roller 2223, or the pressing roller 2222 and the pressing roller 2223 are located within the second heating device 232. The second heating device 232 heats the thermoplastic resin coated on the continuous fiber fabric passing through the pressing roller 2222 and the pressing roller 2223 to keep the thermoplastic resin at a certain temperature during the pressing process, so that the thermoplastic resin passing through the pressing roller 2223 maintains its temperature and is rapidly cooled and shaped after entering the cooling unit, forming a flat surface of the composite board and preventing warping.

[0122] In some embodiments, the preparation device of the continuous fiber reinforced thermoplastic composite board further includes a cooling unit. The cooling unit includes: a first cooling device 31, arranged after the first pressing roller assembly 221, including: at least a pair of cooling rollers 311, and the at least a pair of cooling rollers 311 are adapted to cooperate with each other to cool the thermoplastic resin infiltrated in the continuous fiber fabric after being pressed by the first pressing roller assembly 221; a second cooling device 32, arranged after the second pressing roller assembly 222, including: at least a pair of cooling rollers 321, and the at least a pair of cooling rollers 321 are adapted to cooperate with each other to cool the thermoplastic resin infiltrated in the continuous fiber fabric after being pressed by the second pressing roller assembly 222. The continuous fiber fabric passing through the cooling rollers is rapidly cooled, and the thermoplastic resin infiltrated in the continuous fiber fabric is rapidly cooled and shaped when it has fluidity and a certain temperature, thus ensuring the flatness of its surface.

[0123] In some embodiments, the temperature of the cooling roller 311 of the first cooling device 31 is -10°C to 10°C; in some embodiments, the temperature of the cooling roller 321 of the second cooling device 32 is -10°C to 10°C.

[0124] Continue to refer Figure 2 The first coating device 211, the first lamination roller assembly 221, the first heating device 231 and the first cooling device 31 are arranged before the turning unit 5, the second coating device 212, the second lamination roller assembly 222, the second heating device 232 and the second cooling device 32 are arranged after the turning unit 5, the first coating device 211 is arranged above the continuous fiber fabric transmission path, the first heating device 231 is an infrared oven below the first lamination roller assembly 221, the second coating device 212 is arranged above the continuous fiber fabric transmission path, and the second heating device 232 is an infrared oven below the second lamination roller assembly 222.

[0125] After being pulled and flattened by the transition flattening device 11, the continuous fiber fabric is horizontally transmitted to the first laminating roller assembly 221, with the first side of the continuous fiber fabric facing upward. When the continuous fiber fabric passes through the first coating device 211, the first coating device 211 coats the first side of the continuous fiber fabric with a thermoplastic resin, and then laminarizes the continuous fiber fabric through the first laminating roller assembly 221. During laminating, the continuous fiber fabric is heated by the first heating device 231, and after laminating, the continuous fiber fabric is cooled by the first cooling device 231, thereby completing the impregnation of the continuous fiber fabric with the thermoplastic resin from the first side. The continuous fiber fabric continues to be transmitted to the turning roller 51, and the transmission direction changes from the horizontal direction to the vertical direction after passing through the turning roller 51. After the continuous fiber fabric transmitted in the vertical direction passes through the turning roller 52, its transmission direction changes to the horizontal direction. After being turned over, the second side of the continuous fiber fabric faces upward, and the continuous fiber fabric continues to be transmitted horizontally, and the second side of the continuous fiber fabric is impregnated with the thermoplastic resin and cooled through the second coating device 212, the second laminating roller assembly 222, the second heating device 232, and the second cooling device 32.

[0126] In some embodiments, the cooling unit further includes an air cooling device 33 or a water cooling device (not shown in the figure). In some embodiments, the air cooling device 33 or the water cooling device is arranged after the second cooling device 32, and is used to further cool the continuous fiber fabric impregnated with the thermoplastic resin after being cooled by the second cooling device, so as to remove the internal stress and avoid the problems such as warping or unevenness caused by the internal stress over time.

[0127] The embodiments of the present disclosure further provide a method for preparing a continuous fiber fabric reinforced thermoplastic composite plate. The method uses the preparation device described in any of the above embodiments to prepare the continuous fiber fabric reinforced thermoplastic composite plate. The method comprises the following steps:

[0128] S1: Provide a continuous fiber fabric through a continuous fiber fabric providing unit;

[0129] S2: Coat both sides of the continuous fiber fabric with a thermoplastic resin through a resin providing device, press the coated thermoplastic resin and the continuous fiber fabric together by a pressing device so that the thermoplastic resin infiltrates the continuous fiber fabric, and heat the thermoplastic resin during the pressing process through a heating device.

[0130] In the method for preparing a continuous fiber fabric reinforced thermoplastic composite board according to an embodiment of the present disclosure, in some embodiments, during the pressing process of the continuous fiber fabric coated with the thermoplastic resin, the heating temperature of the thermoplastic resin is 100°C to 200°C. For different thermoplastic resins, different heating temperatures can be set to better improve the fluidity of the thermoplastic resin.

[0131] In some embodiments, by introducing hot oil or hot steam inside the pressing rollers, the temperature of each pressing roller of the pressing device is 100°C to 300°C to improve the fluidity of the thermoplastic resin during the pressing process. The temperature of the pressing rollers can be set according to the type or components of the thermoplastic resin.

[0132] In the method for preparing a continuous fiber fabric reinforced thermoplastic composite board according to an embodiment of the present disclosure, in some embodiments, step S1 includes:

[0133] S11: Pretreat the continuous fiber fabric, and the pretreatment includes: infiltrating the continuous fiber fabric with a sizing agent.

[0134] According to the types of the continuous fiber fabric and the thermoplastic resin and the performance requirements for preparing the composite board, a sizing agent with specific components is formulated to improve the interfacial adhesion between the continuous fiber fabric and the thermoplastic resin, thereby improving the mechanical strength of the composite board. In some embodiments, the sizing agent includes at least one of a silane coupling agent, a film-forming agent, a crosslinking agent, a compatibilizer, and an antistatic agent. In some embodiments, the sizing agent is a water-soluble sizing agent, exists in the form of an aqueous solution, and the mass fraction of the sizing agent in the aqueous solution is 5% to 10%. The sizing agent includes: 5% to 10% of a silane coupling agent, 30% to 70% of a film-forming agent, 5% to 20% of a crosslinking agent, 1% to 10% of a compatibilizer, and 2% to 5% of an antistatic agent.

[0135] In some embodiments, after the infiltration pretreatment, the continuous fiber fabric infiltrated with the sizing agent is dried to evaporate the moisture, which is more conducive to winding or subsequent flattening and infiltration with the thermoplastic resin.

[0136] In some embodiments, step S1 further includes:

[0137] S12: After pre-treating the continuous fiber fabric, heat it to activate the sizing agent infiltrated in the continuous fiber fabric, and the heating temperature is 20°C to 450°C.

[0138] In some embodiments, step S1 further includes:

[0139] S13: Traction and flattening of the continuous fiber fabric are performed through a pre-traction roller assembly and a flattening roller assembly to regularize the fiber directions of the continuous fiber fabric.

[0140] In some embodiments, the rotational speed of the pre-traction roller of the pre-traction roller assembly is 1 to 2 mm / min, and the rotational speed of the flattening roller in the flattening roller assembly is 1 to 2 mm / min. In some embodiments, the rotational speed of the pre-traction roller is less than or equal to the rotational speed of the flattening roller, and the rotational speed of the pre-traction roller is 90% to 100% of the rotational speed of the flattening roller.

[0141] In the method for preparing a continuous fiber fabric reinforced thermoplastic composite plate according to an embodiment of the present disclosure, in some embodiments, coating the thermoplastic resin on both sides of the continuous fiber fabric includes: simultaneously coating the thermoplastic resin on both sides of the continuously vertically transported continuous fiber fabric through a first coating device and a second coating device, or coating the thermoplastic resin on both sides of the continuously horizontally transported continuous fiber fabric before and after horizontal flipping of the continuous fiber fabric. Coating the thermoplastic resin on both sides of the continuously vertically transported continuous fiber fabric can be achieved through Figure 1 the preparation device of the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiment; coating the thermoplastic resin on both sides of the continuously horizontally transported continuous fiber fabric before and after horizontal flipping of the continuous fiber fabric can be achieved through Figure 1 the preparation device of the continuous fiber fabric reinforced thermoplastic composite plate according to the embodiment; details are not described herein again.

[0142] In some embodiments, the first coating device and the second coating device are extruders, and the extrusion of the thermoplastic resin is controlled by adjusting the extrusion amount, extrusion pressure, extruder temperature, etc. of the extruder. In some embodiments, the main pump pressure of the extruder is 2 MPa to 8 MPa, and in some embodiments, it is 4 MPa to 6 MPa; in some embodiments, the extruder temperature is 120 to 320°C, and in some embodiments, it is 180 to 300°C or 120 to 250°C; in some embodiments, the extrusion die head temperature is 200 to 350°C, and in some embodiments, it is 230 to 250°C or 280 to 320°C.

[0143] A method for preparing a continuous fiber fabric reinforced thermoplastic composite panel according to an embodiment of the present disclosure. In some embodiments, the preparation method further includes: S3: Rapidly cooling and shaping the thermoplastic resin by a cooling roll, and further cooling the thermoplastic resin by an air cooling or water cooling device to remove stress.

[0144] In some embodiments, the cooling unit includes at least a pair of cooling rolls, and each pair of cooling rolls is adapted to cooperate with each other to cool the thermoplastic resin from both sides of the continuous fiber fabric. The continuous fiber fabric passing through the cooling rolls is rapidly cooled, and the thermoplastic resin infiltrating the continuous fiber fabric is rapidly cooled and shaped when it has fluidity and a certain temperature, thereby ensuring the flatness of its surface. In some embodiments, the temperature of the cooling roll is adjusted to -10°C to 10°C.

[0145] In some embodiments, the cooling unit further includes: a water cooling device or / and an air cooling device, which is arranged behind the cooling roll and is used to continuously cool the continuous fiber fabric infiltrated with the thermoplastic resin after being cooled by the cooling roll to remove internal stress. In some embodiments, the water cooling device is a cooling water tank, and the temperature of the cooling water in the cooling water tank is 0°C to 10°C.

[0146] A method for preparing a continuous fiber fabric reinforced thermoplastic composite panel according to an embodiment of the present disclosure. In some embodiments, the preparation method further includes: After cooling, a continuous fiber fabric reinforced thermoplastic composite panel is obtained, and it can be cut and wound according to needs.

[0147] A method for preparing a continuous fiber fabric reinforced thermoplastic composite panel according to an embodiment of the present disclosure. In some embodiments, the continuous fiber fabric includes: continuous glass fiber fabric, continuous carbon fiber fabric, continuous aramid fiber fabric, continuous alumina fiber fabric, continuous polyester fiber fabric, or continuous glass fiber polyester fiber mixed woven fabric.

[0148] A method for preparing a continuous fiber fabric reinforced thermoplastic composite panel according to an embodiment of the present disclosure. In some embodiments, the thermoplastic resin includes: at least one of polypropylene resin, polyethylene resin, polyvinyl chloride resin, polyethylene terephthalate resin, nylon resin, polyoxymethylene resin, polycarbonate resin, and polyphenylene sulfide resin. In some embodiments, the thermoplastic resin is a thermoplastic resin modified with an additive, and the additive includes: at least one of a compatibilizer, an antioxidant, a heat resistant agent, and a masterbatch.

[0149] The following specifically describes the preparation method and preparation device of the continuous fiber fabric reinforced thermoplastic composite panel of the present disclosure in combination with specific embodiments. Embodiment 1 and Embodiment 2 respectively use Figure 1 and Figure 2 of the preparation device to prepare the continuous fiber fabric reinforced thermoplastic composite panel.

[0150] Example 1

[0151] (1) Continuously transport the EWR400 fiberglass square cloth in the horizontal direction through the pretreatment device 102 and perform surface infiltration treatment with an infiltrant. The infiltrant is a water-soluble infiltrant with 8 wt% of effective components. The effective components of the infiltrant include: 8 wt% of acyloxy silane coupling agent, 70 wt% of maleic anhydride modified polypropylene emulsion, 10 wt% of water-based blocked isocyanate crosslinking agent, 10 wt% of compatibilizer, and 2 wt% of antistatic agent; dry the infiltrated fiber fabric and wind it up for standby. The drying temperature in the oven is 200 - 300 °C;

[0152] (2) Load the EWR400 fiberglass square cloth treated with the infiltrant into the unwinding device 105 for active unwinding. The unwinding speed is 1.5 m / min, the speed of the pre-traction roller of the pre-traction roller assembly 111 is 1.5 m / min, and the speed of the flattening roller of the flattening roller assembly 1012 is 1.5 mm / min. Regularize the fiber directions of the continuous fiberglass fabric through pre-traction and flattening. After the continuous fiberglass fabric passes through the transition roller 104, the transmission direction changes from horizontal to vertical and enters the infrared oven used as the infiltrant activation device 103 in the vertical direction. The temperature of the infrared oven is set at 400 °C to activate the infiltrant on the surface of the continuous fiberglass fabric;

[0153] (3) The extruder evenly coats the modified pp (polypropylene) resin onto the two surfaces of the continuous fiberglass fabric transmitted in the vertical direction through two extrusion dies. The pressure of the extrusion main pump is 4 MPa, the temperature of the extruder is 140 - 250 °C, and the temperature of the extrusion die is 230 - 250 °C;

[0154] (4) Thermally press and infiltrate the pp resin coated on the continuous fiberglass fabric through the three pressing rollers of the pressing device 202. The temperature of the pressing rollers is 230 - 240 °C, the pressure of the pressing rollers is 5 MPa, the heating device 203 is an oven, the pressing device 22 is arranged in the oven, and the oven temperature is set at 160 °C to bake the pp resin to ensure its fluidity and thus ensure the infiltration effect of the pp resin; The connecting lines of the roller axes of the cross-sections of the three pressing rollers form a right angle. The continuous fiberglass fabric transmitted in the vertical direction is converted to horizontal transmission after passing through the three pressing rollers;

[0155] (5) Transmit the continuous fiberglass fabric infiltrated with pp resin to the cooling unit 3, pass through a pair of cooling rollers 301 with a temperature of -5 °C for rapid cooling and shaping to ensure surface flatness; then transmit it into the water cooling device 302 to cool and remove internal stress. The temperature of the cooling water is 5 - 10 °C;

[0156] (6) For the continuously formed continuous fiber fabric reinforced thermoplastic composite board after cooling, it is towed by the towing device 401, trimmed and cut, and then wound to obtain a continuous glass fiber reinforced pp composite board.

[0157] Example 2

[0158] (1) The continuously woven fabric of 600 g / m nylon fiber and glass fiber transported horizontally is surface infiltrated with a sizing agent by the pretreatment device 12. The sizing agent is a water-soluble sizing agent with 5 wt% active components. The active components of the sizing agent include: 5 wt% amino silane coupling agent, 70 wt% polyester polyurethane emulsion, 15 wt% water-based blocked isocyanate crosslinking agent, 5 wt% compatibilizer, 3 wt% dispersant, and 2 wt% antistatic agent; the infiltrated fiber fabric is dried and wound for standby. The drying temperature of the oven is 300 - 350 °C; 2 (2) The continuously woven fabric of nylon fiber and glass fiber infiltrated with the sizing agent is loaded into the unwinding device 14 for active unwinding. The unwinding speed is 2 m / min. The speeds of the two pairs of pre-traction rollers of the pre-traction roller assembly 111 are 2 m / min, and the speed of the flattening rollers of the flattening roller assembly 112 is 2 mm / min. The continuous fiber fabric is transported into the infrared oven used as the sizing agent activation device 13 by traction of the first pair of pre-traction rollers 111. The temperature of the infrared oven is set at 400 °C to activate the sizing agent on the surface of the continuous fiber fabric; the continuous fiber fabric after passing through the oven is tractioned by the second pair of pre-traction rollers 111 and flattened by the flattening rollers, and the directions of each fiber are regular;

[0159] (3) The extruder uniformly coats the modified nylon resin onto the first side of the continuously transported continuous fiber fabric through the extrusion die head. The first side faces upward and is located below the extrusion die head. The pressure of the extrusion main pump is 6 MPa, the temperature of the extruder is 180 - 300 °C, and the temperature of the extrusion die head is 280 - 320 °C;

[0160] (4) The nylon resin coated on the continuous fiber fabric is hot-pressed and infiltrated by three horizontally distributed pressing rollers of the pressing device 22. The temperature of the pressing rollers is 180 - 300 °C, and the pressure of the pressing rollers is 5 MPa. The first heating device 231 is an infrared oven, which is arranged below the two pressing rollers (2212, 2213) of the pressing device 22. The temperature of the infrared oven is set at 280 °C to bake the nylon resin to ensure its fluidity and thus ensure the infiltration effect of the nylon resin;

[0161] (4) The nylon resin coated on the continuous fiber fabric is hot-pressed and infiltrated by three horizontally distributed pressing rollers of the pressing device 22. The temperature of the pressing rollers is 180 - 300 °C, and the pressure of the pressing rollers is 5 MPa. The first heating device 231 is an infrared oven, which is arranged below the two pressing rollers (2212, 2213) of the pressing device 22. The temperature of the infrared oven is set at 280 °C to bake the nylon resin to ensure its fluidity and thus ensure the infiltration effect of the nylon resin;

[0162] (5) The continuous fiber fabric after being infiltrated with nylon resin on one side passes through a pair of cooling rollers 311 for rapid cooling and shaping. The temperature of the cooling rollers is -5°C. The cooled continuous fiber fabric continues to be transported horizontally to the flipping unit 5, and through two flipping rollers (51, 52), it completes a horizontal flip and continues to be transported horizontally. The second side of the continuous fiber fabric, which originally faced downward, now faces upward, facilitating resin infiltration from the second side of the continuous fiber fabric.

[0163] (6) The extruder evenly coats the modified nylon resin onto the second side of the continuous fiber fabric being transported horizontally through an extrusion die head. The pressure of the extrusion main pump is 6 MPa, the temperature of the extruder is 180 - 300°C, and the temperature of the extrusion die head is 280 - 320°C.

[0164] (7) The nylon resin coated on the continuous fiber fabric is thermally pressed and infiltrated through three horizontally distributed pressing rollers of the pressing device 22. The temperature of the pressing rollers is 180 - 300°C, and the pressure of the pressing rollers is 5 MPa. The second heating device 232 is an infrared oven, which is arranged below two of the pressing rollers (2222, 2223) of the pressing device 22. The temperature of the infrared oven is set at 280°C, which is used to bake the nylon resin to ensure its fluidity and thus ensure the infiltration effect of the nylon resin.

[0165] (8) The continuous fiber fabric after being infiltrated with nylon resin on both sides passes through a pair of cooling rollers 321 with a temperature of -5°C for rapid cooling and shaping, and then passes through an air cooling device 33 to cool and remove internal stress.

[0166] (9) The woven fiber fabric reinforced nylon resin composite board is pulled by a traction device 41 at a traction speed of 2 m / min, trimmed and cut, and then wound to obtain a continuous nylon fiber and glass fiber woven fabric reinforced nylon composite board.

[0167] The mechanical properties of the continuous glass fiber reinforced pp composite board in Example 1 were tested. At the same time, the mechanical properties of the composite board (Comparative Example 1) prepared without pretreating the EWR400 continuous glass fiber square cloth with a sizing agent under the preparation conditions of Example 1 were tested, as well as the mechanical properties of the composite board (Comparative Example 2) prepared without using a heating device for heating during pressing under the preparation conditions of Example 1. The test results are recorded in Table 1 below.

[0168] Table 1 Performance test results of continuous glass fiber reinforced pp composite board

[0169]

[0170] As can be seen from the test results in Table 1, the continuous glass fiber reinforced PP composite board prepared in Example 1 has better mechanical properties. Due to the poor wetting effect of the PP resin on the continuous glass fiber fabric, the mechanical properties of the continuous glass fiber reinforced PP composite boards in Comparative Example 1 and Comparative Example 2 are relatively poor.

[0171] Mechanical property tests were carried out on the continuous glass fiber reinforced PP composite board prepared in Example 1, the continuous glass fiber reinforced PP composite board prepared by a conventional press composite method, and the continuous glass fiber reinforced PP composite board prepared by a continuous Teflon belt mechanism. The test results are recorded in Table 2 below.

[0172] Table 2 Performance test results of continuous glass fiber reinforced PP composite boards prepared by different preparation devices

[0173]

[0174] As can be seen from Table 2, compared with the continuous glass fiber reinforced PP composite board prepared by the continuous Teflon belt mechanism, the continuous glass fiber reinforced PP composite board prepared by the preparation device of the embodiment of the present disclosure has better mechanical properties, higher production efficiency, a flat appearance and no warping; compared with the continuous glass fiber reinforced PP composite board prepared by the press, the continuous glass fiber reinforced PP composite board prepared by the preparation device of the embodiment of the present disclosure has comparable mechanical properties, and continuous production has a high production efficiency, a flat appearance and no warping.

[0175] The embodiments of the present disclosure also provide a continuous fiber fabric reinforced thermoplastic composite board, which can be prepared by using the preparation method of the continuous fiber fabric reinforced thermoplastic composite board of any of the above embodiments, or can be prepared by using the preparation device of the continuous fiber fabric reinforced thermoplastic composite board of any of the above embodiments.

[0176] The continuous fiber fabric reinforced thermoplastic composite board of the embodiment of the present disclosure has good mechanical properties, a flat appearance and no warping problem, the flatness reaches the A-surface standard, and it can be continuously produced with high production efficiency.

[0177] The above is only an exemplary embodiment adopted to illustrate the principle of the present disclosure and is not used to limit the protection scope of the present disclosure. 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 disclosure, and these modifications and improvements are also within the protection scope of the present disclosure.

Claims

1. A preparation device for a continuous fiber fabric reinforced thermoplastic composite plate, characterized in that Comprising: A continuous fiber fabric providing unit for providing a continuous fiber fabric; A resin infiltration unit adapted to receive the continuous fiber fabric provided by the continuous fiber fabric providing unit and infiltrate the continuous fiber fabric with a thermoplastic resin. The resin infiltration unit includes: A resin providing device adapted to coat the thermoplastic resin on one or both sides of the continuous fiber fabric; A pressing device adapted to press the thermoplastic resin and the continuous fiber fabric together; A heating device adapted to heat the thermoplastic resin during the pressing process.

2. The preparation device according to claim 1, characterized in that, The continuous fiber fabric providing unit includes: a transition flattening device for transporting and flattening the continuous fiber fabric so that the fiber directions of the continuous fiber fabric entering the resin infiltration unit are regular. The transition flattening device includes: A pre-traction roller assembly including at least two pre-traction rollers adapted to cooperatively traction the continuous fiber fabric from both sides of the continuous fiber fabric; A flattening roller assembly including at least one flattening roller for flattening the continuous fiber fabric.

3. The preparation device according to claim 2, characterized in that, The continuous fiber fabric providing unit further includes: a pretreatment device adapted to infiltrate the continuous fiber fabric with an infiltrant before the continuous fiber fabric is transported into the transition flattening device.

4. The preparation device according to claim 3, characterized in that, The continuous fiber fabric providing unit further includes: an infiltrant activation device adapted to provide heat to the continuous fiber fabric after being processed by the pretreatment device so that the infiltrant infiltrated in the continuous fiber fabric is activated.

5. The preparation device according to claim 4, characterized in that, The infiltrant activation device includes: an infrared oven.

6. The preparation device according to claim 1, characterized in that, The pressing device includes at least two pressing rollers.

7. The preparation device according to claim 6, characterized in that, The material of the pressing roller is metal, and hot oil or steam is adapted to be introduced into the pressing roller to maintain the temperature of the pressing roller.

8. The preparation device according to claim 1, characterized in that, The heating device is an oven, and the pressing device is located inside the oven.

9. The preparation device according to claim 1, characterized in that, The heating device is an infrared oven.

10. The preparation device according to claim 1, characterized in that, Further comprising: A cooling unit for receiving the continuous fiber fabric passing through the resin infiltration unit and cooling the thermoplastic resin infiltrated in the continuous fiber fabric.

11. The preparation device according to claim 10, characterized in that, The cooling unit includes: at least a pair of cooling rollers adapted to cooperatively squeeze and cool the thermoplastic resin from both sides of the continuous fiber fabric.

12. The preparation device according to claim 11, characterized in that, The position of the cooling roller is adjustable.

13. The preparation device according to claim 11, characterized in that, The cooling unit further includes: an air cooling device or a water cooling device adapted to further cool the continuous fiber fabric with the infiltrated thermoplastic resin cooled by the cooling roller.

14. The preparation device according to claim 1, characterized in that, The resin providing device includes: a first coating device and a second coating device adapted to coat the thermoplastic resin on both sides of the continuous fiber fabric.

15. The preparation device according to claim 14, characterized in that, The first coating device and the second coating device respectively include: a double-layer co-extrusion die head adapted to coat two layers of thermoplastic resin on both sides of the continuous fiber fabric respectively.

16. The preparation device according to claim 14, wherein The continuous fiber fabric providing unit further includes: at least one transition roller, and one of the transition rollers is used to change the transport direction of the continuous fiber fabric from a horizontal direction to a vertical direction; The first coating device and the second coating device are disposed opposite to each other on two sides of the continuous fiber fabric, and are adapted to coat the thermoplastic resin on both sides of the continuous fiber fabric when the continuous fiber fabric passes in the vertical direction.

17. The preparation device according to claim 16, wherein, The pressing device includes three pressing rollers, and the connecting lines of the roller axes of the cross-sections of the three pressing rollers form a right angle, so that the continuous fiber fabric transmitted in the vertical direction is changed to be transmitted in the horizontal direction after passing through the three pressing rollers.

18. The preparation device according to claim 14, characterized in that, It further includes: A turning unit, adapted to turn the continuously fiber fabric transmitted horizontally, so that the orientations of both sides of the continuous fiber fabric are replaced, and continue to be transmitted in the horizontal direction; The first coating device is disposed before the turning unit and is adapted to coat the thermoplastic resin on one side of the continuous fiber fabric before turning; the second coating device is disposed after the turning unit and is adapted to coat the thermoplastic resin on the other side of the continuous fiber fabric after turning; The pressing device includes a first pressing roller assembly and a second pressing roller assembly. The first pressing roller assembly and the second pressing roller assembly each include at least two pressing rollers. The first pressing roller assembly is disposed between the first coating device and the turning unit and is adapted to press the thermoplastic resin coated on one side of the continuous fiber fabric against the continuous fiber fabric; the second pressing roller assembly is disposed after the second coating device and is adapted to press the thermoplastic resin coated on the other side of the continuous fiber fabric against the continuous fiber fabric; The heating device includes: a first heating device, adapted to heat the thermoplastic resin when the first pressing roller assembly performs pressing; a second heating device, adapted to heat the thermoplastic resin when the second pressing roller assembly performs pressing.

19. The preparation device according to claim 18, characterized in that, The turning unit includes two turning rollers, and is adapted to horizontally turn the continuous fiber fabric transmitted horizontally through the first coating device and then continue to be transmitted horizontally to the second coating device.

20. The preparation device according to claim 18, characterized in that, The first pressing roller assembly includes three pressing rollers arranged horizontally; the second pressing roller assembly includes three pressing rollers arranged horizontally.

21. A method for preparing a continuous fiber fabric reinforced thermoplastic composite plate, characterized in that, Using the preparation device according to any one of claims 1-20 to prepare a continuous fiber fabric reinforced thermoplastic composite board, the preparation method includes the following steps: S1: Provide a continuous fiber fabric through a continuous fiber fabric providing unit; S2: Coat the thermoplastic resin on both sides of the continuous fiber fabric through a resin providing device, press the coated thermoplastic resin and the continuous fiber fabric by a pressing device, and heat the thermoplastic resin through the heating device during the pressing process.

22. The preparation method according to claim 21, wherein The preparation method includes the following steps: S3: Rapidly cool and shape the thermoplastic resin by a cooling roller, and further cool the thermoplastic resin by an air cooling or water cooling device to remove stress.

23. The preparation method according to claim 21, wherein, The temperature for heating the thermoplastic resin during the pressing process is 100°C to 200°C.

24. The preparation method according to claim 21, characterized in that, The temperature of each pressing roller of the pressing device is 100°C to 300°C.

25. The preparation method according to claim 21, characterized in that, The S1 includes: S11: Pretreat the continuous fiber fabric, where the pretreatment includes: impregnating the continuous fiber fabric with an impregnating agent.

26. The preparation method according to claim 25, wherein The impregnating agent includes at least one of a silane coupling agent, a film-forming agent, a cross-linking agent, a compatibilizer, and an antistatic agent.

27. The preparation method according to claim 25, characterized in that, S1 further includes: S12: After pretreating the continuous fiber fabric, heat it to activate the impregnating agent impregnated in the continuous fiber fabric, where the heating temperature is 20°C to 450°C.

28. The preparation method according to claim 21, wherein S1 includes: S13: Traction and flattening of the continuous fiber fabric are performed through a pre-traction roller assembly and a flattening roller assembly to regularize the fiber directions of the continuous fiber fabric. The rotation speed of the pre-traction roller in the pre-traction roller assembly is 1 to 2 mm / min, and the rotation speed of the flattening roller in the flattening roller assembly is 1 to 2 mm / min.

29. The preparation method according to claim 21, wherein In S2, coating the thermoplastic resin on both sides of the continuous fiber fabric includes: simultaneously coating the thermoplastic resin on both sides of the continuously vertically transported continuous fiber fabric or successively coating the thermoplastic resin on both sides of the continuously horizontally transported continuous fiber fabric through a first coating device and a second coating device.

30. The preparation method according to any one of claims 21-29, characterized in that The continuous fiber fabric includes: a continuous glass fiber fabric, a continuous carbon fiber fabric, a continuous aramid fiber fabric, a continuous alumina fiber fabric, a continuous polyester fiber fabric, or a continuous glass fiber polyester fiber mixed woven fabric; The thermoplastic resin includes at least one of a polypropylene resin, a polyethylene resin, a polyvinyl chloride resin, a polyethylene terephthalate resin, a nylon resin, a polyoxymethylene resin, a polycarbonate resin, and a polyphenylene sulfide resin.

31. A continuous fiber fabric reinforced thermoplastic composite board prepared by the preparation method according to any one of claims 21-30.

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