Trapezoidal continuous fiber impregnation reinforcing device

Abstract

The invention discloses a trapezoidal continuous fiber impregnation reinforcing device which is of a trapezoidal structure and comprises an inlet mechanism, a melt impregnation module and an outlet adjusting mechanism. The inlet mechanism is arranged on the wide-distance side, and the outlet adjusting mechanism is arranged on the narrow-distance side. The melt impregnation module comprises an impregnation top tank, an impregnation bottom tank and a dispersion impregnation device; a top tank heating structure is arranged in the infiltration top tank; a bottom groove heating structure and a cleaning structure are arranged in the infiltration bottom groove; the dispersing and infiltrating device is positioned between the infiltrating top tank and the infiltrating bottom tank; the dispersing and soaking device is of a trapezoidal structure and comprises a positioning roller, a soaking roller and a fixed roller; the positioning roller shaft penetrates through the dipping roller and the fixed roller, and the position and the distance are fixed through an adjustable device; the dipping roller comprises a roller body, the middle of the roller body is a supporting roller, and the periphery of the supporting roller is a dynamic roller; flow guide grooves with concave-convex structures are uniformly formed in the periphery of the dynamic roller; the fixed roller is a smooth round roller and is of a fixed structure.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of long fiber reinforced thermoplastic melt impregnation forming technology, in particular to a trapezoidal continuous fiber impregnation reinforcing device for long fiber reinforced thermoplastic materials. BACKGROUND

[0002] Thermoplastic composites have excellent performance such as high stiffness, high strength, low density, fatigue resistance, corrosion resistance, recyclability, etc. In some high-performance terminal fields, they are more popular than conventional materials (such as aluminum, steel, etc.) and develop the fastest. Compared with thermosetting materials, thermoplastic materials do not need to be crosslinked and cured, can be processed multiple times, and the forming process is more convenient and efficient, so thermoplastic materials have been developing steadily in recent years, especially fiber-reinforced thermoplastic materials.

[0003] In the current melt impregnation process technology, the most commonly used continuous fiber melt impregnation forming process has simple equipment, high production efficiency, and can be produced continuously. The fiber or fabric is impregnated in the molten resin to prepare a prepreg. In order to achieve uniform impregnation, a melt with too high viscosity cannot be selected. If the material viscosity is too high, impregnation will become difficult, especially for long fiber reinforced thermoplastic materials. Short impregnation time and high viscosity can cause the resin to be difficult to fully penetrate into the fiber bundle, resulting in "dry spots" and excessive porosity (greater than 10%) in the fiber bundle, thereby affecting the quality of the product. At the same time, most resins need to be processed at a high temperature of 300℃ or above (such as PEEK with a melting point of 343℃), and the resin is prone to degradation at high temperature, further increasing the viscosity, thereby causing impregnation difficulty.

[0004] On the other hand, high-viscosity melt will generate strong shear force when flowing in the mold, causing the fiber to be oriented and deflected or broken (especially for fibers with an aspect ratio >1000). The melt front flows faster than the inside, pushing the fiber to the edge to form a "fountain flow", thereby causing the edge fiber to be rich and the center to be sparse, affecting the uniformity of the fiber distribution and affecting the product quality.

[0005] Therefore, how to form good impregnation between long fibers and different viscosity resin materials, so that they are fully contacted and mixed, and the damage to long fiber materials during the preparation and forming process of the composite material is reduced, is a key problem faced by the material preparation and forming process at present. At the same time, in the composite material, how to ensure that the continuous long fiber is more evenly distributed and the fiber breakage rate is as low as possible during the impregnation process, and reduce the problem of fiber breakage and aggregation into a group during operation, is also a technical problem that needs to be solved urgently. SUMMARY

[0006] The purpose of the present application is to provide a trapezoidal continuous fiber impregnation reinforcing device for long fiber reinforced thermoplastic materials to solve the problems of impregnation difficulty and uneven fiber distribution of long fiber materials in different viscosity resin mold structures in the prior art. The improvement of the resin inlet mechanism flow channel makes the distribution of different viscosity resin materials more uniform in the delivery cross-section direction, and the combination with uniformly distributed fiber yarn is more sufficient, further utilizes the trapezoidal mold structure to realize dynamic shearing when high viscosity resin material flows to reduce the viscosity and break through the high viscosity resin impregnation limit, at the same time, utilizes the multi-stage pressure gradient in the traction direction of the dispersion impregnation device to realize the deep impregnation of the resin and fiber mixture, and utilizes the combination structure of the stationary roller and dynamic roller in the dispersion impregnation device to realize the mechanical dynamic yarn spreading of the long fiber in the longitudinal and transverse impregnation directions, so as to realize the sufficient impregnation of high viscosity resin and continuous fiber and the uniformity of fiber yarn distribution in the mixture.

[0007] In order to solve the above technical problems, the present application provides a trapezoidal continuous fiber impregnation reinforcing device for long fiber reinforced thermoplastic materials, which has the following specific structure: It is provided in a trapezoidal structure, which includes an inlet mechanism, a molten impregnation module, and an outlet adjusting mechanism; the inlet mechanism is arranged on the wide side; and the outlet adjusting mechanism is arranged on the narrow side. The molten impregnation module includes an impregnation top groove, an impregnation bottom groove, and a dispersion impregnation device; the impregnation top groove is provided with a top groove heating structure; the impregnation bottom groove is provided with a bottom groove heating structure and a cleaning structure; the dispersion impregnation device is located between the impregnation top groove and the impregnation bottom groove and is an independent structure, which can be replaced individually according to process requirements; the dispersion impregnation device is provided in a trapezoidal structure, which includes a positioning roller, an impregnation roller, and a stationary roller; the positioning roller shaft is a cylindrical structure, the number of which is 2, which penetrates the impregnation roller and the stationary roller and is fixed in position and spacing by an adjustable device; the impregnation roller includes a roller body, the middle part of which is a supporting roller, and the periphery of the supporting roller is a dynamic roller; the dynamic roller is uniformly provided with a concave-convex structure guide groove on the circumferential periphery; and the stationary roller is a smooth round roller and is a fixed structure.

[0008] The inlet mechanism includes an inlet module, a side guard plate, and an anti-overflow block; the inlet module is located on the wide side of the impregnation bottom model and is fixed by bolts; the side guard plate is located on both sides of the inlet module and has the function of plugging fluid to prevent overflow; and the anti-overflow block is located on the top of the inlet face module and has the functions of preventing backflow and guiding fiber yarn for the inlet resin material.

[0009] The import module comprises a storage transition bin, a fluid separation plate, corrugated guide columns, an import port and an export port; the storage transition bin is a fan-shaped cavity structure, the middle position of the storage transition bin is the fluid separation plate, and the fluid separation plate has a flow guiding and dispersing effect; a plurality of corrugated guide columns are arranged on the inner wall of the storage transition bin, and the overall structure is in a convex-concave structure; the import port is located at the bottom of the import module and is connected with a die of an external resin extrusion device; and the export port is located at the top of the import module and is connected with the infiltration bottom groove to form an export structure.

[0010] The overall structure of the infiltration top groove is a trapezoid, and the impregnation structure on the side of the infiltration top groove facing the infiltration bottom groove is fish scale-shaped and arranged in a staggered manner.

[0011] The overall structure of the infiltration bottom groove is a trapezoid, and the side of the infiltration bottom groove facing the infiltration top groove is provided with an infiltration cavity, and the top surface structure of the infiltration cavity is a corrugated fold line structure; the bottom of the infiltration bottom groove is uniformly provided with through holes, and the through holes are connected with an external cleaning structure to realize plugging and fixing. The outlet adjusting mechanism comprises an adjusting die and a lifting driving mechanism assembly, the adjusting die is located on the narrow side of the infiltration bottom die, and the upper part of the adjusting die is connected with the narrow end side of the infiltration top groove; the lifting driving mechanism assembly provides lifting power in the height direction of the adjusting die.

[0012] The lifting driving mechanism assembly comprises a driving structure and a synchronous lifting mechanism, and the synchronous lifting mechanism is fixed with the adjusting die by means of bolts or welding.

[0013] Compared with the prior art, the trapezoidal continuous fiber impregnation reinforcing device has the following advantages: a special structure of the resin import flow channel is adopted, so that different viscosity resin materials are more uniformly distributed in the conveying section direction, and are more fully combined with uniformly distributed fiber yarns, further, dynamic shearing of the resin material is realized through the trapezoidal melt impregnation module to reduce the viscosity and break through the limitation of high viscosity resin impregnation, at the same time, the resin and fiber yarn mixture are subjected to multi-stage pressure gradient changes in the traction direction to realize deep impregnation, and the combination structure of the stationary roller and the dynamic roller in the intermediate dispersion infiltration device is used to realize mechanical dynamic spreading of the continuous fiber in the longitudinal and transverse impregnation directions, so that continuous fiber thermoplastic composite sheet and coil materials with different thicknesses and widths can be uniformly and continuously produced. The present application realizes multi-stage pressure gradient changes of resin and fiber bundle in the traction direction to realize deep impregnation and mechanical dynamic spreading of fiber yarns in the production process in the melt impregnation mixing of continuous fiber reinforced thermoplastic materials, and further improves the mechanical strength, high temperature performance and impact resistance of the continuous fiber reinforced composite product. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 The overall structure of the trapezoidal continuous fiber impregnation reinforcing device is shown in the figure.

[0015] Figure 2 : The whole structure profile diagram of the trapezoidal continuous fiber impregnation reinforcement device Figure 3 : The impregnation top groove diagram of the trapezoidal continuous fiber impregnation reinforcement device Figure 4 : The impregnation top groove profile diagram of the trapezoidal continuous fiber impregnation reinforcement device Figure 5 : The impregnation bottom groove diagram of the trapezoidal continuous fiber impregnation reinforcement device Figure 6 : The impregnation top groove profile diagram of the trapezoidal continuous fiber impregnation reinforcement device Figure 7 : The inlet module profile diagram Figure 8 : The whole structure diagram of the dispersion impregnation device Figure 9 : The impregnation roller profile structure diagram Figure 10 : The dynamic roller surface structure diagram In the figure, 1, the inlet mechanism, 11, the inlet module, 12, the side guard plate, 13, the anti-overflow block, 110, the storage transition warehouse, 111, the fluid separation plate, 112, the corrugated guide column, 113, the resin feeding port, 114, the resin discharging port, 115, the yarn inlet, 116, the continuous fiber mixture outlet; 2, the melt impregnation module, 21, the impregnation top groove, 22, the impregnation bottom groove, 23, the dispersion impregnation device, 24, the cleaning structure, 210, the impregnation top groove body, 211, the top heating structure, 212, the top impregnation reinforcement structure, 220, the impregnation cavity, 221, the notch, 222, the bottom heating structure, 223, the bottom impregnation reinforcement structure, 230, the positioning roller, 231, the impregnation roller, 232, the stationary roller, 2311, the roller body, 2312, the dynamic roller, 2313, the supporting roller, 2314, the uniform distribution flow guide direction groove, 3, the outlet adjusting mechanism, 31, the adjusting mold, 32, the lifting driving mechanism assembly, 321, the driving structure, 322, the synchronous lifting mechanism. DETAILED DESCRIPTION

[0016] The specific embodiments of the present application are described in further detail below in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present application, but are not used to limit the scope of the present application.

[0017] In the description of the present application, it should be noted that unless otherwise expressly specified and limited, the terms "mounting", "connection", "contact", "fixing", "butting", should be understood in a broad sense, for example, it can be pipeline connection, or pipe connection, or equipment connection; it can be separate connection, or integral connection; it can be direct connection, or indirect connection through intermediate medium; it can be internal connection of two elements, or external connection of two elements; it can be direct contact, or indirect contact; it can be contact between movable parts, or contact between fixed parts; it can be fixation between two parts, or fixation between equipment; it can be butting between two parts, or butting between equipment; 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.

[0018] As shown in Figures 1-10 , the trapezoidal continuous fiber impregnation reinforcing device is schematically shown in the figure, which has a flat trapezoidal structure, including an inlet mechanism 1, a melting impregnation module 2, and an outlet adjusting mechanism 3. The inlet mechanism 1 is arranged at the wide distance side; the outlet adjusting mechanism 3 is arranged at the narrow distance side. The inlet mechanism 1 includes an inlet module 11, a side protection plate 12, and an anti-overflow block 13. As shown in Figure 7 , the inlet module 11 includes a storage transition bin 110, a fluid separation plate 111, a corrugated guide column 112, a resin feeding port 113, a resin feeding port 114, and a yarn feeding port 115. The entire inlet module 11 is located at the wide distance side of the infiltration bottom groove 22 and is fixed by bolts. The side protection plate 12 is located on both sides of the inlet module 11 and has the function of plugging fluid to prevent overflow. The anti-overflow block 13 is located at the top of the inlet module 11, which has the function of preventing the backflow of inlet resin material and guiding the fiber yarn.

[0019] The melting impregnation module 2 includes an infiltration top groove 21, an infiltration bottom groove 22, a dispersion infiltration device 23, and a cleaning structure 24.

[0020] The infiltration top groove 21 is arranged in a trapezoidal structure, and a top heating structure 211 is arranged inside the infiltration top groove 21. The bottom surface of the infiltration top groove 21 is provided with a top infiltration reinforcing structure 212. The top heating structure 211 is usually an electric heating pipe.

[0021] The infiltration bottom groove 22 includes an infiltration bottom groove body 221, a lower heating structure 222, a cleaning structure 24, and a bottom infiltration reinforcing structure 223. The dispersion infiltration device 23 is located at the intermediate position between the infiltration top groove 21 and the infiltration bottom groove 22 and is an independent structure, which can be replaced individually according to process requirements. The dispersion infiltration device 23 includes a positioning roller 230, an impregnation roller 231, and a stationary roller 232.

[0022] The outlet adjusting mechanism 3 comprises an adjusting mold 31 and a lifting driving mechanism assembly 32. The adjusting mold 31 is located at the narrow side of the infiltration bottom groove 22 and connected with the narrow end side of the infiltration top groove 21. The lifting driving mechanism assembly 32 provides lifting power in the height direction of the adjusting mold and comprises a driving mechanism 321 and a synchronous lifting mechanism 322.

[0023] The design of the technical solution focuses on the step-by-step and alternating winding impregnation of the fiber and resin mixture in the melting impregnation module 2 through the dispersion impregnation device 23. The dispersion impregnation device 23 has a ladder-shaped structure, including positioning rollers 230 on both sides, a plurality of impregnation rollers 231 in the middle, and a plurality of stationary rollers 232. The impregnation roller 231 includes a roller body 2311, a dynamic roller 2312, a support roller 2313, and a uniform distribution flow guide groove 2314. The positioning roller shaft 230 is in a cylindrical structure, with a number of 2, penetrating through the impregnation roller 231 and the stationary roller 232, and being fixed in position and spacing through an adjustable device. The plurality of impregnation rollers 231 and the plurality of stationary rollers 232 have a gradually shortened structure, and the overall combination forms a ladder-shaped structure.

[0024] The middle part of the roller body 2311 of the impregnation roller 231 is the support roller 2313, and the periphery of the support roller 2313 is the dynamic roller 2312. The dynamic roller 2312 has a concave-convex structure flow guide groove 2314 uniformly distributed on the periphery. The stationary roller 232 is a smooth round roller and has a fixed structure, and its diameter is smaller than that of the impregnation roller 231. Further, during the operation of the device, the impregnation direction of the fiber and resin mixture in the melting impregnation module 2 includes the front-end conveying impregnation area and the rear-end compact loose area. The middle area of the front-end conveying impregnation area is the impregnation roller 231, and the middle area of the rear-end compact loose area is the impregnation roller 231 and the stationary roller 232. The fiber and resin mixture in the front-end conveying impregnation area uses the impregnation roller 231, and the fiber and resin mixture in the rear-end compact loose area uses the impregnation roller 231 and the stationary roller 232 for alternating action to improve the impregnation efficiency. During work, the resin and fiber bundle in the melting impregnation mixing of continuous fiber reinforced thermoplastic materials realize multi-stage pressure gradient change in the traction direction to realize deep impregnation and mechanical dynamic spreading of fiber yarns in the production process, further improving the mechanical strength, high temperature performance and impact resistance of the continuous fiber reinforced composite material product.

[0025] As Figure 7As shown, in the embodiments of the present application, the resin material is connected with the resin feeding port 113 in the inlet module 11 through the screw extrusion device outlet, enters the storage transition bin, the inside of which is fan-shaped, and the resin material is gradually excluded through the wave structure fluid movement of the corrugated guide column 113. The fluid separation plate 111 is arranged at the position 1 / 4-1 / 3 from the top, and the length is 1 / 3-1 / 2 of the transverse length of the resin feeding port 113, which uniformly distributes the fluid flow of the resin material in the cross-sectional direction. The fiber yarn is combined with the resin material in the resin feeding port 113 through the yarn inlet 115.

[0026] As shown in Figure 9 and as shown in Figure 10 The impregnation roller 231 is a roller shaft ring structure, the dynamic roller 232 and the supporting roller 233 are located at the middle position of the roller body 231, the dynamic roller 232 is a cylindrical structure and is sleeved on the supporting roller 233 and rotates under the action of the traction force of the glass fiber mixture, reduces the friction resistance in the impregnation traction process, improves the impregnation efficiency of the fiber yarn and the resin mixture, and effectively reduces the amount of broken fibers in the traction process. The uniformly distributed flow guide groove 234 on the periphery of the dynamic roller 232 is a smooth and gentle dense small wave structure, which plays a yarn guiding and dispersing role on the fiber during the forward rotation of the dynamic roller 232, reduces the uneven dispersion of the fiber in the impregnation process, and is also beneficial to the more uniform dispersion of the fiber in the trapezoidal structure gradual impregnation process of the fiber and the resin mixture.

[0027] As shown in Figure 4 and as shown in Figure 6 The top impregnation enhancement structure 212 and the bottom impregnation enhancement structure 223 are also shown in the figure. The inside of the top impregnation enhancement structure 212 is arranged in a fish scale shape, and the bottom impregnation enhancement structure 223 is provided with an impregnation bottom groove 22. The overall structure of the impregnation bottom groove 22 is trapezoidal, and the side facing the impregnation top groove 21 is provided with an impregnation cavity 220. The top surface structure of the impregnation cavity 220 is a corrugated fold line structure. The bottom of the impregnation bottom groove 22 is uniformly provided with through holes, which are connected with the external cleaning structure 24 to realize plugging and fixing.

[0028] The inside of the bottom impregnation enhancement structure 223 is a plurality of small corrugated fold line structures, which jointly increase the sufficient impregnation of the fiber and resin mixture in the molten impregnation module 2. Further, a plurality of through holes are arranged at the bottom of the bottom impregnation enhancement structure 223, which are connected with the external cleaning structure 24 and fixed by bolts, which are used for sampling detection and cleaning of the accumulated broken fibers at the bottom during production.

[0029] In a preferred embodiment of the present application, the long fiber impregnation mixing device further comprises a top infiltration enhancement structure 212 and a bottom infiltration enhancement structure 223 temperature control system (not shown in the figure), which is divided into an upper heating structure 211 and a lower heating structure 222 control part, and the upper heating structure 211 and the lower heating structure 222 are flexibly controlled in temperature by using independent temperature sensors (not shown in the figure). When the measured temperature of any position is lower than the preset temperature, the upper heating structure 211 and the lower heating structure 222 are heated to the preset temperature, so that the temperature of each position of the top infiltration enhancement structure 212 and the bottom infiltration enhancement structure 223 reaches the temperature requirement of the molten material impregnation.

[0030] It should be noted that the so-called "preset temperature" can be flexibly adjusted according to actual needs, and here the "preset temperature" is not specifically limited.

[0031] In a preferred embodiment of the present application, the trapezoidal continuous fiber impregnation enhancement device further comprises a fixed support structure (not shown in the figure), which is arranged at the bottom of the molten impregnation module 2 and connected by bolt connection or welding, and can be adjusted in height. The setting of the fixed support structure can play the role of leveling installation and height adjustment of the trapezoidal continuous fiber impregnation enhancement device.

[0032] The above only describes the preferred embodiments of the present application and does not limit the present application. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A trapezoidal continuous fiber impregnation reinforcement device, characterized in that: It has a trapezoidal structure and includes an inlet mechanism, a melt impregnation module, and an outlet adjustment mechanism; the inlet mechanism is located on the wide-space side; the outlet adjustment mechanism is located on the narrow-space side. The melt impregnation module includes an impregnation top tank, an impregnation bottom tank, and a dispersion impregnation device. The top tank is equipped with a top tank heating structure; the bottom tank is equipped with a bottom tank heating structure and a cleaning structure. The dispersion impregnation device is located between the top tank and the bottom tank. The dispersion impregnation device has a trapezoidal structure and includes a positioning roller, an impregnation roller, and a stationary roller. The positioning roller shaft passes through the impregnation roller and the stationary roller and is fixed in position and spacing via an adjustable device. The impregnation roller includes a roller body, a support roller in the middle, and a dynamic roller around the support roller. The dynamic roller has evenly distributed concave-convex guiding grooves around its circumference. The stationary roller is a smooth circular roller and has a fixed structure. The inlet module includes a storage transition chamber, a fluid separator, corrugated guide pillars, an inlet, and an outlet. The storage transition chamber has a fan-shaped cavity structure, with a fluid separator in the middle for guiding and dispersing flow. Several corrugated guide pillars are installed on the inner wall of the storage transition chamber, forming a convex-concave structure. The inlet is located at the bottom of the inlet module. The outlet is located at the top of the inlet module, connecting with the impregnation tank to form an outlet structure. The impregnation tank has a trapezoidal structure, with an impregnation cavity on the side facing the top impregnation tank. The top surface of the impregnation cavity has a corrugated zigzag structure. The bottom of the impregnation tank has evenly distributed through-holes, which are connected to an external cleaning structure for sealing and fixation.

2. The trapezoidal continuous fiber impregnation reinforcement device according to claim 1, characterized in that: The import mechanism includes an import module, side protective plates, and anti-overflow blocks; the import module is located on the wide side of the immersion bottom mold; the side protective plates are located on both sides of the import module; and the anti-overflow blocks are located on the top of the import surface module.

3. The trapezoidal continuous fiber impregnation reinforcement device according to claim 1, characterized in that: The overall structure of the top impregnation tank is trapezoidal, and the impregnation structure on the side facing the bottom impregnation tank is fish-scale shaped and staggered.

4. The trapezoidal continuous fiber impregnation reinforcement device according to claim 1, characterized in that: The outlet adjustment mechanism includes an adjustment mold and a lifting drive mechanism assembly. The adjustment mold is located on the narrow side of the immersion bottom mold, and the upper part of the adjustment mold is connected to the narrow end side of the immersion top groove. The lifting drive mechanism assembly provides lifting power in the height direction of the adjustment mold.

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