Continuous fiber prepreg wire manufacturing system and method

Abstract

The invention belongs to the related technical field of composite material additive manufacturing, and discloses a continuous fiber prepreg wire manufacturing system and method.The system comprises a solution impregnation device and a melt impregnation device; a resin solution is accommodated in the solution dipping box body and a dipping guide wheel is arranged at the bottom; the melt impregnation device comprises a melt impregnation box body, a molten resin supply structure, an impregnation roller and a guide roller, the molten resin supply structure is connected with the impregnation roller and used for conveying molten resin into the impregnation roller, and the impregnation roller is provided with an overflow channel of the molten resin; the fiber material firstly bypasses the dipping guide wheel for solution dipping, then bypasses the guide roller and the dipping roller, and is subjected to melt dipping at the dipping roller. According to the invention, through solution and melt dual impregnation, the infiltration degree of the fiber and the resin is greatly improved; molten resin is introduced into the dipping roller in real time, so that the consumption of the resin is reduced, the process cost is reduced, and the infiltration effect of the high-viscosity resin on fibers is improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field related to additive manufacturing of composite materials, and more particularly, to a continuous fiber prepreg filament manufacturing system and method. BACKGROUND

[0002] Thermoplastic reinforced resin-based composite materials have the advantages of rapid prototyping, low cost, high toughness, impact resistance, room temperature storage, and recyclability compared to traditional thermosetting reinforced resin-based composite materials. In recent years, with the development of additive manufacturing technology, the use of composite materials has exceeded 50%, and non-load-bearing parts, secondary load-bearing parts, and primary load-bearing parts have been gradually replaced. Higher service performance requirements are put forward for continuous fiber reinforced thermoplastic composite parts.

[0003] Additive manufacturing technology is considered one of the important directions for future production of thermoplastic composite materials due to its high design freedom, high resource utilization, fast manufacturing speed, and strong process flexibility. Currently, the additive manufacturing methods of continuous fiber reinforced composite materials mainly include two forms: prepreg filaments and in-situ impregnation. Due to the short impregnation time of fibers and resin in the in-situ impregnation process, the interface bonding degree is poor, and the internal porosity defects are difficult to control. Therefore, prepreg filaments have become a research hotspot. However, due to the high viscosity of linear molecular chain structure of thermoplastic resin, the impregnation degree between resin and fiber still needs to be improved. At present, there is no method to prepare fully impregnated and high-performance continuous fiber thermoplastic functional prepreg filaments. SUMMARY

[0004] In view of the above defects or improvement needs of the prior art, the present application provides a continuous fiber prepreg filament manufacturing system and method to solve the problem of insufficient impregnation and poor impregnation degree between resin and fiber in the current continuous fiber prepreg process.

[0005] To achieve the above-mentioned purpose, according to one aspect of the present application, a continuous fiber prepreg filament manufacturing system is provided, characterized in that it comprises a solution impregnation device and a melt impregnation device; the solution impregnation device comprises a solution impregnation box body, the inside of the solution impregnation box body contains a resin solution and the bottom is provided with an impregnation guide roller; The melt impregnation device comprises a melt impregnation box body, a melt resin supply structure, an impregnation roller and a guide roller, the impregnation roller and the guide roller are respectively arranged in the inside of the melt impregnation box body, the melt resin supply structure is connected with the impregnation roller and is used to supply melt resin to the inside of the impregnation roller, and the impregnation roller is provided with a melt resin overflow channel; The fiber material is firstly impregnated with the solution in the inside of the solution impregnation box through the impregnation guide roller, and then is sent into the inside of the melt impregnation box, passes through the guide roller and the impregnation roller, and is melt impregnated at the impregnation roller to perform secondary impregnation manufacturing.

[0006] According to the continuous fiber prepreg manufacturing system, the solution impregnation box is provided with openings on two sides, and guide rollers are arranged at the openings to convey the fiber material; the inside of the solution impregnation box is further provided with an ultrasonic vibration rod; the solution impregnation box is further connected with a liquid level detector, and the surface is further provided with a liquid inlet for supplementing the solution and a switch valve for discharging waste liquid.

[0007] According to the continuous fiber prepreg manufacturing system, the guide roller is rotatably connected to the melt impregnation box and is provided with a heating rod inside to independently heat; a pressure roller is arranged in cooperation with the guide roller near the outlet of the melt impregnation box. The melt resin supply structure comprises a screw extruder and an electric eye hopper, the outlet of the screw extruder is communicated to the inside of the impregnation roller, the electric eye hopper is connected to the screw extruder, and a heating ring is sleeved on the screw extruder to heat the resin into a melt state.

[0008] According to the continuous fiber prepreg manufacturing system, the solution impregnation device is further provided with a fiber spreading device; the fiber spreading device comprises a fiber spreading mounting plate and a series of equal-width positioning grooves, a first convex pin, a high-width positioning groove, a second convex pin and two active fiber spreading bearings arranged in front of and behind the fiber spreading mounting plate in sequence; both ends of the fiber spreading mounting plate are respectively provided with high-speed cameras for detecting the surface quality of the fiber material before and after spreading; an ion wind rod is arranged between the active fiber spreading bearings and the high-speed cameras to eliminate static accumulation caused by mechanical friction. According to the continuous fiber prepreg manufacturing system, the solution impregnation device is further provided with a series of unwinding mechanisms, deviation correcting mechanisms and glue removing devices arranged in front of and behind the solution impregnation device in sequence; a drying and preheating device is further arranged between the solution impregnation device and the melt impregnation device. The unwinding mechanism comprises a linear movement structure, an unwinding servo motor and an air expansion shaft; the air expansion shaft is connected to the unwinding servo motor and is used for winding the fiber material and unwinding through controllable rotation; the unwinding servo motor is connected to the linear movement structure arranged along the air expansion shaft in the axial direction; The deviation correcting mechanism comprises a deviation correcting support, at least one channel arranged on the deviation correcting support and a group of grating sensors arranged on the upper and lower sides of the channel; the linear movement structure is used for moving according to the detection result of the grating sensors to realize deviation correction. The glue removing device comprises a glue removing box body and a heating pipe arranged inside the glue removing box body, which is used for heating and removing glue of the passing fiber material; and the drying preheating device comprises a drying box body and a heating pipe arranged inside the drying box body, which is used for drying and preheating the passing fiber material. The continuous fiber prepreg yarn manufacturing system further comprises a plurality of unwinding mechanisms arranged at the unwinding support. The top of the glue removing box body is provided with a glue removing guide wheel; the top of the fiber spreading mounting plate is further provided with a row of fiber winding guide wheels along the process direction; the glue removing guide wheel and the fiber winding guide wheels are used for conveying the fiber material of the single yarn. The inside of the solution impregnation box body is provided with a plurality of groups of impregnation guide wheels, which are used for conveying a plurality of fiber materials.

[0009] The continuous fiber prepreg yarn manufacturing system further comprises a core-shell device, a cooling device, a traction device, a line diameter detection device and a winding device arranged in sequence behind the melt impregnation device. The core-shell device comprises a core-shell box body, a heating rod arranged inside the core-shell box body and a melt resin supply structure communicated to the inside of the core-shell box body; the core-shell box body is provided with an inlet and an outlet, wherein a core-shell outlet die is arranged at the outlet. The cooling device comprises a cooling mounting plate and an annular air knife arranged on the cooling mounting plate; the core-shell device is fixed on the cooling mounting plate, and an annular air knife is further arranged in front of the core-shell device. The traction device is used for providing conveying power of the fiber material; the line diameter detection device is used for detecting the size of the fiber material; and the winding device is used for winding the manufactured fiber material.

[0010] The continuous fiber prepreg yarn manufacturing system further comprises a first tension detection mechanism arranged between the deviation correction mechanism and the glue removing device, a cantilever tension sensor arranged on the fiber spreading mounting plate between two active fiber spreading bearings, a second tension detection mechanism arranged at the end of the cooling mounting plate and a third tension detection mechanism arranged between the line diameter detection device and the winding device. The fiber spreading mounting plate is further provided with a pair of pressure roller groups guided and pulled by servo motors on the front and rear sides of the cantilever tension sensor. The tension detection mechanisms and the tension sensors are used for cooperating with the conveying powers to realize constant tension in the fiber material manufacturing process.

[0011] According to another aspect of the present application, a continuous fiber prepreg yarn manufacturing method is provided, which comprises: The fiber material is first impregnated with a resin solution, and then impregnated with a molten resin to realize secondary impregnation manufacturing; wherein the temperature of the resin solution impregnation is set to 220-240 DEG C, and the resin solution is anhydrous ethanol solution of PA6 resin powder; the temperature of the molten resin in the molten resin impregnation is set to 230-260 DEG C.

[0012] According to the continuous fiber prepreg yarn manufacturing method provided by the application, a plurality of fiber materials are used to manufacture functional prepreg yarns; the plurality of fiber materials include continuous carbon fiber filaments and continuous carbon nanotube fibers, and the functional prepreg yarns are manufactured by wrapping the carbon nanotube fibers with the fiber filaments.

[0013] Overall, compared with the prior art, the continuous fiber prepreg yarn manufacturing system and method provided by the application has the following advantages: 1. The solution and melt of the thermoplastic resin are used for double impregnation of the fiber material, the interface bonding between the fiber and the resin is increased, the impregnation degree of the fiber and the resin is greatly improved, and the mechanical properties and surface quality of the prepreg yarn are improved; the molten resin is introduced into the inside of the impregnation roller in real time, the fiber that has passed through the molten resin overflowing from the surface of the impregnation roller is impregnated, which is beneficial to reduce the resin consumption and reduce the process cost, and the small-range supply of the molten resin is also beneficial to avoid overheating of a large amount of resin, thereby ensuring the effective utilization of the molten resin; in addition, when the fiber that has passed through the molten resin overflowing from the surface of the impregnation roller is impregnated, the fiber can also cut the resin, thereby being beneficial to improve the impregnation effect of the high-viscosity resin on the fiber; 2. The screw extruder is used for feeding to avoid waste and excessive heating of the resin, the microstructure design of the impregnation roller can realize the adaptation of different specifications of the fiber under the premise of sufficient impregnation, and the movable heating guide roller can accurately control the temperature and increase the shearing force of the resin, thereby increasing the impregnation effect; 3. The fiber material to be treated in the fiber spreading device is first passively spread under the action of the convex pin through the mechanical restraint device, and then actively spread under the reciprocating movement of the spreading roller through the dynamic control device, the combination of passive spreading and active spreading enables the spreading device to have multiple spreading modes, which can strengthen the spreading effect, thereby improving the adaptability when facing different fiber types, and the superposition of the two spreading modes is also beneficial to ensure the spreading effect, thereby being beneficial to ensure the high-quality production of the fiber; 4. The tension control system provided by the application decouples the multiple-section tension of the production line to realize the stable tension state of the entire production line; at the same time, the tension sensor is reasonably arranged, which is beneficial to effectively correct the factors such as the friction fluctuation of the roller system in the production line and the resistance change in the impregnation / drying process, thereby realizing the accurate control of the multiple-section tension with high stability and high consistency; 5. The internal functional fiber composite and the external functional shell can be coated for different application conditions, i.e. the filaments are compounded for different use conditions, realizing multifunctional integrated and high-performance continuous fiber thermoplastic functional prepreg filament preparation for industrial production. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 is a schematic diagram of a continuous fiber prepreg filament manufacturing system provided by the present application.

[0015] Figure 2 is a structural schematic diagram of a unwinding mechanism provided by the present application.

[0016] Figure 3 is a structural schematic diagram of a deviation rectifying mechanism provided by the present application.

[0017] Figure 4 is a structural schematic diagram of a first tension detection mechanism provided by the present application.

[0018] Figure 5 is a structural schematic diagram of a degumming device provided by the present application.

[0019] Figure 6 is a structural schematic diagram of a filament spreading device provided by the present application.

[0020] Figure 7 is a structural schematic diagram of an equal-width positioning groove provided by the present application.

[0021] Figure 8 is a structural schematic diagram of a first convex pin provided by the present application.

[0022] Figure 9 is a structural schematic diagram of a solution impregnation device provided by the present application.

[0023] Figure 10 is a structural schematic diagram of a drying and preheating device provided by the present application.

[0024] Figure 11 is a structural schematic diagram of a melting impregnation device provided by the present application.

[0025] Figure 12 is a cross-sectional structural schematic diagram of an impregnation roller provided by the present application.

[0026] Figure 13 is a structural schematic diagram of a limiting plate provided by the present application.

[0027] Figure 14 is a structural schematic diagram of a chamfering piece provided by the present application.

[0028] Figure 15 is a structural schematic diagram of a core-shell device provided by the present application.

[0029] Figure 16 is a structural schematic diagram of the cooling device provided by the present application.

[0030] Figure 17 is a structural schematic diagram of the traction device provided by the present application.

[0031] Figure 18 is a structural schematic diagram of the third tension detection mechanism provided by the present application.

[0032] Figure 19 is a structural schematic diagram of the winding device provided by the present application.

[0033] Figure 20 is a sectional schematic diagram of the fiber pre-impregnated product provided by the present application.

[0034] In all the drawings, the same reference signs are used to represent the same elements or structures, wherein: 1, unwinding mechanism; 1-1 and 1-2, air expansion shaft; 1-3 and 1-4, unwinding servo motor; 1-5 and 1-6, shaft coupling; 1-7, unwinding support; 1-8 and 1-9, screw guide rail module; 2, deviation rectifying mechanism; 2-1, deviation rectifying support; 2-2 and 2-3, grating sensor; 3, first tension detection mechanism; 3-1, first mounting plate; 3-2- and 3-3, ceramic guide hole; 3-4 and 3-5, first tension spring guide wheel; 3-6 and 3-7, first tension sensor; 4, glue removing device; 4-1, glue removing inner container; 4-2, glue removing quartz heating tube; 4-3, glue removing aerogel thermal insulation layer; 4-4, glue removing outer shell; 4-5, glue removing guide wheel; 5, fiber spreading device; 5-1, fiber spreading mounting plate; 5-2, equal-width positioning groove; 5-3, first convex pin; 5-4, high-width positioning groove; 5-5, second convex pin; 5-6 and 5-7, fiber spreading servo motor; 5-8 and 5-9, active fiber spreading bearing; 5-10, cantilever type tension sensor; 5-11 and 5-12, fiber spreading conveying servo motor; 5-13 and 5-14, fiber spreading rubber pair of compression rollers; 5-15 and 5-16, high-speed camera; 5-17, ion wind rod; 5-18, fiber winding guide wheel; 6, solution impregnation device; 6-1, solution impregnation box body; 6-2 and 6-3, guide roller; 6-4 and 6-5, impregnation guide wheel; 6-6, ultrasonic vibration rod; 6-7, liquid level detector; 6-8, liquid inlet; 6-9, switch valve port; 7, drying preheating device; 7-1, drying inner container; 7-2, drying quartz heating tube; 7-3, drying aerogel thermal insulation layer; 7-4, drying outer shell; 8, melt impregnation device; 8-1, melt impregnation inner container; 8-2, impregnated aerogel thermal insulation layer; 8-3, impregnated shell; 8-4, impregnated quartz heating tube; 8-5 and 8-6, impregnated screw extruder; 8-7 and 8-8, impregnated servo motor; 8-9 and 8-10, impregnated speed reducer; 8-11 and 8-12, impregnated electric eye hopper; 8-13 and 8-14, impregnated roller; 8-15, impregnated heating ring; 8-16, guide roller; 8-17, bearing; 8-18, pressure roller; 8-19, impregnated exit die; 141, first runner; 142, second runner; 143, limiting plate; 144, baffle; 145, thermocouple; 146, chamfering piece; 9, core-shell device; 9-1, core-shell support; 9-2, core-shell inner container; 9-3, core-shell aerogel thermal insulation layer; 9-4, encapsulation shell; 9-5, heating rod; 9-6, core-shell screw extruder; 9-7, core-shell heating ring; 9-8, core-shell servo motor; 9-9, core-shell speed reducer; 9-10, core-shell electric eye hopper; 9-11, core-shell exit die; 10, cooling device; 10-1, second mounting plate; 10-2 and 10-3, annular air knife; 10-4, second tension spring guide wheel; 10-5, second tension sensor; 11, traction device; 11-1, traction support; 11-2, traction rubber pair of compression roller group; 11-3, traction servo motor; 11-4, traction speed reducer; 11-5, air cylinder; 11-6, traction guide wheel; 12, wire diameter detection device; 13, third tension detection mechanism; 13-1, third mounting plate; 13-2, third tension spring guide wheel; 13-3, third tension sensor; 13-4, meter counter; 14, winding device; 14-1, screw guide rail module; 14-2, winding servo motor; 14-3, slip shaft; 14-4, tray. DETAILED DESCRIPTION

[0035] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to the drawings and examples. It should be understood that the specific examples described herein are only used to explain the present application and do not limit the present application. In addition, the technical features involved in each embodiment of the present application described below can be combined with each other as long as they do not conflict with each other.

[0036] Please refer to Figure 1 The present embodiment provides a continuous fiber prepreg manufacturing system, which comprises a solution impregnation device 6 and a melt impregnation device 8; the solution impregnation device 6 comprises a solution impregnation box body 6-1, the inside of the solution impregnation box body 6-1 contains a resin solution and the bottom is provided with an impregnation guide wheel; The melt impregnation device 8 comprises a melt impregnation box, a melt resin supply structure, an impregnation roller and a guide roller 8-16, the impregnation roller and the guide roller 8-16 are respectively arranged in the interior of the melt impregnation box, the melt resin supply structure is connected with the impregnation roller and used for conveying melt resin to the interior of the impregnation roller, and the impregnation roller is provided with a melt resin overflow channel; The fiber material is firstly impregnated with the solution in the interior of the solution impregnation box 6-1 through the impregnation guide roller, and then sent into the interior of the melt impregnation box, wound around the guide roller 8-16 and the impregnation roller, and impregnated with melt resin at the impregnation roller to perform secondary impregnation manufacturing.

[0037] In some embodiments, referring to Figure 9 , both sides of the solution impregnation box 6-1 are respectively provided with openings and guide rollers, i.e., guide rollers 6-2 and 6-3, which are used for conveying the fiber material; the interior of the solution impregnation box 6-1 is further provided with an ultrasonic vibration rod 6-6; the solution impregnation box 6-1 is further connected with a liquid level detector 6-7 for real-time detection of the internal liquid level, and is further provided with a liquid inlet 6-8 for supplementing the solution and a switch valve opening 6-9 at the bottom for discharging waste liquid.

[0038] The solution impregnation device 6 in the embodiment is used for wrapping the widened fiber material with resin solution; the solution impregnation box 6-1 can be a stainless steel box, the fiber enters the box from the guide roller 6-2, is impregnated with resin solution, and is taken out from the guide roller 6-3, the impregnation guide roller 6-4 and the impregnation guide roller 6-5 arranged in the bottom of the box can guide two kinds of fiber materials, such as fiber raw filaments and functional filaments; the ultrasonic vibration rod 6-6 embedded in the interior is used for increasing the dispersion uniformity of resin powder, fully mixing the resin solution, and improving the impregnation effect of the resin.

[0039] In some embodiments, referring to Figure 11 , the guide roller 8-16 is rotatably connected to the melt impregnation box and is provided with a heating rod in the interior for independent heating; the guide roller near the outlet of the melt impregnation box is matched with a press roller; the fiber impregnated with melt resin is pressed between the press roller 18 and the corresponding guide roller 16. The guide roller 8-16 group is used for guiding the fiber dry filaments and increasing the impregnation stroke; the impregnation roller is used for overflowing thermoplastic resin to fully impregnate the fiber dry filaments; the fiber dry filaments enter the fiber inlet of the impregnation box and are wound around the guide roller 8-16 and the impregnation roller in a Z-shaped manner. The guide roller 8-16 can comprise a roller rod, a shaft sleeve, a bearing seat, a heating rod and a thermocouple; the shaft sleeve structure is adopted, the brass rod is sleeved with the stainless steel shaft sleeve, and independent heating and temperature control detection of the positioning roller are realized.

[0040] The molten resin supply structure includes a screw extruder and an electric eye hopper, the outlet of the screw extruder is communicated to the inside of the immersion roller, the electric eye hopper is connected to the screw extruder, and a heating ring, i.e., an immersion heating ring 8-15, is sleeved on the screw extruder to heat the resin into a molten state. The screw extrusion device controls the flow rate through a servo motor, and the automatic feeding system, i.e., the electric eye hopper, can dry the resin particles in real time, reduce the bubbles generated during the extrusion process, and at the same time, the detection device at the hopper ensures that the number of resin particles is within a controllable range.

[0041] The bottom of the molten immersion box is open and placed on the workbench, and the bottom is provided with a heating pipe, i.e., an immersion quartz heating pipe 8-4. The bottom of the immersion box can also be placed with a waste collecting device for collecting excessive overflow of resin for recycling, reducing material cost while realizing closed-loop production and sustainable production. The waste collecting device can include a box body and a pull handle. At the same time, a heating pipe can be arranged at the bottom of the box body to ensure the required temperature inside the box body.

[0042] In some embodiments, referring to Figure 12 , the overflow channel includes a first flow channel 141 extending through one end of the immersion roller in the axial direction inside the immersion roller and a second flow channel 142 communicating the first flow channel 141 to the surface of the immersion roller, and the fiber raw material bypasses the outlet of the second flow channel 142 corresponding to the surface of the immersion roller. The first flow channel 141 is communicated with the outlet of the molten resin supply structure.

[0043] Further, the opening size of the second flow channel 142 of the immersion roller can be adjusted according to the fiber specifications. When small tow fibers are immersed, a small size opening can provide penetration pressure and reduce waste of resin particles. When large tow fiber bundles are immersed, a large size opening can provide a larger resin overflow amount and a larger immersion contact area per unit time.

[0044] In some embodiments, referring to Figure 11 , the immersion roller is provided with a plurality of immersion rollers 8-14 with the outlet of the second flow channel 142 upwardly arranged and immersion rollers 8-13 with the outlet of the second flow channel 142 downwardly arranged. The fiber dry yarn passes through the guide roller 8-16 and the immersion roller in sequence, bypasses from below the immersion roller 8-13, and bypasses from above the immersion roller 8-14, so that the resin can uniformly coat the upper and lower surfaces of the fiber to fully immerse.

[0045] In some embodiments, referring to Figure 11 , Figure 12 and Figure 13The surface of the impregnation roller is provided with a cutting surface, the second flow channel 142 is communicated to the cutting surface, and the fiber raw material passes around the cutting surface; further comprising a limiting plate 143, the limiting plate 143 is arranged above the cutting surface and connected to the impregnation roller, the limiting plate 143 is connected with a baffle 144 on both sides in the axial direction of the second flow channel 142, and the limiting plate 143 is provided with a notch on both sides in the circumferential direction at the part between the two baffles 144, the fiber raw material passes through the limiting plate 143 from the notch and passes around the cutting surface between the two baffles 144. The baffles 144 on both sides of the second flow channel 142 limit the molten resin overflowing from the second flow channel 142 between the two baffles 144, so as to be fully impregnated with the fiber passing between the two baffles. The limiting plate 143 can be connected and fixed at one side with the end surface of the impregnation roller.

[0046] In some embodiments, with reference to Figure 12 and Figure 14 The cutting surface is further connected with a chamfer 146 on both sides in the circumferential direction, the baffle 144 is located between the chamfers 146 on both sides, and the fiber raw material passes around between the chamfers 146 and the limiting plate 143. The chamfer 146 can provide an arc surface on the fiber path, which can reduce the winding angle and prevent the fiber from breaking, and the chamfers 146 on both sides and the two baffles 144 can enclose a molten resin storage pool, which is beneficial to better impregnate the fiber.

[0047] A thermocouple 145 can also be arranged on the impregnation roller for detecting the temperature of the impregnation roller, and the impregnation heating ring 8-15 can be used for heating when the temperature is not up to standard.

[0048] In some embodiments, with reference to Figure 11 The impregnation box is provided with a fiber inlet and a fiber outlet, and a detachable impregnation outlet die 8-19 is connected to the fiber outlet, the impregnation outlet die 8-19 is a circular nozzle structure gradually reduced in the process direction or a square port structure. The impregnation outlet die 8-19 is used for controlling the specifications and types of the prepared prepreg; the impregnation outlet die 8-19 adopts a circular nozzle when preparing a prepreg filament, and the opening diameter of the nozzle is adjusted according to the fiber content requirement; the impregnation outlet die 8-19 adopts a rectangular nozzle when preparing a prepreg narrow strip, and the width and thickness of the nozzle are adjusted according to the fiber content requirement.

[0049] The melting impregnation device 8 is used for heating resin particles and fully impregnating fiber filaments; the melting impregnation box body includes a melting impregnation inner container 8-1, an impregnation aerogel thermal insulation layer 8-2, and an impregnation shell 8-3 for overall wrapping, a bottom of the box body is provided with an impregnation quartz heating tube 8-4 for providing an ambient temperature, impregnation screw extruders 8-5 and 8-6 are used for melting resin particles for feeding, corresponding impregnation servo motors 8-7 and 8-8 and impregnation speed reducers 8-9 and 8-10 are provided, and impregnation electric eye hoppers 8-11 and 8-12 are installed at hopper mouths for automatic feeding; the impregnation screw extruders 8-5 and 8-6 are correspondingly connected with impregnation rollers 8-13 and 8-14, the impregnation rollers 8-13 and 8-14 are internally provided with holes for overflowing resin to impregnate the upper and lower surfaces of the passing fibers; an impregnation heating ring 8-15 is used for heating the impregnation screw extruders 8-5 and 8-6 and the impregnation rollers 8-13 and 8-14, an internal guide roller 8-16 is used for increasing the impregnation stroke of the fibers and guiding, a bearing 8-17 is used for enabling the guide roller 8-16 to rotate, a heating rod is arranged in the guide roller for independent heating, a compression roller 8-18 is used for compressing the impregnated fibers to ensure the impregnation quality, and an impregnation outlet die 8-19 is used for collecting the impregnated fibers to form a prepreg.

[0050] The screw extruder is used for feeding in the embodiment, resin waste and excessive heating are avoided, the microstructure design of the impregnation roller can realize the adaptation of different specifications of fibers on the premise of sufficient impregnation, the movable heating guide roller can accurately control the temperature and increase the shearing force of the resin to increase the impregnation effect, and the detachable design of the impregnation outlet die ensures the compatible preparation of the fiber and tape materials.

[0051] The prepreg for additive manufacturing and the universal impregnation device for narrow tapes provided in the embodiment can realize real-time feeding through the screw extruder, the positioning roller group and the impregnation roller group can fully impregnate the expanded fiber dry yarn, and the replaceable outlet die can satisfy the universal preparation of different types and specifications of prepregs. The universal impregnation of the continuous fiber prepreg and the prepreg narrow tape can be realized by changing the opening size of the impregnation roller group and the form of the outlet die, the equipment investment cost is reduced, and the product quality consistency is increased.

[0052] In some embodiments, reference is made to Figure 1 and Figure 6, the solution impregnation device 6 further comprises a fiber spreading device 5 before the solution impregnation device 6; the fiber spreading device 5 comprises a fiber spreading mounting plate 5-1 and, in sequence from front to back on the fiber spreading mounting plate 5-1, an equal-width positioning groove 5-2, a first convex pin 5-3, a high-width positioning groove 5-4, a second convex pin 5-5, and two active fiber spreading bearings, namely an active fiber spreading bearing 5-8 and an active fiber spreading bearing 5-9; both ends of the fiber spreading mounting plate 5-1 are respectively provided with a high-speed camera 5-15 and a high-speed camera 5-16 for detecting the surface quality of the fiber before and after spreading, and an ion wind rod 5-17 is further arranged between the active fiber spreading bearing 5-9 and the high-speed camera 5-16 to eliminate static accumulation caused by mechanical friction. The fiber spreading device 5 is used for detecting defects of the fiber raw wire and spreading the fiber raw wire; the fiber spreading device 5 comprises the fiber spreading mounting plate 5-1, the equal-width positioning groove 5-2, the first convex pin 5-3, the high-width positioning groove 5-4, the second convex pin 5-5, the fiber raw wire is passively spread through the positioning groove and the convex pin, the fiber spreading servo motor 5-6 and the fiber spreading servo motor 5-7 control the transverse movement of the linear bearing to mechanically spread, the high-speed camera 5-15 detects the surface quality of the fiber raw wire, the high-speed camera 5-16 detects the surface quality of the fiber after spreading, the ion wind rod 5-17 eliminates static accumulation caused by mechanical friction, and the wire guide pulley 5-18 is used for winding the fiber and the wire without spreading. Refer to Figure 7 The groove width of the equal-width positioning groove 5-2 is consistent with the initial width of the fiber wire, and the groove width of the high-width positioning groove 5-4 is greater than the groove width of the equal-width positioning groove 5-2. That is, the groove width of the equal-width positioning groove 5-2 can be the same as the initial width of the fiber wire, and the groove width of the high-width positioning groove 5-4 can be consistent with the target width of the fiber wire after being spread by the first convex pin 5-3. The positioning groove is an annular groove arranged on the outer wall of a cylinder, and the fiber wire passes through the groove, thereby playing a limiting role, as shown in Figure 7 .

[0053] The fiber spreading servo motor can be connected with the linear bearing, namely the active fiber spreading bearing, through a cam connector, and the rotary motion of the motor is converted into linear reciprocating motion through the cam connector. The cam connector can also be realized through other transmission conversion modes, and the linear driving structure can also adopt a linear electric cylinder, etc., for the purpose of providing linear reciprocating motion, and the specific mode is not limited. Two groups of active fiber spreading bearings are arranged in front of and behind the active fiber spreading bearing to enhance the flexibility of active fiber spreading control and ensure the effect of active fiber spreading.

[0054] The components of the fiber spreading device 5 are detachable and can be connected to the fiber spreading mounting plate 5-1 in an adjustable up-down position. The fiber spreading mounting plate 5-1 can be provided with multiple hole positions to adjust the distance and height between the positioning groove, the convex pin and the fiber spreading roller. The width and depth of the equal-width positioning groove 5-2 and the high-width positioning groove 5-4 can be matched with different specifications of fiber filaments by adjustment and replacement. The first convex pin 5-3 and the second convex pin 5-5 can be matched with different specifications of fiber filaments by adjustment and replacement of the diameter and length. Referring to Figure 8 , the first convex pin 5-3 and the second convex pin 5-5 can adjust the efficiency and width of fiber spreading by changing the radius of curvature. That is, by changing the groove width of the equal-width positioning groove 5-2 and the high-width positioning groove 5-4, and the radius of curvature of the first convex pin 5-3 and the second convex pin 5-5, not only can different specifications of fiber filaments be matched, but also the width of the spread can be self-defined adjusted; thereby further improving the adaptability of different fiber types.

[0055] The fiber spreading device 5 combines passive fiber spreading and mechanical fiber spreading. For the characteristics of materials that are easy to bend and brittle, the tension can be maintained constant. For different specifications of fiber, only the accessories need to be replaced to achieve one machine for multiple uses. The front and rear cameras can accurately monitor online. The static electricity elimination device further ensures the surface quality.

[0056] Referring to Figure 6 , the fiber spreading device 5 further comprises a plurality of fiber winding guide rollers 5-18 arranged in front and back above the fiber spreading mounting plate 5-1, for selectively directly conveying fiber filament materials. When preparing functional filament materials by combining fiber raw filaments and functional filaments, the fiber raw filaments can be alternately wound up and down through the mechanical restraint device and the dynamic control device for fiber spreading operation, and the functional filaments, which do not need to be spread, can be conveyed by being wound through the fiber winding guide rollers 5-18 above in sequence, so as to realize the conveying of two kinds of filament materials and further realize the preparation of functional filament materials. The fiber filament material can also be wound through the fiber winding guide roller 5-18 first and then enter the dynamic control device to perform active fiber spreading operation alone, or pass through the mechanical restraint device first and then wind through the fiber winding guide roller 5-18 for conveying to perform passive fiber spreading operation alone, which is not limited. The arrangement of the fiber winding guide roller 5-18 improves the flexibility and adaptability of the fiber spreading device.

[0057] In some embodiments, referring to Figure 1 , the solution impregnation device 6 further comprises a front and back arranged unwinding mechanism 1, deviation correction mechanism 2 and glue removal device 4 before the solution impregnation device 6 and the melt impregnation device 8, and an oven preheating device 7 is further arranged between the solution impregnation device 6 and the melt impregnation device 8; Referring to Figure 2 , the unwinding mechanism 1 comprises a linear motion structure, an unwinding servo motor and an air expansion shaft; the air expansion shaft is connected to the unwinding servo motor and is used for winding fiber filament materials and achieving unwinding through controllable rotation, and the unwinding servo motor is connected to the linear motion structure arranged along the axial direction of the air expansion shaft. With reference to Figure 3 , the deviation rectifying mechanism 2 comprises a deviation rectifying support 2-1, at least one channel provided on the deviation rectifying support 2-1, and a set of grating sensors provided on both sides of the channel; the linear movement structure is used to move according to the detection results of the grating sensors to realize deviation rectification. With reference to Figure 5 , the glue removing device 4 comprises a glue removing box body and a heating pipe provided inside the glue removing box body, which is used to heat and remove glue from the passing fiber material; with reference to Figure 10 , the drying and preheating device 7 comprises a drying box body and a heating pipe provided inside the drying box body, which is used to dry and preheat the passing fiber material. In some embodiments, with reference to Figure 2 , a fiber unwinding support 1-7 is further provided at the fiber unwinding mechanism 1; a plurality of fiber unwinding mechanisms 1 are provided, and the plurality of fiber unwinding mechanisms 1 and the fiber unwinding support 1-7 are used to realize combined fiber unwinding manufacturing of multiple fiber materials. With reference to Figure 4 , a glue removing guide wheel 4-5 is provided on the top of the glue removing box body; with reference to Figure 5 , a row of fiber winding guide wheels 5-18 is further provided above the fiber spreading mounting plate 5-1 along the process direction; the glue removing guide wheel 4-5 and the fiber winding guide wheel 5-18 are used to transport the fiber material of a single fiber material. With reference to Figure 9 , a plurality of groups of impregnation guide wheels, such as impregnation guide wheels 6-4 and 6-5, are provided inside the solution impregnation box body 6-1, which are used to transport multiple fiber materials.

[0058] In some specific embodiments, with reference to Figure 2 , the fiber unwinding mechanism 1 is used to provide fiber raw filaments and functional filaments; the fiber unwinding mechanism 1 comprises air expansion shafts 1-1 and 1-2 for mounting fiber reels, fiber unwinding servo motors 1-3 and 1-4 for controlling the rotation of the fiber reels, a coupling 1-5 and a coupling 1-6 for connecting the two air expansion shafts, a fiber unwinding support 1-7 for mounting a functional filament material disc for passive unwinding, and a lead screw guide rail module 1-8 and a lead screw guide rail module 1-9 for controlling the left and right movement of the air expansion shafts for deviation rectification and centering; two fiber unwinding mechanisms 1 and the fiber unwinding support 1-7 can realize the free combination preparation of single fiber, fiber + functional filament, and fiber + fiber.

[0059] With reference to Figure 3, the deviation correction mechanism 2 is used to identify the deflection direction and distance of the fiber filament; the deviation correction mechanism 2 includes a deviation correction support 2-1, two groups of grating sensors 2-2 and 2-3 which detect the position of the fiber filament in real time, and feed back signals to the lead screw guide module 1-8 and 1-9; the moving direction of the fiber reel is opposite to the deflection direction of the fiber filament, so as to control the deflection angle of the fiber and make it in the axial direction; compared with the traditional limiting deviation correction of the reflection type sensor, the grating sensor can detect the position coordinates of the fiber in real time, and cooperate with the lead screw guide module to achieve accurate dynamic deviation correction.

[0060] Reference Figure 5 , the glue removing device 4 is used to remove the sizing agent of the fiber filament; the glue removing box body includes a glue removing inner container 4-1, a glue removing aerogel thermal insulation layer 4-3, and a glue removing shell 4-4. The glue removing quartz heating pipe 4-2 provides the required environmental temperature for glue removal, the glue removing aerogel thermal insulation layer 4-3 prevents heat overflow, improves energy utilization efficiency and prevents the operator from being scalded, the glue removing shell 4-4 wraps the thermal insulation layer, and the glue removing guide wheel 4-5 winds the fiber and the wire material such as functional wire material which does not need to be removed.

[0061] Reference Figure 10 , the drying preheating device 7 is used to remove the moisture on the surface of the fiber filament and promote the preliminary infiltration of the resin solution; the drying preheating box body includes a drying inner container 7-1, a drying aerogel thermal insulation layer 7-3, and a drying shell 7-4; the drying quartz heating pipe 7-2 provides the required environmental temperature for glue removal, the drying aerogel thermal insulation layer 7-3 prevents heat overflow, improves energy utilization efficiency and prevents the operator from being scalded, and the drying shell 7-4 wraps the thermal insulation layer.

[0062] In some embodiments, reference Figure 1 , the melt impregnation device is sequentially provided with a core-shell device 9, a cooling device 10, a traction device 11, a wire diameter detection device 12, and a winding device 14 at the rear end; Reference Figure 15 , the core-shell device 9 includes a core-shell box body, a heating rod 9-5 arranged inside the core-shell box body, and a melt resin supply structure communicated to the inside of the core-shell box body; the core-shell box body is provided with an inlet and an outlet, and a core-shell outlet mold 9-11 is arranged at the outlet; Reference Figure 16 , the cooling device 10 includes a cooling mounting plate, i.e., a second mounting plate 10-1, and an annular air knife arranged on the cooling mounting plate; the core-shell device 9 is fixed on the cooling mounting plate, and an annular air knife 10-2 is further arranged before the core-shell device 9; Reference Figure 17 , the traction device 11 is used to provide the conveying power of the fiber wire material; the wire diameter detection device 12 is used to detect the size of the fiber wire material; and the winding device 14 is used to wind the finished fiber wire material.

[0063] In particular, referring to Figure 15 , the core-shell device 9 is used to wrap the functional resin shell for the prepreg filaments; the core-shell box body includes a core-shell inner container 9-2, a core-shell aerogel fiber thermal insulation layer 9-3, and an encapsulation shell 9-4 for overall wrapping, is placed on a core-shell support 9-1, a heating rod 9-5 at the bottom is used to heat and keep warm the resin melt, a core-shell screw extruder 9-6 is used to melt the resin particles for continuous feeding, a core-shell heating ring 9-7 is used to heat the core-shell screw extruder 9-6, a core-shell servo motor 9-8 and a core-shell speed reducer 9-9 control the rotation of the core-shell screw extruder 9-6, a core-shell electric eye hopper 9-10 is installed at the hopper for automatic feeding, and a core-shell outlet die 9-11 is used to collect the prepreg filaments wrapped with the resin shell; the shape of the core-shell outlet die 9-11 is the same as that of the impregnation outlet die 8-19, and the size is larger than that of the impregnation outlet die 8-19, so as to facilitate wrapping the resin layer outside the fiber.

[0064] Referring to Figure 16 , the cooling device 10 is used for rapid cooling and forming of the impregnated filaments; the cooling device 10 includes a second mounting plate 10-1, an annular air knife 10-2, and an annular air knife 10-3; the design of the double-sided annular air knife can quickly realize the rapid cooling of the impregnated filaments, prevent heat stress concentration, and ensure the surface quality. Figure 17

[0065] The traction device 11 is used to pull the impregnated prepreg filaments; the traction device 11 includes a traction support 11-1, a traction rubber pair of compression roller groups 11-2, a traction servo motor 11-3 and a traction speed reducer 11-4, an air cylinder 11-5, and a traction guide wheel 11-6; the traction speed reducer 11-4 is connected with the traction servo motor 11-3, the traction servo motor 11-3 is connected with one of the traction rubber pair of compression roller groups 11-2 through a transmission structure, and is used to drive the one conveying roller to rotate, the air cylinder 11-5 is connected with the other conveying roller in the traction rubber pair of compression roller groups 11-2, and is used to drive the other conveying roller to move up and down to adjust the compression degree of the fiber filaments. The traction guide wheel 11-6 is connected to the traction support 11-1, and is used to pass through the fiber filaments for fiber conveying.

[0065] The diameter detection device 12 is used to measure the diameter of the impregnated filaments or the width and thickness of the narrow strip; the winding device 14 is used to wind and arrange the formed impregnated filaments; referring to Figure 19 , the winding device 14 includes a lead screw guide rail module 14-1 for transverse movement, a winding servo motor 14-2 controls the rotation of a slip shaft 14-3, and a tray 14-4 tightly winds the filaments.

[0066] In some embodiments, referring to Figure 1Further comprising a first tension detection mechanism 3 arranged between the deviation rectifying mechanism 2 and the glue removing device 4, a cantilever tension sensor 5-10 arranged on the fiber spreading mounting plate 5-1 between two active fiber spreading bearings, a second tension detection mechanism arranged at the end of the cooling mounting plate, and a third tension detection mechanism 13 arranged between the wire diameter detection device 12 and the winding device 14; The fiber spreading mounting plate 5-1 is further provided with a pair of pressure roller groups guided and pulled by servo motors on both sides of the cantilever tension sensor 5-10. Each tension detection mechanism and tension sensor is used to cooperate with the corresponding conveying power to keep the tension constant during the fiber filament manufacturing process.

[0067] Specifically, referring to Figure 4 , the first tension detection mechanism 3 is used to detect the tension of the rectified fiber and guide it. The first tension detection mechanism 3 includes a first mounting plate 3-1, a first guide roller, a first tension spring guide roller, and a first tension sensor connected to the first mounting plate 3-1. The fiber filament alternately passes through the first guide roller, the first tension spring guide roller, and the first tension sensor. The unwinding mechanism 1 is used to adjust the fiber unwinding conveying speed according to the detection information of the first tension sensor to regulate the fiber tension. The first tension spring guide roller includes a guide roller and a tension spring structure connecting the guide roller and the first mounting plate 3-1. That is, the guide roller of the first tension spring guide roller is elastically fixed to the first mounting plate 3-1 by the tension spring structure, so that the guide roller of the first tension spring guide roller has an up-and-down vibration space, thereby relieving the tension fluctuation of the passing fiber by floating up and down.

[0068] A plurality of sets of the first guide roller, the first tension spring guide roller, and the first tension sensor can be arranged on the first mounting plate to simultaneously convey multiple fiber filaments, which can adapt to the composite manufacturing process of multiple fibers. When two sets of unwinding mechanisms 1 are provided to convey two fiber filaments, the two fiber filaments pass through the ceramic guide holes 3-2 and 3-3 for limiting and alternately pass through the two sets of first tension detection mechanisms. One fiber filament passes through the lower first guide roller, first tension spring guide roller 3-4, and first tension sensor 3-6, and the other fiber filament passes through the upper first guide roller, first tension spring guide roller 3-5, and first tension sensor 3-7. The first tension sensor 3-6 and the first tension sensor 3-7 detect the tension values of the two fiber filaments in real time and feed back signals to the unwinding servo motors 1-3 and 1-4, thereby adjusting the tension by controlling the unwinding speed.

[0069] Referring to Figure 6, cantilever tension sensor 5-10 detects the tension value in the unwinding process, unwinding conveying servo motor 5-11 and unwinding conveying servo motor 5-12 correspondingly control the guiding traction of unwinding rubber pair of compression roller groups 5-13 and 5-14, and the fiber material passes between the rubber pair of compression roller groups and around the cantilever tension sensor 5-10; the compression roller group is used to adjust the fiber conveying speed according to the detection information of the cantilever tension sensor 5-10 to regulate the fiber tension. Alternatively, the compression roller group before the cantilever tension sensor 5-10 is used to adjust the fiber conveying speed according to the detection information of the cantilever tension sensor to regulate the fiber tension.

[0070] Reference Figure 16 , the second tension detection mechanism is arranged on the cooling mounting plate, i.e. the second mounting plate 10-1, and includes a second guide roller, a second tension spring guide roller 10-4 and a second tension sensor 10-5 connected to the second mounting plate 10-1, and the fiber material alternately passes above and below the second guide roller, the second tension spring guide roller 10-4 and the second tension sensor 10-5; the tension spring eliminates the tension fluctuation in the pre-dipping process, and the tension sensor detects the tension value of the pre-dipped fiber material. The compression roller group in the unwinding device is used to adjust the fiber conveying speed according to the detection information of the second tension sensor 10-5 to regulate the fiber tension. Alternatively, the compression roller group before the second tension detection mechanism is used to adjust the fiber conveying speed according to the detection information of the second tension sensor 10-5 to regulate the fiber tension.

[0071] Reference Figure 18 , the third tension detection mechanism 13 is used for tension detection of the pre-dipped fiber material; the third tension detection mechanism 13 includes a third mounting plate 13-1 and a third guide roller, a third tension spring guide roller 13-2 and a third tension sensor 13-3 connected to the third mounting plate, and the fiber material alternately passes above and below the third guide roller, the third tension spring guide roller 13-2 and the third tension sensor 13-3. The tension spring alleviates the tension fluctuation, and the tension sensor detects the tension value. The winding device 14 and / or the traction device 11 are used to adjust the fiber winding conveying speed according to the detection information of the third tension sensor 13-3 to regulate the fiber tension. Alternatively, the winding device 14 is used to adjust the fiber winding conveying speed according to the detection information of the third tension sensor 13-3 to regulate the fiber tension.

[0072] The third mounting plate 13-1 of the third tension detection mechanism 13 is further provided with a meter 13-4 for measuring the length of the pre-dipped fiber material. The whole production line is divided into four tension areas, and the traction device is used as the main traction speed to regulate the speed at different positions to maintain the stability of the tension.

[0073] The method for implementing the scheme: four sections of tension are controlled by five groups of motors. The first section is the tension between the unwinding motor and the unwinding motor, which is identified by a tension sensor and the speed of the unwinding motor is adjusted. The second section is the tension between the unwinding motor and the unwinding motor, and the tension fluctuation is adjusted by the speed of the unwinding motor. The third section of tension is the tension between the unwinding motor and the traction motor, and the tension fluctuation is adjusted by the speed of the unwinding motor. The fourth section of tension is the tension between the traction motor and the winding motor, and the speed of the winding motor is adjusted to maintain constant tension. The whole production line takes the traction motor as the speed reference, and adjusts the motors of different mechanisms to maintain constant tension in different sections.

[0074] The control effect: by taking the motor of the traction device as the speed reference, the gradient tension control is performed on the unwinding device, so that the fiber maintains constant tension in different processes. At the same time, for the speed error caused by the motor response, the tension compensation is performed through the device of the floating tension spring to maintain constant tension.

[0075] In other embodiments, a continuous fiber prepreg manufacturing method is also provided, which can be implemented based on any one of the above-mentioned continuous fiber prepreg manufacturing systems; the manufacturing method comprises: The fiber filament is first impregnated with a resin solution, and then impregnated with a molten resin to realize secondary impregnation manufacturing; wherein the temperature of the resin solution impregnation is set to 220-240°C, and the resin solution is a PA6 resin powder ethanol solution; the temperature of the molten resin in the molten resin impregnation is set to 230-260°C.

[0076] In some specific embodiments, a plurality of fiber filaments are used to manufacture functional prepreg; the plurality of fiber filaments include continuous carbon fiber filaments and continuous carbon nanotube fibers, and the functional prepreg is manufactured by wrapping the carbon nanotube fibers with the carbon fiber filaments. The carbon fiber provides high strength to the filament, and the carbon nanotube fiber enhances the electrical conductivity and thermal conductivity of the filament. Experimental verification shows that the functional prepreg manufactured by the continuous carbon fiber filaments and the continuous carbon nanotube fibers can obtain better performance in terms of tensile properties, thermal conductivity of printed samples, and electrical conductivity of printed samples.

[0077] Further, the manufacturing method further comprises: arranging a plurality of fiber conveying mechanisms and a plurality of tension detection mechanisms along the production line, the plurality of fiber conveying mechanisms and the plurality of tension detection mechanisms are arranged in cross, the fiber conveying mechanism is used to provide fiber conveying power, and the tension detection mechanism comprises a tension sensor; the fiber conveying mechanism is used to adjust the fiber conveying speed according to the detection information of the tension sensor to regulate the fiber tension. Optionally, the fiber conveying mechanism is used to adjust the fiber conveying speed according to the detection information of the adjacent tension detection mechanism to regulate the fiber tension at the fiber conveying mechanism.

[0078] In some embodiments, a preparation method using the continuous fiber functional prepreg yarn manufacturing device described above includes the following steps: The 1K continuous carbon fiber filament is fixed on the air expansion shaft 1-1, and the continuous carbon nanotube fiber is fixed on the air expansion shaft 1-2; The continuous carbon fiber filament and the continuous carbon nanotube fiber are sequentially threaded through the deviation correction mechanism 2, the first tension detection mechanism 3, the glue removal device 4, the yarn spreading device 5, the solution impregnation device 6, the drying and preheating device 7, the melting impregnation device 8, the core-shell device 9, the cooling device 10, the traction device 11, the wire diameter detection device 12, the third tension detection mechanism 13, and the winding device 14; PA6 resin particles are added to the impregnation screw extruder 8-5 and the impregnation screw extruder 8-6, and the three-section temperatures of the screw extruders are set to 230°C, 245°C, and 260°C, respectively; PPS resin particles are added to the core-shell screw extruder 9-6, and the three-section temperatures of the screw extruder are set to 280°C, 300°C, and 320°C, respectively; the environmental temperature of the glue removal device 4 is set to 400°C, and the temperature of the drying and preheating device 7 is set to 220-240°C; PA6 resin powder is dissolved in anhydrous ethanol and added to the solution impregnation device 6; The unwinding servo motor 1-3 and the unwinding servo motor 1-4 of the unwinding mechanism 1, the servo motor of the yarn spreading device 5, the servo motor of the melting impregnation device 8, the servo motor of the core-shell device 9, the servo motor of the traction device 11, and the servo motor of the winding device 14 are started; The deviation correction mechanism 2 recognizes fiber deflection, the grating sensor feeds back the position coordinates of the fiber to the lead screw guide rail module, the fiber filament is always in the axial position, the first tension sensor detects the tension value and feeds it back to the unwinding servo motor to control the unwinding speed, the tension balance is adjusted through the speed difference, the fiber filament enters the glue removal device 4 to remove the surface sizing agent, is fully spread in the yarn spreading device 5, is wrapped with resin solution in the solution impregnation device 6, is dried and pre-impregnated in the melting impregnation die 8, the resin particles are melted and impregnated by the screw extruder, a prepreg yarn with a diameter of 0.4 mm is formed at the outlet 8-19 of the impregnation die, is wrapped with a PPS resin shell in the core-shell device 9 to form a functional waterproof shell, avoids water absorption of nylon to reduce the mechanical properties of the material, is quickly cooled and formed in the cooling device 10, is frictionally pulled by the traction device 11, the prepreg yarn diameter is measured by the wire diameter detection device 12, the third tension detection mechanism 13 relieves tension fluctuations and measures the length of the prepreg yarn that passes through, and finally the required continuous fiber functional prepreg yarn is obtained through the winding device 14; as shown in Figure 20 .

[0079] Those skilled in the art can easily understand that the above description is only the preferred embodiment of the present application, and is not intended to limit the present application. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A continuous fiber prepreg filament manufacturing system, characterized in that, It includes a solution impregnation device and a melt impregnation device; the solution impregnation device includes a solution impregnation tank, the interior of which contains a resin solution and the bottom is provided with impregnation guide rollers; The melt impregnation device includes a melt impregnation tank, a melt resin supply structure, an impregnation roller, and a guide roller. The impregnation roller and the guide roller are respectively disposed inside the melt impregnation tank. The melt resin supply structure is connected to the impregnation roller and is used to supply melt resin into the impregnation roller. The impregnation roller is provided with an overflow channel for melt resin. The fiber filaments are first impregnated with the solution inside the solution impregnation tank, passing around the impregnation guide rollers, and then fed into the melt impregnation tank, passing around the guide rollers and the impregnation rollers, and melt impregnated at the impregnation rollers for secondary impregnation manufacturing.

2. The continuous fiber prepreg filament manufacturing system as described in claim 1, characterized in that, The solution impregnation tank has openings on both sides and guide rollers at the openings for conveying fiber filaments; the interior of the solution impregnation tank is also equipped with an ultrasonic vibrator; the solution impregnation tank is also connected to a liquid level detector, and the surface is also equipped with a liquid inlet for replenishing the solution and a valve for discharging waste liquid.

3. The continuous fiber prepreg filament manufacturing system as described in claim 1, characterized in that, The guide roller is rotatably connected to the melt impregnation tank and has a heating rod inside for independent heating; wherein the guide roller near the outlet of the melt impregnation tank is fitted with a pressure roller; The molten resin supply structure includes a screw extruder and a photoelectric sensor hopper. The outlet of the screw extruder is connected to the interior of the impregnation roller. The photoelectric sensor hopper is connected to the screw extruder, and a heating ring is fitted on the screw extruder to heat the resin to a molten state.

4. The continuous fiber prepreg filament manufacturing system as described in claim 1, characterized in that, The solution impregnation device is preceded by a fiber spreading device; the fiber spreading device includes a fiber spreading mounting plate and, on the fiber spreading mounting plate, a positioning groove of equal width, a first convex pin, a height and width positioning groove, a second convex pin, and two active fiber spreading bearings arranged sequentially at the front and rear; high-speed cameras are respectively provided at both ends of the fiber spreading mounting plate to detect the surface quality of the fiber before spreading and the surface quality after spreading, and an ion wind bar is also provided after the active fiber spreading bearings and between the high-speed cameras to eliminate the static electricity accumulation caused by mechanical friction.

5. The continuous fiber prepreg filament manufacturing system as described in claim 4, characterized in that, Before the solution impregnation device, there are also an unwinding mechanism, a correction mechanism and a glue removal device arranged in sequence. A drying and preheating device is also provided between the solution impregnation device and the melt impregnation device. The unwinding mechanism includes a linear motion structure, an unwinding servo motor, and an air shaft; the air shaft is connected to the unwinding servo motor and is used to wind fiber filaments and achieve unwinding through controllable rotation; the unwinding servo motor is connected to the linear motion structure arranged along the axial direction of the air shaft. The correction mechanism includes a correction bracket, at least one channel on the correction bracket, and a set of grating sensors on the upper and lower sides of the channel; the linear movement structure is used to move according to the detection results of the grating sensors to achieve correction. The adhesive removal device includes an adhesive removal chamber and a heating tube disposed inside the adhesive removal chamber for heating and removing adhesive from the passing fiber filaments; the drying and preheating device includes a drying chamber and a heating tube disposed inside the drying chamber for drying and preheating the passing fiber filaments.

6. The continuous fiber prepreg filament manufacturing system as described in claim 5, characterized in that, It also includes an unwinding bracket provided at the unwinding mechanism; there are multiple unwinding mechanisms, and the multiple unwinding mechanisms and the unwinding brackets are used to realize the combined unwinding and manufacturing of various fiber filaments; The top of the degumming box is provided with degumming guide rollers; a row of winding guide rollers is also provided above the filament spreading mounting plate along the process travel direction; the degumming guide rollers and the winding guide rollers are used to transport the fiber filaments of a single filament. The interior of the solution impregnation tank is equipped with multiple sets of impregnation guide rollers for conveying various fiber filaments.

7. The continuous fiber prepreg filament manufacturing system as described in claim 5, characterized in that, The melt impregnation device is followed by a core-shell device, a cooling device, a traction device, a wire diameter detection device, and a winding device in sequence; The core-shell device includes a core-shell box, a heating rod disposed inside the core-shell box, and a molten resin supply structure connected to the core-shell box; the core-shell box is provided with an inlet and an outlet, wherein a core-shell outlet mold is provided at the outlet. The cooling device includes a cooling mounting plate and an annular air knife disposed on the cooling mounting plate; the core shell device is fixed on the cooling mounting plate, and an annular air knife is also disposed in front of the core shell device; The traction device is used to provide the power for conveying the fiber filaments; the wire diameter detection device is used to detect the size of the fiber filaments; and the winding device is used to wind up the manufactured fiber filaments.

8. The continuous fiber prepreg filament manufacturing system as described in claim 7, characterized in that, It also includes a first tension detection mechanism disposed between the correction mechanism and the adhesive removal device, a cantilever tension sensor disposed between two active yarn spreading bearings on the yarn spreading mounting plate, a second tension detection mechanism disposed at the end of the cooling mounting plate, and a third tension detection mechanism disposed between the yarn diameter detection device and the winding device. The spreading mounting plate is also equipped with servo motor driven pressure roller groups on both the front and rear sides of the cantilever tension sensor to guide and pull them. Each tension detection mechanism and tension sensor is used in conjunction with each conveying power source to achieve constant tension during the fiber filament manufacturing process.

9. A method for manufacturing continuous fiber prepreg filaments, characterized in that, include: The fiber filaments are first impregnated with a resin solution, and then impregnated with molten resin to achieve a two-stage impregnation process. The resin solution impregnation temperature is set to 220℃-240℃, and the resin solution is an anhydrous ethanol solution of PA6 resin powder. The molten resin impregnation temperature is set to 230℃-260℃.

10. The method for manufacturing continuous fiber prepreg filament as described in claim 9, characterized in that, Functional prepreg filaments are manufactured using a variety of fiber filaments, including continuous carbon fiber precursors and continuous carbon nanotube fibers, to form functional prepreg filaments in which the precursor fibers encapsulate the carbon nanotube fibers.

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