Melt dipping type continuous fiber prepreg tape production equipment

Abstract

The invention relates to melt impregnation type continuous fiber prepreg tape production equipment. The melt impregnation type continuous fiber prepreg tape production equipment comprises a frame body, and a miniaturized unwinding mechanism, a limiting mechanism, a desizing mechanism, a yarn spreading mechanism, a double-screw melt extrusion mechanism, a sizing mechanism, a rolling mechanism, a traction mechanism and a winding mechanism which are integrated on the frame body. The mechanisms are arranged on the frame body in a three-dimensional layout of at least two layers, and the double-screw melt extrusion mechanism is arranged on the side of the dipping mechanism and at an inlet of the dipping mechanism. After being unwound, the fiber yarn enters the size dipping mechanism after being subjected to limiting, size removing and yarn spreading treatment in sequence, is combined with molten resin conveyed by the double screws, and is finally wound after being subjected to rolling and traction. The volume and the weight of the equipment are reduced by more than 90% through miniaturization design, and the occupied area is obviously reduced through layered layout; hot pressing and drying links are omitted, and the screw shearing heat of the double-screw melt extrusion mechanism and a heating jacket cooperative temperature control technology are combined, so that the overall power consumption is reduced by more than 85% while the uniform melting of the resin is ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material manufacturing equipment, and in particular to a production equipment for melt-impregnated continuous fiber prepreg tape. BACKGROUND

[0002] Continuous fiber reinforced thermoplastic prepreg tape has great application potential in the fields of aerospace, new energy vehicles, high-end equipment manufacturing, etc. due to its high strength, high modulus, excellent impact toughness, good designability, high temperature resistance, and recyclability. The preparation process and equipment are the core elements that determine the quality, production efficiency, and performance stability of the final product in the preparation process of the prepreg tape.

[0003] Melt impregnation is one of the mainstream processes for preparing such prepreg tapes. By heating thermoplastic resin to a molten state and combining it with continuous fibers, rapid and continuous production of prepreg tapes can be achieved. However, the widely used melt-impregnated continuous fiber reinforced thermoplastic prepreg tape production equipment has many significant defects, which severely limits its application in research and development verification and small batch production scenarios. 1. High energy consumption and high material loss: To meet the requirements of continuous production and resin melting, the existing equipment needs to maintain a high temperature and high pressure environment for a long time, resulting in high power and heat consumption. The heating power of the screw extruder is generally more than 200kW, which puts high demands on the power supply of the production site. At the same time, the equipment startup, debugging and formula switching process is time-consuming and long, and a large amount of resin raw materials are needed for single trial production, resulting in serious material loss. This makes the equipment unsuitable for research and development activities that require frequent formula adjustment, small batch sample preparation and process verification.

[0004] 2. Large and heavy equipment, limited installation and transportation, and high cost: The existing equipment has a large overall volume, and the floor area of a single device is usually more than 50 square meters. Due to its large weight, it can only be installed on the ground floor. This not only requires the enterprise to have a large production space, but also makes it difficult or even impossible to deploy the equipment in space-limited environments such as small laboratories in universities or research institutions, and compact areas in enterprise research and development centers. The large volume and weight also result in high costs for equipment transportation, installation and infrastructure.

[0005] In summary, the inherent defects of the existing melt-impregnated prepreg tape production equipment in terms of high energy consumption, high loss, large volume, and high weight make it difficult to meet the core needs of universities, research institutions, and enterprise research and development bases for material formula development, process parameter optimization, small batch sample preparation, and rapid technology iteration. Therefore, there is an urgent need to develop a new melt-impregnated equipment that can overcome the above shortcomings. SUMMARY

[0006] The present application aims to at least solve one of the technical problems existing in the prior art. To this end, the present application provides a melt impregnation type continuous fiber prepreg tape production equipment, which aims to at least solve the problems of high energy consumption, large loss, large volume and high weight of the melt impregnation type prepreg tape production equipment in the related art.

[0007] The present application provides a continuous fiber prepreg tape production equipment, which comprises a frame body and a miniaturized unwinding mechanism, a limiting mechanism, a desizing mechanism, a yarn spreading mechanism, a double screw melting extrusion mechanism, a sizing mechanism, a rolling mechanism, a traction mechanism and a winding mechanism. The unwinding mechanism, the limiting mechanism, the desizing mechanism, the yarn spreading mechanism, the double screw melting extrusion mechanism, the sizing mechanism, the rolling mechanism, the traction mechanism and the winding mechanism are arranged on the frame body in at least two layers. The double screw melting extrusion mechanism is arranged on one side of the sizing mechanism, and the resin outlet of the double screw melting extrusion mechanism is connected with the resin inlet of the sizing mechanism. The free end of the fiber yarn wound on the unwinding mechanism passes through the limiting mechanism, the desizing mechanism, the yarn spreading mechanism, the sizing mechanism, the rolling mechanism and the traction mechanism in sequence, and is finally wound on the winding mechanism.

[0008] The melt impregnation type continuous fiber prepreg tape production equipment according to the present application further comprises an exhaust system and a sealing cover. The sealing cover is sleeved on the outside of the double screw melting extrusion mechanism, and the air inlet end of the exhaust system is used to communicate with the inside of the sealing cover.

[0009] The melt impregnation type continuous fiber prepreg tape production equipment according to the present application is provided with at least one unwinding mechanism.

[0010] The limiting mechanism of the melt impregnation type continuous fiber prepreg tape production equipment according to the present application comprises: A horizontal limiting roller group comprises two vertical limiting guide rollers. The spacing between the two vertical limiting guide rollers is adjustable. The fiber yarn passes through the middle region of the two vertical limiting guide rollers, and the fiber yarn located on both sides in the horizontal direction is in contact with the adjacent vertical limiting guide roller. A vertical limiting roller group comprises two horizontal limiting guide rollers. The spacing between the two horizontal limiting guide rollers is adjustable. The fiber yarn passes through the middle region of the two horizontal limiting guide rollers, and the top and bottom of the fiber yarn are in contact with the corresponding horizontal limiting guide roller.

[0011] The desizing mechanism of the melt impregnation type continuous fiber prepreg tape production equipment according to the present application comprises: An oven is provided with a yarn inlet and a yarn outlet on both sides along the extension direction of the fiber yarn. A first heating module is arranged inside the oven. A guide roller set includes an inlet guide roller and an outlet guide roller, a contact surface of the inlet guide roller with the fiber yarn, a center surface of the yarn inlet, a center surface of the yarn outlet, and a contact surface of the outlet guide roller with the fiber yarn are located in the same plane.

[0012] The melt impregnation type continuous fiber prepreg tape production equipment provided by the present application, the yarn spreading mechanism includes two friction guide rollers and a vibration assembly, the vibration assembly includes a first linear extension mechanism and a yarn spreading guide roller, the yarn spreading guide roller is connected with the extension end of the first linear extension mechanism, and the axis of the yarn spreading guide roller is perpendicular to the extension direction of the first linear extension mechanism, the two friction guide rollers and the yarn spreading guide roller form a triangle, the extension direction of the first linear extension mechanism is perpendicular to the plane where the axes of the two friction guide rollers are located, and the first linear extension mechanism drives the yarn spreading guide roller to reciprocate.

[0013] The melt impregnation type continuous fiber prepreg tape production equipment provided by the present application, the impregnation mechanism includes a first extrusion plate and a second extrusion plate, the first extrusion plate is fixedly connected with the frame body, the second extrusion plate is rotationally connected with the first extrusion plate, the side surfaces of the first extrusion plate and the second extrusion plate close to each other are provided with wave-shaped protrusions, when the second extrusion plate is rotated to the working position, the wave-shaped protrusions of the first extrusion plate and the second extrusion plate are staggered, and the distance between the wave-shaped protrusions of the first extrusion plate and the second extrusion plate is equal everywhere.

[0014] The melt impregnation type continuous fiber prepreg tape production equipment provided by the present application, the rolling mechanism includes a first fixed guide roller, a first movable guide roller and a third linear extension mechanism, the axis of the first fixed guide roller is parallel to the axis of the first movable guide roller, the first movable guide roller is drivingly connected with the extension end of the third linear extension mechanism, and the third linear extension mechanism is used for driving the first movable guide roller to approach or move away from the first fixed guide roller along a direction perpendicular to the axis of the first fixed guide roller.

[0015] The melt impregnation type continuous fiber prepreg tape production equipment provided by the present application, the traction mechanism includes a second fixed guide roller, a second movable guide roller and a fourth linear extension mechanism, the axis of the second fixed guide roller is parallel to the axis of the second movable guide roller, the second movable guide roller is drivingly connected with the extension end of the fourth linear extension mechanism, the fourth linear extension mechanism is used for driving the second movable guide roller to approach or move away from the second fixed guide roller along a direction perpendicular to the axis of the second fixed guide roller, and the outer circumferential surfaces of the second fixed guide roller and the second movable guide roller are provided with friction materials.

[0016] The winding mechanism comprises a winding guide roller, a guide roller driving device and a wire arranging device, the guide roller driving device is in transmission connection with the winding guide roller, and the wire arranging device is arranged on the upstream side of the winding guide roller.

[0017] The present application has the following advantages due to the above technical solutions: The present application provides a melt impregnation type continuous fiber prepreg tape production equipment, which comprises a frame body and a miniaturized unwinding mechanism, a limiting mechanism, a desizing mechanism, a yarn spreading mechanism, a double screw melt extrusion mechanism, a sizing mechanism, a roller pressing mechanism, a traction mechanism and a winding mechanism. The unwinding mechanism, the limiting mechanism, the desizing mechanism, the yarn spreading mechanism, the double screw melt extrusion mechanism, the sizing mechanism, the roller pressing mechanism, the traction mechanism and the winding mechanism are arranged in at least two layers on the frame body. The double screw melt extrusion mechanism is arranged on one side of the sizing mechanism, and the resin outlet of the double screw melt extrusion mechanism is connected with the resin inlet of the sizing mechanism. The double screw melt extrusion mechanism is used for delivering molten resin into the sizing mechanism. The free end of the fiber yarn wound on the unwinding mechanism passes through the limiting mechanism, the desizing mechanism, the yarn spreading mechanism, the sizing mechanism, the roller pressing mechanism and the traction mechanism in sequence, and is finally wound on the winding mechanism. Compared with the traditional melt impregnation type prepreg tape forming equipment, the miniaturized design of each mechanism reduces the size and weight by more than 90%, and the multiple mechanisms are distributed in at least two layers on the frame body, which reduces the floor area, breaks through the space limitation, improves the convenience of movement, and meets the use requirements of small space scenes such as laboratories and small research and development centers. The miniaturized design of the double screw melt extrusion mechanism reduces the power of the heating and traction mechanisms, cancels the hot pressing and hot drying parts, thereby reducing the overall equipment power, and reducing the power consumption by more than 85%. The use of electricity, experimental cost and circuit requirements for the site are reduced, which can meet the application requirements of small laboratories and other scenes. The screw rotation shear heat of the double screw melt extrusion mechanism and the heating sleeve cooperate to realize uniform melting of the resin, and local overheating decomposition is avoided. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are some embodiments of the present application, and those skilled in the art can also obtain other drawings according to these drawings without creative labor.

[0019] Figure 1 is a structural schematic diagram of the melt impregnation type continuous fiber prepreg tape production equipment provided by an embodiment of the present application; Figure 2 is a structural schematic diagram of the sizing mechanism provided by an embodiment of the present application.

[0020] Reference signs: 100: frame body; 110: electrical box; 120: horizontal mounting plate; 130: vertical mounting plate; 200: unwinding mechanism; 300: limiting mechanism; 310: vertical limiting guide roller; 320: horizontal limiting guide roller; 400: sizing mechanism; 410: oven; 430: outlet guide roller; 500: yarn spreading mechanism; 510: friction guide roller; 520: yarn spreading guide roller; 530: first linear extension mechanism; 600: sizing mechanism; 610: first extrusion plate; 620: second extrusion plate; 700: double screw melting extrusion mechanism; 900: roller pressing mechanism; 910: first fixed guide roller; 920: first movable guide roller; 930: third linear extension mechanism; 1000: traction mechanism; 1010: second fixed guide roller; 1020: second movable guide roller; 1030: fourth linear extension mechanism; 1100: winding mechanism; 1110: winding guide roller; 1120: wire winder; 1200: fiber yarn. DETAILED DESCRIPTION

[0021] In order to make the objects, technical solutions and advantages of the present application clearer, the technical solutions in the present application will be described clearly and completely below with reference to the drawings in the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0022] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0023] In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second", etc. can explicitly or implicitly include one or more of the features. In the description of the present application, the meaning of "a plurality of" is two or more, unless otherwise explicitly and specifically limited.

[0024] In the present application, unless specifically defined otherwise, the terms "mounting", "connected", "connecting", "fixed", "fixedly connected", "connection", "fixedly connected", "connected", "fixed", and the like should be understood broadly, for example, can be fixedly connected, can be detachably connected, or integrated; can be mechanically connected, or electrically connected; can be directly connected, or indirectly connected through an intermediate medium; can be internal communication of two elements or interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0025] In the present application, unless specifically defined otherwise, the first feature is "on" or "under" the second feature can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature "above", "over" and "on" the second feature can be that the first feature is directly above or obliquely above the second feature, or only indicates that the horizontal height of the first feature is higher than that of the second feature. The first feature "below", "under" and "under" the second feature can be that the first feature is directly below or obliquely below the second feature, or only indicates that the horizontal height of the first feature is less than that of the second feature.

[0026] In the description of the present application, the description of the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present application, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine the different embodiments or examples described in the present application and the features of the different embodiments or examples without contradiction.

[0027] The application provides a melt impregnation type continuous fiber prepreg tape production equipment, which comprises a frame body and a miniaturized unwinding mechanism, a limiting mechanism, a desizing mechanism, a yarn spreading mechanism, a double-screw melt extrusion mechanism, a sizing mechanism, a rolling mechanism, a traction mechanism and a winding mechanism, the unwinding mechanism, the limiting mechanism, the desizing mechanism, the yarn spreading mechanism, the double-screw melt extrusion mechanism, the sizing mechanism, the rolling mechanism, the traction mechanism and the winding mechanism are arranged on the frame body in at least two layers, the double-screw melt extrusion mechanism is arranged on one side of the sizing mechanism, the resin outlet of the double-screw melt extrusion mechanism is connected with the resin inlet of the sizing mechanism, and the double-screw melt extrusion mechanism is used for conveying melt resin into the sizing mechanism. The free end of the fiber yarn wound on the unwinding mechanism sequentially passes through the limiting mechanism, the desizing mechanism, the yarn spreading mechanism, the sizing mechanism, the rolling mechanism and the traction mechanism, and is finally wound on the winding mechanism. Compared with a traditional melt impregnation type prepreg tape forming equipment, the miniaturized design of each mechanism reduces the size and weight by more than 90%, and the multiple mechanisms are arranged on the frame body in at least two layers, thereby reducing the floor area, breaking through the space limitation, improving the convenience of movement, and meeting the use requirements of small space scenes such as laboratories and small research and development centers. The miniaturized design of the double-screw melt extrusion mechanism reduces the power of the heating and traction mechanisms, cancels the hot pressing and hot drying parts, thereby reducing the overall equipment power, and reducing the power consumption by more than 85%, thereby reducing the electricity cost, experiment cost and circuit requirement of the site, and meeting the application requirements of small laboratory scenes. The screw rotation shearing heat of the double-screw melt extrusion mechanism and the heating sleeve cooperate to realize uniform melting of the resin, and local overheating decomposition is avoided.

[0028] The application will be described below in combination with Figure 1 The application provides a melt impregnation type continuous fiber prepreg tape production equipment.

[0029] The application provides a melt impregnation type continuous fiber prepreg tape production equipment, which comprises a frame body 100, an unwinding mechanism 200, a limiting mechanism 300, a desizing mechanism 400, a yarn spreading mechanism 500, a double-screw melt extrusion mechanism 700, a sizing mechanism 600, a rolling mechanism 900, a traction mechanism 1000 and a winding mechanism 1100.

[0030] The frame body 100 can comprise an electrical box 110, a horizontal mounting plate 120 and a vertical mounting plate 130, the electrical box 110 is arranged at the bottom and is provided with a roller at the bottom, so as to facilitate movement, the horizontal mounting plate 120 is arranged at the top of the electrical box 110, and the vertical mounting plate 130 is arranged at the top rear side of the horizontal mounting plate 120.

[0031] The unwinding mechanism 200, the limiting mechanism 300, the desizing mechanism 400, the yarn spreading mechanism 500, the double-screw melting extrusion mechanism 700, the sizing mechanism 600, the roller pressing mechanism 900, the traction mechanism 1000 and the winding mechanism 1100 are all designed to be small in size, specifically, compared with the traditional prepreg forming equipment, the size, weight and energy consumption of the above mechanisms are reduced by more than 85%.

[0032] In a specific embodiment, referring to Figure 1 On the upper half of the vertical mounting plate 130, the unwinding mechanism 200, the limiting mechanism 300, the desizing mechanism 400 and the yarn spreading mechanism 500 are arranged in sequence from right to left, the sizing mechanism 600 is arranged on the left side of the lower half of the vertical mounting plate 130, the double-screw melting extrusion mechanism 700 is arranged on the top of the horizontal mounting plate 120 and located in front of the sizing mechanism 600, and the roller pressing mechanism 900, the traction mechanism 1000 and the winding mechanism 1100 are arranged in sequence from left to right on the top of the horizontal mounting plate 120 and located on the right side of the sizing mechanism 600. In this way, the layered installation of the above mechanisms is realized, and the planar space occupation is reduced.

[0033] The fiber yarn 1200 drawn out by the unwinding mechanism 200 passes through the limiting mechanism 300, the desizing mechanism 400, the yarn spreading mechanism 500, the sizing mechanism 600, the hot drying mechanism 700, the hot pressing mechanism 800, the roller pressing mechanism 900 and the traction mechanism 1000 in sequence, and finally the finished prepreg is wound on the winding mechanism 1100.

[0034] The prepreg production equipment provided by the embodiment of the present application has the following characteristics: Equipment integration: the core mechanism modules such as unwinding, limiting, desizing, yarn spreading, sizing, roller pressing and winding are integrated in one body, and an up-down layered compact arrangement structure is adopted to effectively compress the equipment space size. The overall size of the equipment is 2.95*0.55*1.1 m (not including the independent supporting double-screw melting extrusion mechanism 700), and the double-screw melting extrusion mechanism 700 is an independent module (size is 0.8*0.3*0.35 m) which can be flexibly connected to the main integrated system. This design not only realizes the integration of the main core process unit, but also adapts to different resin systems through the independent double-screw melting extrusion mechanism 700, and the whole equipment is convenient to move and install, which meets the use requirements of small space scenes such as laboratories and small research centers.

[0035] Low power consumption: the device miniaturizes high-power mechanisms, uses a small double-screw melting extrusion mechanism 700 to melt resin, reduces the power of the heating and traction mechanism 1000, and cancels part of the hot pressing mechanism and the hot drying mechanism, thereby reducing the overall device power. The total power consumption is only 9kwh, which is 85% lower than the power consumption of the existing melt impregnation type prepreg tape forming equipment, which can greatly reduce the electricity cost.

[0036] In some embodiments, an exhaust system and a sealing cover are further included, the sealing cover is sleeved outside the double-screw melting extrusion mechanism 700, which can prevent the leakage of irritating gas during production, the air inlet end of the exhaust system is in communication with the inside of the sealing cover, and the controllable emission of irritating gas in the sealing cover can be realized, which is significantly better than other traditional equipment in environmental protection and operation health.

[0037] In some embodiments, the unwinding mechanism 200 can be provided with at least two, so that multiple fiber yarns 1200 can be parallel to produce thermoplastic prepreg tapes of different widths.

[0038] The unwinding mechanism 200 can be a driven guide roller with tension control function, which can apply constant tension to the fiber yarn 1200 while releasing the fiber yarn 1200.

[0039] In some embodiments, the limiting mechanism 300 includes a horizontal limiting roller group and a vertical limiting roller group.

[0040] The horizontal limiting roller group includes two vertical limiting guide rollers 310, the axes of the two vertical limiting guide rollers 310 extend in the vertical direction, and the plane where the axes of the two vertical limiting guide rollers 310 extend is perpendicular to the vertical mounting plate 130. The horizontal distance between the two vertical limiting guide rollers 310 is adjustable to limit the horizontal movement of fiber yarns 1200 of different widths.

[0041] Specifically, the horizontal limiting roller group is installed on the vertical mounting plate 130 through a first mounting plate, and the first mounting plate is installed vertically on the vertical mounting plate 130. The vertical limiting guide rollers 310 can also be driven guide rollers, and the two vertical limiting guide rollers 310 are both in sliding connection with the first mounting plate and slide in a direction perpendicular to the front side of the vertical mounting plate 130. A locking assembly is further provided between the vertical limiting guide rollers 310 and the first mounting plate. When the locking assembly is unlocked, the positions of the two vertical limiting guide rollers 310 and the distance therebetween can be adjusted, and when the locking assembly is locked, the positions of the two vertical limiting guide rollers 310 are limited.

[0042] Similarly, the vertical limiting roller set includes two horizontal limiting guide rollers 320, the axes of which extend in a direction perpendicular to the front side of the vertical mounting plate 130, and the plane in which the axes of the two horizontal limiting guide rollers 320 extend is perpendicular to the horizontal mounting plate 120. The longitudinal spacing of the two horizontal limiting guide rollers 320 is adjustable to limit the up-and-down movement of the fiber yarn 1200 of different heights.

[0043] Specifically, a second mounting plate is arranged on the top of the first mounting plate on both the front and rear sides, the second mounting plate is perpendicular to the first mounting plate and parallel to the front side of the vertical mounting plate 130. The horizontal limiting guide roller 320 is also a driven guide roller, the horizontal limiting guide roller 320 is mounted between the two second mounting plates and is in sliding connection with the second mounting plates in the vertical direction. A locking assembly is also arranged between the horizontal limiting guide roller 320 and the second mounting plate, when the locking assembly is unlocked, the position of the two horizontal limiting rollers and the longitudinal spacing therebetween can be adjusted, and when the locking assembly is locked, the position of the two horizontal limiting guide rollers 320 is limited.

[0044] The two vertical limiting guide rollers 310 and the two horizontal limiting guide rollers 320 form a cross-shaped structure to limit the position of the fiber yarn 1200 in the horizontal and vertical directions.

[0045] In some embodiments, the desizing mechanism 400 is used to completely remove the resin attached to the surface of the continuous fiber yarn 1200, which includes an oven 410 and a guide roller set.

[0046] The inside of the oven 410 is provided with a first heating module, which can be a plurality of heating resistance wires, for example, and the temperature can be continuously adjustable from room temperature to 400°C. The yarn inlet and the yarn outlet are respectively arranged at both ends of the oven 410 in the extension direction of the fiber yarn 1200, and the yarn inlet and the yarn outlet can be rectangular strip-shaped through holes and are aligned in the left-right direction.

[0047] The guide roller set includes an inlet guide roller and an outlet guide roller 430, the contact surface of the inlet guide roller with the fiber yarn 1200, the center surface of the yarn inlet, the center surface of the yarn outlet, and the contact surface of the outlet guide roller 430 with the fiber yarn 1200 are located on the same plane. In other words, in this embodiment, the yarn inlet and the yarn outlet arranged on the oven 410 are aligned in the left-right direction, in order to make the fiber yarn 1200 pass through the yarn inlet and the yarn outlet smoothly, the fiber yarn 1200 needs to be stretched into a horizontal posture through the oven 410, therefore, the inlet guide roller and the outlet guide roller 430 on the left and right sides of the oven 410 stretch the fiber yarn 1200 into a horizontal posture.

[0048] In some embodiments, the yarn spreading mechanism 500 comprises two friction guide rollers 510 and a vibration assembly, the vibration assembly comprising a first linear telescopic mechanism 530 and a yarn spreading guide roller 520, the yarn spreading guide roller 520 being connected to the telescopic end of the first linear telescopic mechanism 530, and the axis of the yarn spreading guide roller 520 being perpendicular to the telescopic direction of the first linear telescopic mechanism 530, the two friction guide rollers 510 and the yarn spreading guide roller 520 forming a triangle, the telescopic direction of the first linear telescopic mechanism 530 being perpendicular to the plane in which the axes of the two friction guide rollers 510 lie, and the first linear telescopic mechanism 530 driving the yarn spreading guide roller 520 to reciprocate.

[0049] Specifically, the rear ends of the two friction guide rollers 510 can be connected to the vertical mounting plate 130, and the plane in which the axes of the two friction guide rollers 510 lie is horizontal, the first linear telescopic mechanism 530 being arranged below the two friction guide rollers 510 in the middle, and the first telescopic mechanism extending downward and retracting upward, the yarn spreading guide roller 520 being arranged at the telescopic end of the first telescopic mechanism, and the axis of the yarn spreading guide roller 520 being parallel to the axes of the friction guide rollers 510.

[0050] In operation, the fiber yarn 1200 first passes through the upstream friction guide roller 510, then passes through the bottom end of the yarn spreading guide roller 520, and then passes through the downstream friction guide roller 510, the first telescopic mechanism driving the yarn spreading guide roller 520 to vibrate up and down at a high frequency and a low amplitude, so that the fiber bundle of the fiber yarn 1200 is fully spread out.

[0051] It should be noted that the first linear telescopic mechanism 530 can be a pneumatic cylinder.

[0052] In some embodiments, the pulp dipping mechanism comprises a first pressing plate 610 and a second pressing plate 620, the first pressing plate 610 being fixedly connected to the frame, the second pressing plate 620 being rotatably connected to the first pressing plate 610, the side surfaces of the first pressing plate 610 and the second pressing plate 620 close to each other being provided with wave-shaped protrusions, when the second pressing plate 620 is rotated to the working position, the wave-shaped protrusions of the first pressing plate 610 and the second pressing plate 620 are staggered, and the distance between the wave-shaped protrusions of the first pressing plate 610 and the second pressing plate is equal everywhere.

[0053] Specifically, the first pressing plate 610 is horizontally arranged, and the rear side of the first pressing plate 610 is fixedly connected to the vertical mounting plate, the left side of the second pressing plate 620 being rotatably connected to the left side of the first pressing plate 610, and the rotation axis being perpendicular to the vertical mounting plate. The second pressing plate 620 can be flipped upward and leftward to open, or downward and rightward to close, when the second pressing plate 620 is closed, the first pressing plate 610 is parallel to the second pressing plate, at this time, the pulp dipping mechanism 600 is in the working position.

[0054] The top surface of the first extrusion plate 610 and the bottom surface of the second extrusion plate 620 are provided with wave-shaped protrusions, when the second extrusion plate 620 is closed, the protruding ends of the wave-shaped protrusions on the second extrusion plate 620 are located between the two protruding ends of the wave-shaped protrusions of the first extrusion plate 610, and the distance between the wave-shaped protrusions of the two is equal everywhere.

[0055] The resin outlet of the twin-screw melt extrusion mechanism 700 is connected with the impregnation mechanism 600 on one side of the impregnation mechanism to inject the molten resin into the area between the first extrusion plate 610 and the second extrusion plate 620.

[0056] In some embodiments, the rolling mechanism 900 includes a first fixed guide roller 910, a first movable guide roller 920, and a third linear extension mechanism 930, the axis of the first fixed guide roller 910 is parallel to the axis of the first movable guide roller 920, the first movable guide roller 920 is drivingly connected with the extension end of the third linear extension mechanism 930, and the third linear extension mechanism 930 is used to drive the first movable guide roller 920 to move close to or away from the first fixed guide roller 910 along a direction perpendicular to the axis of the first fixed guide roller 910.

[0057] Specifically, the first fixed guide roller 910 is mounted on the top of the horizontal mounting plate 120 through a first bracket, and the axis of the first fixed guide roller 910 is perpendicular to the vertical mounting plate 130, the third linear extension mechanism 930 is arranged on the top of the first bracket, and the extension end is arranged downward, the first movable guide roller 920 is connected with the extension end of the third linear extension mechanism 930, and the first movable guide roller 920 can be located directly above the first fixed guide roller 910, and the axis of the first movable guide roller 920 is also perpendicular to the vertical mounting plate 130.

[0058] The third linear extension mechanism 930 is used to drive the first movable guide roller 920 to move up and down, so as to adjust the distance between the bottom end of the first movable guide roller 920 and the top end of the first fixed guide roller 910, and further control the thickness of the prepreg passing through the rolling mechanism 900.

[0059] A heating pipe is arranged in the interior of the first movable guide roller 920 and the first fixed guide roller 910, and the temperature of the heating pipe can be continuously adjustable within room temperature-400°C.

[0060] In some embodiments, the traction mechanism 1000 includes a second fixed guide roller 1010, a second movable guide roller 1020, and a fourth linear extension mechanism 1030, the axis of the second fixed guide roller 1010 is parallel to the axis of the second movable guide roller 1020, the second movable guide roller 1020 is drivingly connected with the extension end of the fourth linear extension mechanism 1030, and the fourth linear extension mechanism 1030 is used to drive the second movable guide roller 1020 to move close to or away from the second fixed guide roller 1010 along a direction perpendicular to the axis of the second fixed guide roller 1010.

[0061] Specifically, the second fixed guide roller 1010 is mounted on the top of the horizontal mounting plate 120 through a second bracket, and the axis of the second fixed guide roller 1010 is perpendicular to the vertical mounting plate 130; the fourth linear extension mechanism 1030 is arranged on the top of the second bracket, and the extension end is arranged downward; the second movable guide roller 1020 is connected with the extension end of the fourth linear extension mechanism 1030, and the second movable guide roller 1020 can be located directly above the second fixed guide roller 1010, and the axis of the second movable guide roller 1020 is also perpendicular to the vertical mounting plate 130.

[0062] The fourth linear extension mechanism 1030 is used to drive the second movable guide roller 1020 to move up and down, so as to adjust the distance between the bottom end of the second movable guide roller 1020 and the top end of the second fixed guide roller 1010, and then clamp the prepreg between the second movable guide roller 1020 and the second fixed guide roller 1010.

[0063] In addition, a separate motor can be arranged on the second fixed guide roller 1010 to rotate, and the speed can be adjusted (0-500 mm / s); the second fixed guide roller 1010 and the second movable guide roller 1020 can be polyurethane coated wheels with a diameter of 100 mm, which can drive the prepreg to move forward by friction, and the third linear extension mechanism 930 is used to press and open and close.

[0064] In some embodiments, the winding mechanism 1100 includes a winding guide roller 1110, a guide roller driving device and a wire arranging device 1120. The guide roller driving device can be a motor, which drives the winding guide roller 1110 to rotate, and the speed is matched with the speed of the traction mechanism 1000 by friction. The wire arranging device 1120 reciprocates along the front and back directions, drives the prepreg to reciprocate along the front and back directions, and then winds on the winding guide roller 1110.

[0065] The melt impregnation type continuous fiber prepreg production equipment provided by the application is suitable for continuous fibers including glass fiber, aramid fiber, basalt fiber and carbon fiber, and suitable for thermoplastic resins including polypropylene (PP), polycarbonate (PC), polyamide 6 (PA6), polyamide 66 (PA66), polyphthalamide (PPA), polyether sulfone (PES), polyphenylene sulfide (PPS), polyether ether ketone (PEEK) and polyether ketone ketone (PEKK).

[0066] The production steps of the equipment mainly include unwinding, desizing, yarn spreading, melt extrusion, impregnation, roller pressing and winding.

[0067] In a specific embodiment, the melt impregnation type continuous fiber prepreg production equipment is used to prepare a continuous carbon fiber reinforced thermoplastic polycarbonate composite prepreg, and the raw materials used are as follows: Continuous carbon fiber (T700, 12K continuous carbon fiber); Polycarbonate (PC) resin powder (400 mesh).

[0068] The preparation steps of the continuous carbon fiber reinforced thermoplastic polycarbonate prepreg tape are as follows: Place the carbon fiber on the unwinding mechanism 200. There are two fixed conical rings on the unwinding mechanism 200, which are fixed with screws. The inner conical ring is fixed inward, and then the carbon fiber roll is placed in, and the other conical ring is used to support the carbon fiber roll, and then tightened and fixed.

[0069] Pull out the carbon fiber bundle and pass through the limiting mechanism 300 to prevent the fiber yarn 1200 from shifting up, down, left and right.

[0070] Continue to pass the carbon fiber through the sizing mechanism 400, and start heating after passing through, with a temperature setting of 120-150°C.

[0071] The carbon fiber reaches the yarn spreading mechanism 500. The carbon fiber is passed through the friction guide roller 510, the yarn spreading guide roller 520, and the friction guide roller 510, respectively, to reach the sizing mechanism 600.

[0072] At the same time, the double screw in the double screw melting extrusion mechanism 700 realizes the positive displacement conveying and strong shear mixing of the material through the meshing structure. The shear heat generated by the rotation of the screw and the segmented heating jacket work together. The preheating section is preheated to 200-220°C, the compression section is raised to 240-260°C for melting, and the metering section is kept at 220-240°C for stable extrusion, ensuring that the melt viscosity is maintained at 400-600 Pa·s, while the extrusion amount is controlled at 4-6 kg / h (coordinated by screw speed and metering section temperature, accuracy ±0.5 kg / h). The polycarbonate resin is quickly melted to a uniform low viscosity state under precise temperature control, and the screw speed is 200-300 r / min. The liquid resin enters the sizing mechanism 600 through the metal connecting pipe.

[0073] The carbon fiber enters the sizing mechanism 600 from the left side, and when passing through the area between the first extrusion plate 610 and the second extrusion plate 620, the thermoplastic liquid resin provided by the double screw melting extrusion mechanism 700 makes the carbon fiber uniformly coated with a layer of resin on the surface during the process of being guided out from the right side of the sizing mechanism 600, realizing efficient sizing operation of the carbon fiber.

[0074] After the carbon fiber reaches the roller pressing mechanism 900, first turn on the circulating water cooler, set the temperature to 15°C, and turn on the internal circulation to ensure that the first fixed guide roller 910 and the first movable guide roller 920 of the roller pressing mechanism 900 do not damage the electric slip ring and other devices during heating. Raise the first movable guide roller 920, then pass the carbon fiber through the roller pressing mechanism 900, and reach the traction mechanism 1000.

[0075] The device can be equipped with two roller pressing mechanisms 900, the heating temperature of which can be set to 180-200℃ and 240-260℃ respectively, and the first moving guide roller 920 is kept in a raised state.

[0076] The second moving guide roller 1020 of the traction mechanism 1000 is raised, and then the carbon fiber passes through the traction mechanism 1000 and reaches the winding mechanism 1100. The second moving guide roller 1020 of the traction mechanism 1000 is kept in a raised state.

[0077] The carbon fiber reaches the winding mechanism 1100. First, the receiving disc is installed on the winding shaft, and the two ends are fixed with friction discs and conical discs, and then the carbon fiber is wound tightly on the receiving disc.

[0078] After the preparation of the carbon fiber is completed, the carbon fiber at each position is manually tensioned, and the first moving guide roller 920 and the second moving guide roller 1020 are pressed and closed.

[0079] After all the preparations are completed, when all the temperatures reach the set temperature and the impregnation mechanism 600 is filled with liquid resin, the yarn spreading mechanism 500 is started, the rotating speed is set to 200r / min; then the motors of the traction mechanism 1000 and the winding mechanism 1100 are turned on, and the speed is set to 40mm / s and 50mm / s respectively. After the formed prepreg reaches the winding mechanism 1100, the unformed carbon fiber in front is removed, and then the prepreg is fixed on the winding shaft, and the continuous carbon fiber reinforced prepreg is prepared.

[0080] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and are not limited thereto; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement to part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application, and they should be covered in the scope of the claims and the specification of the present application. Especially, as long as there is no structural conflict, each technical feature mentioned in each embodiment can be combined in any way. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A melt-impregnation type continuous fiber prepreg tape production equipment, characterized in that, The system includes a frame (100) and a miniaturized unwinding mechanism (200), a limiting mechanism (300), a desizing mechanism (400), a yarn spreading mechanism (500), a twin-screw melt extrusion mechanism (700), a sizing mechanism (600), a roller pressing mechanism (900), a traction mechanism (1000), and a winding mechanism (1100). The unwinding mechanism (200), the limiting mechanism (300), the desizing mechanism (400), the yarn spreading mechanism (500), the twin-screw melt extrusion mechanism (700), the sizing mechanism (600), the roller pressing mechanism (900), the traction mechanism (1000), and the winding mechanism (1100) are further defined. 0) The twin-screw melt extrusion mechanism (700) is arranged in at least two layers on the frame (100). The twin-screw melt extrusion mechanism (700) is located on one side of the sizing mechanism (600), and the resin outlet of the twin-screw melt extrusion mechanism (700) is connected to the resin inlet of the sizing mechanism (600). The free end of the fiber yarn (1200) wound on the unwinding mechanism (200) passes through the limiting mechanism (300), the desizing mechanism (400), the yarn spreading mechanism (500), the sizing mechanism (600), the roller pressing mechanism (900), and the traction mechanism (1000) in sequence, and is finally wound on the winding mechanism (1100).

2. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, It also includes an exhaust system and a sealing cover, the sealing cover being fitted over the outside of the twin-screw melt extrusion mechanism (700), and the air inlet end of the exhaust system being used to communicate with the interior of the sealing cover.

3. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, At least one unwinding mechanism (200) is provided.

4. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The limiting mechanism (300) includes: The horizontal limiting roller group includes two vertical limiting guide rollers (310), the distance between the two vertical limiting guide rollers (310) is adjustable, the fiber yarn (1200) passes through the middle area of ​​the two vertical limiting guide rollers (310), and the fiber yarn (1200) located on both sides in the horizontal direction contacts the adjacent vertical limiting guide roller (310); The vertical limiting roller assembly includes two horizontal limiting guide rollers (320), the distance between the two horizontal limiting guide rollers (320) is adjustable, the fiber yarn (1200) passes through the middle area of ​​the two horizontal limiting guide rollers (320), and the top and bottom of the fiber yarn (1200) are in contact with the corresponding horizontal limiting guide roller (320).

5. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The desizing mechanism (400) includes: The oven (410) has a yarn inlet and a yarn outlet on both sides along the extension direction of the fiber yarn (1200), and a first heating module is provided inside the oven (410). The guide roller assembly includes an inlet guide roller and an outlet guide roller (430). The contact surface between the inlet guide roller and the fiber yarn (1200), the center surface of the yarn inlet, the center surface of the yarn outlet, and the contact surface between the outlet guide roller (430) and the fiber yarn (1200) are located on the same plane.

6. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The yarn spreading mechanism (500) includes two friction guide rollers (510) and a vibration assembly. The vibration assembly includes a first linear telescopic mechanism (530) and a yarn spreading guide roller (520). The yarn spreading guide roller (520) is connected to the telescopic end of the first linear telescopic mechanism (530), and the axis of the yarn spreading guide roller (520) is perpendicular to the telescopic direction of the first linear telescopic mechanism (530). The two friction guide rollers (510) and the yarn spreading guide roller (520) form a triangle. The telescopic direction of the first linear telescopic mechanism (530) is perpendicular to the plane containing the axes of the two friction guide rollers (510). The first linear telescopic mechanism (530) drives the yarn spreading guide roller (520) to reciprocate.

7. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The impregnation mechanism (600) includes a first extrusion plate (610) and a second extrusion plate (620). The first extrusion plate (610) is fixedly connected to the frame, and the second extrusion plate (620) is rotatably connected to the first extrusion plate (610). The sides of the first extrusion plate (610) and the second extrusion plate (620) that are close to each other are provided with wavy protrusions. When the second extrusion plate (620) is rotated to the working position, the wavy protrusions of the first extrusion plate (610) and the second extrusion plate (620) are staggered, and the distance between the wavy protrusions of the first extrusion plate (610) and the second extrusion plate (620) is equal everywhere.

8. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The rolling mechanism (900) includes a first fixed guide roller (910), a first movable guide roller (920), and a third linear telescopic mechanism (930). The first fixed guide roller (910) is parallel to the axis of the first movable guide roller (920). The first movable guide roller (920) is connected to the telescopic end of the third linear telescopic mechanism (930). The third linear telescopic mechanism (930) is used to drive the first movable guide roller (920) to move closer to or away from the first fixed guide roller (910) in a direction perpendicular to the axis of the first fixed guide roller (910).

9. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The traction mechanism (1000) includes a second fixed guide roller (1010), a second movable guide roller (1020), and a fourth linear telescopic mechanism (1030). The second fixed guide roller (1010) is parallel to the axis of the second movable guide roller (1020). The second movable guide roller (1020) is connected to the telescopic end of the fourth linear telescopic mechanism (1030). The fourth linear telescopic mechanism (1030) is used to drive the second movable guide roller (1020) to move closer to or away from the second fixed guide roller (1010) in a direction perpendicular to the axis of the second fixed guide roller (1010). The outer peripheral surfaces of the second fixed guide roller (1010) and the second movable guide roller (1020) are provided with friction material.

10. The melt-impregnation continuous fiber prepreg tape production equipment according to claim 1, characterized in that, The winding mechanism (1100) includes a winding guide roller (1110), a guide roller drive device, and a wire guide (1120). The guide roller drive device is connected to the winding guide roller (1110) in a transmission manner, and the wire guide (1120) is located on the upstream side of the winding guide roller (1110).

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