Continuous fiber reinforced composite structure and preparation method thereof

Abstract

The invention relates to the technical field of additive manufacturing, in particular to a continuous fiber reinforced composite structure and a preparation method thereof. The preparation method comprises the following steps that continuous fiber reinforced thermoplastic resin composite wires are adopted to be printed into a preformed composite component according to a preset model, and the component is of a hollow structure; and filling the hollow part of the preformed composite material component with thermosetting resin, and carrying out thermocuring to form the continuous fiber reinforced double-resin-based composite structure. The hollow structure is filled with the thermosetting resin to form the continuous fiber double-resin-based reinforced composite material, on one hand, the hollow structure can be filled with the thermosetting resin, the double-resin-based composite structure is formed through combination of the thermoplastic resin and the thermosetting resin, and the mechanical property of the composite material is improved; and on the other hand, pores in a preformed composite material component formed by the composite wires can be filled, and the mechanical performance of the composite material structure is further enhanced.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, specifically to a continuous fiber-reinforced composite structure and its preparation method. Background Technology

[0002] Additive manufacturing, also known as 3D printing, is a manufacturing process that builds objects by adding materials layer by layer. Compared to traditional subtractive manufacturing (such as cutting and drilling), additive manufacturing can utilize materials more efficiently and produce parts with complex shapes and structures that are difficult to achieve using traditional manufacturing methods. The core idea of ​​additive manufacturing is to decompose a three-dimensional model into multiple thin layers, and then stack materials layer by layer through specific processes to form a complete solid object. Each layer can be precisely controlled according to the digital model to ensure that the size and shape of the final product meet the design requirements. Compared to the molding process of traditional fiber-reinforced resin composite materials, additive manufacturing has a simpler process, lower processing costs, and higher material utilization. It can also achieve the integrated molding of complex structural parts, providing an effective way to rapidly manufacture lightweight composite material structures. Currently, to improve the mechanical properties of additive manufacturing, fiber materials are mostly used as raw materials. However, the uneven distribution and porosity of fiber materials in additive products result in poor mechanical properties that cannot meet application requirements. Summary of the Invention

[0003] Therefore, the technical problem to be solved by the present invention is to overcome the defect of poor mechanical properties of fiber additive manufacturing in the prior art, thereby providing a continuous fiber reinforced composite structure and its preparation method.

[0004] To achieve the above objectives, the present invention provides the following technical solution: According to some embodiments of the present invention, the first invention provides a method for preparing a continuous fiber-reinforced composite structure, comprising the following steps: A preformed composite material component is printed using continuous fiber-reinforced thermoplastic resin composite filaments according to a preset model. The component has a through-hole structure. Thermosetting resin is filled into the central part of the preformed composite component and thermosetting is performed to form a continuous fiber-reinforced dual resin-based composite structure.

[0005] In some embodiments of the present invention, the temperature for thermosetting is 80-180°C.

[0006] In some embodiments of the present invention, the thermosetting resin is at least one of polyamide, polyimide, and polyurethane.

[0007] In some embodiments of the present invention, the continuous fiber reinforced thermoplastic resin composite filament includes continuous fiber and thermoplastic resin, and the mass ratio of continuous fiber in the continuous fiber reinforced thermoplastic resin composite filament is 15-30%.

[0008] In some embodiments of the present invention, the continuous fiber includes at least one of carbon fiber, aramid fiber, and glass fiber.

[0009] In some embodiments of the present invention, the thermoplastic resin is at least one of polyamide, polyimide, and polyurethane.

[0010] In some embodiments of the present invention, the thermosetting resin is injected into the central structure of the preformed composite material component.

[0011] In some embodiments of the present invention, the structure of the preformed composite component includes at least one of a flat plate, a three-dimensional rotary structure, or a honeycomb panel.

[0012] According to some embodiments of the present invention, in a second aspect, the present invention provides a continuous fiber reinforced composite structure, which is prepared by any of the above-described methods for preparing continuous fiber reinforced composite structures.

[0013] The technical solution of this invention has the following advantages: This invention provides a method for preparing a continuous fiber reinforced composite structure, comprising the following steps: printing a pre-formed composite material component using continuous fiber reinforced thermoplastic resin composite filaments according to a preset model, wherein the pre-formed composite material component has a through-hole structure; filling the through-hole with thermosetting resin, and thermosetting to form a continuous fiber reinforced dual resin matrix composite material. This invention uses continuous fiber reinforced thermoplastic resin composite filaments to form a pre-formed composite material with a fillable through-hole structure through printing. The composite filaments are highly flexible and can be designed according to actual needs, exhibiting better adaptability in three dimensions. The continuous fiber reinforced dual resin matrix composite material is formed by filling the through-hole with thermosetting resin. The thermosetting resin is liquid at room temperature and has good fluidity. During the filling process, the thermosetting resin can fill the through-hole structure, forming a dual resin matrix composite structure through the combination of thermoplastic and thermosetting resins, thus improving the mechanical properties of the composite material. Furthermore, it can fill the pores in the pre-formed composite material component formed by the composite filaments, further enhancing the mechanical properties of the composite material structure. Attached Figure Description

[0014] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the preformed composite material structure in Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the continuous fiber reinforced composite material structure in Embodiment 1 of the present invention; Figure 3 This is a schematic diagram of the preformed composite material structure in Embodiment 2 of the present invention; Figure 4 This is a schematic diagram of the continuous fiber reinforced composite material structure in Embodiment 2 of the present invention; Figure 5 This is a schematic diagram of the preformed composite material structure in Embodiment 3 of the present invention; Figure 6 This is a side view of the preformed composite material structure in Embodiment 3 of the present invention.

[0016] Figure label: 1-Through-through structure; 2-Flat plate structure; 3-Thermosetting resin filling position; 4-Rotating structure. Detailed Implementation

[0017] The following embodiments are provided to better understand the present invention and are not limited to the preferred embodiments described. They do not constitute a limitation on the content and scope of protection of the present invention. Any product that is the same as or similar to the present invention, derived by any person under the guidance of the present invention or by combining the features of the present invention with other prior art, falls within the protection scope of the present invention.

[0018] For experiments not specifically described in the examples, the procedures or conditions should be followed according to the conventional experimental procedures described in the literature in this field. Reagents or instruments whose manufacturers are not specified are all commercially available conventional reagent products.

[0019] Example 1 This embodiment provides a method for preparing a continuous fiber-reinforced composite structure, and the specific steps and parameters are as follows: (1) Thermoplastic polyamide resin particles are melted in a heated mold, impregnated with carbon fibers, and cured at room temperature to obtain a continuous fiber-reinforced thermoplastic composite filament. The continuous fiber-reinforced thermoplastic composite filament is printed according to a preset model using a 3D printer to prepare a preformed composite material. In this embodiment, the preformed composite material is a flat plate structure 2 with several through-hole structures 1. See details. Figure 1 .

[0020] (2) Place the preformed composite material in the mold, inject the thermosetting polyamide resin into the cavity mold, and ensure that the thermosetting resin completely fills the cavity. In this embodiment, the specific thermosetting resin filling position 3 is the periphery of each through structure and the plate, and heat and cure at 150°C.

[0021] (3) Cool the mold, and after solidification, remove the part to obtain a continuous fiber-reinforced dual resin matrix composite material. See details. Figure 2 .

[0022] Example 2 This embodiment provides a method for preparing a continuous fiber-reinforced composite structure, and the specific steps and parameters are as follows: (1) Thermoplastic polyimide resin particles are melted in a heated mold, impregnated with aramid fibers, and cured at room temperature to obtain a continuous fiber-reinforced thermoplastic composite filament. The continuous fiber-reinforced thermoplastic composite filament is printed according to a preset model using a 3D printer to prepare a preformed composite material. In this embodiment, the preformed composite material is a rotating structure 4 with several through-hole structures 1. See details. Figure 3 .

[0023] (2) Place the preformed composite material in the mold, inject the thermosetting polyimide resin into the cavity mold, and ensure that the thermosetting resin completely fills the cavity. In this embodiment, the specific thermosetting resin filling position 3 is each groove of the rotary structure, and heat and cure at 80°C.

[0024] (3) Cool the mold, and after solidification, remove the part to obtain a continuous fiber-reinforced composite structure. See details below. Figure 4 .

[0025] Example 3 This embodiment provides a method for preparing a continuous fiber-reinforced composite structure, and the specific steps and parameters are as follows: (1) Thermoplastic polyurethane resin particles are melted in a heated mold, impregnated with glass fiber, and cured at room temperature to obtain continuous fiber reinforced thermoplastic composite filament. The continuous fiber reinforced thermoplastic composite filament is printed according to a preset model using a 3D printer to prepare a preformed composite material. In this embodiment, the preformed composite material is a honeycomb panel with several through-hole structures on the surface. See the front view for details. Figure 5 See side view Figure 6 .

[0026] (2) Place the preformed composite material in the mold, inject the thermosetting polyimide resin into the cavity mold, and ensure that the thermosetting resin completely fills the cavity. In this embodiment, the specific filling position is each central structure of the honeycomb panel, and then heat and cure at 180°C.

[0027] (3) Cool the mold, and after solidification, remove the part to obtain a continuous fiber reinforced composite structure.

[0028] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A method for preparing a continuous fiber-reinforced composite structure, characterized in that, Includes the following steps: A pre-formed composite material component is printed using continuous fiber-reinforced thermoplastic resin composite filaments according to a preset model. The component has a through-hole structure. Thermosetting resin is filled into the central part of the preformed composite component and thermosetting is performed to form a continuous fiber-reinforced dual resin-based composite structure.

2. The method for preparing the continuous fiber reinforced composite structure according to claim 1, characterized in that, The thermosetting temperature is 80-180℃.

3. The method for preparing the continuous fiber reinforced composite structure according to claim 1, characterized in that, The thermosetting resin is at least one of polyamide, polyimide, and polyurethane.

4. The method for preparing the continuous fiber reinforced composite structure according to claim 1, characterized in that, The continuous fiber reinforced thermoplastic resin composite filament includes continuous fiber and thermoplastic resin, and the mass ratio of continuous fiber in the continuous fiber reinforced thermoplastic resin composite filament is 15-30%.

5. The method for preparing a continuous fiber reinforced composite structure according to claim 4, wherein the continuous fiber comprises at least one of carbon fiber, aramid fiber, and glass fiber.

6. The method for preparing the continuous fiber reinforced composite structure according to claim 4, characterized in that, The thermoplastic resin is at least one of polyamide, polyimide, and polyurethane.

7. The method for preparing the continuous fiber reinforced composite structure according to claim 1, characterized in that, The thermosetting resin is injected into the central structure of the preformed composite component.

8. The method for preparing the continuous fiber reinforced composite structure according to claim 1, characterized in that, The structure of the preformed composite material component includes at least one of a flat plate, a three-dimensional rotary structure, or a honeycomb panel.

9. A continuous fiber-reinforced composite structure, characterized in that, It is prepared by the preparation method according to any one of claims 1-8.

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