Production equipment for processing polyether-ether-ketone

Abstract

The invention relates to the technical field of high-performance thermoplastic composite material manufacturing, in particular to production equipment for polyether-ether-ketone processing. The device comprises a precise fiber broadening conveying unit, a preheating unit, a dynamic rheological dipping coupling unit and a crystallization shaping unit; the system applies vibration or ultrasonic waves through a high-frequency vibration energy generating device, and the thixotropic effect is induced on the resin and fiber interface; the method is characterized in that the viscosity of the resin is instantaneously reduced by utilizing the shear thinning characteristic, so that the resin permeates into fiber gaps under low macroscopic pressure; according to the invention, the contradiction between high-pressure fiber damage and low-pressure infiltrating difficulty is solved, and low-pressure, lossless and deep impregnation of compact carbon fibers by high-viscosity resin is realized.

Description

Technical Field

[0001] This invention relates to the field of high-performance thermoplastic composite material manufacturing technology, specifically to a production equipment for processing polyetheretherketone (PEEK). Background Technology

[0002] With the continuous expansion of the application fields of high-performance thermoplastic composites, ultrathin prepregs combining polyetheretherketone (PEEK) and carbon fiber have attracted much attention due to their excellent mechanical properties. However, the PEEK melt itself has extremely high viscosity, which poses a significant technical challenge to the microscopic wetting of dense carbon fiber bundles by the resin. Currently, traditional processing techniques mostly rely on physical hot pressing, which forces high-viscosity resin to penetrate into the gaps between fiber monofilaments by applying high macroscopic mechanical pressure. However, this method presents an irreconcilable physical paradox: achieving good wetting results often requires extremely high pressure, which can easily lead to breakage and damage of brittle carbon fibers; if the pressure is reduced to protect the fibers, it is difficult to overcome the resin's huge flow resistance, resulting in incomplete wetting and internal defects due to dry spots. In addition, existing equipment usually lacks the ability to dynamically sense and control the rheological state, making it difficult to adapt to fluctuations in production line speed or differences in raw material batches, and easily causing resin thermal degradation or uneven product quality due to improper energy input. Therefore, how to overcome the flow limitations of high-viscosity resins to achieve rapid and uniform impregnation while maintaining low fiber damage and ensuring quality stability during continuous production has become an urgent problem to be solved in this field. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides a production equipment for processing polyetheretherketone (PEEK). Specifically, the technical solution of the present invention includes: The system comprises a precision fiber spreading and conveying unit, a preheating zone, a dynamic rheological impregnation coupling zone, and a crystallization and shaping zone, which are sequentially arranged along the conveying direction of the precision fiber spreading and conveying unit. The dynamic rheological impregnation coupling zone includes a melt flow channel mold and a high-frequency vibration energy generator arranged opposite each other. The precision fiber spreading and conveying unit is used to convey the carbon fiber spreading band at a constant tension. The high-frequency vibration energy generator is configured to apply a mechanical vibration wave or ultrasonic wave of a specific frequency to the molten polyetheretherketone resin. The dynamic rheological impregnation coupling zone is used to induce a thixotropic effect at the contact interface between the polyetheretherketone resin and the carbon fiber spreading band using the mechanical vibration wave or ultrasonic wave, so as to instantaneously reduce the apparent viscosity of the polyetheretherketone resin and allow it to penetrate into the gaps between the monofilaments of the carbon fiber spreading band while keeping the macroscopic mechanical pressure on the carbon fiber spreading band below a preset damage threshold.

[0004] Preferably, the device further includes a rheological state control module, which is electrically connected to the high-frequency vibration energy generator. The rheological state control module is used to calculate the vibration frequency and amplitude parameters required for the polyether ether ketone resin to undergo shear thinning based on a preset rheological model and the current production line speed, and to generate drive control commands based on the calculated vibration frequency and amplitude parameters. The high-frequency vibration energy generator is used to adjust the energy density of the output mechanical vibration wave or ultrasonic wave in response to the drive control commands.

[0005] Preferably, it further includes a melt impedance monitoring module, which is disposed within the melt flow channel mold and electrically connected to the rheological state control module; the melt impedance monitoring module is used to collect the acoustic impedance feedback signal or mechanical damping feedback signal of the polyetheretherketone resin to the vibration wave in real time, and transmit the collected feedback signal to the rheological state control module; the rheological state control module is used to analyze the actual viscosity state of the current polyetheretherketone resin according to the feedback signal, and when the actual viscosity state is higher than a preset penetration threshold, correct the drive control command to increase the vibration energy density.

[0006] Preferably, the system further includes a wetting defect detection module, which is disposed between the dynamic rheological impregnation coupling zone and the crystallization shaping zone and is electrically connected to the rheological state control module. The wetting defect detection module is used to collect surface microscopic image data or transmitted light spot data of the carbon fiber spread width after impregnation treatment. The rheological state control module is used to identify whether there are dry spot areas in the carbon fiber spread width based on the surface microscopic image data or transmitted light spot data, and when a dry spot area is identified, it generates a compensation command to increase the output power of the high-frequency vibration energy generator.

[0007] Preferably, the high-frequency vibration energy generating device includes an ultrasonic transducer array, which is directly coupled to the mold wall of the melt flow channel mold or directly contacts the polyetheretherketone resin; the ultrasonic transducer array is used to generate an ultrasonic vibration field with a frequency between 20kHz and 100kHz, and the direction of action of the ultrasonic vibration field is perpendicular to the conveying direction of the carbon fiber spreading width or forms a preset angle with the conveying direction.

[0008] Preferably, the melt flow channel mold is internally defined by a wedge-shaped converging flow channel, the cross-sectional area of ​​which gradually decreases along the conveying direction; the wedge-shaped converging flow channel is used to establish a basic melt pressure, and the vibration energy field generated by the high-frequency vibration energy generator is superimposed on the basic melt pressure to form a pulsating shear stress field.

[0009] Preferably, the preheating zone includes an infrared radiation heating unit or a hot air convection heating unit; the preheating zone is used to heat the carbon fiber spread band to a preset temperature range close to the melting point of polyether ether ketone resin, so as to reduce the interfacial thermal resistance when the resin contacts the fiber.

[0010] Preferably, the crystallization and shaping zone includes a multi-stage gradient cooling unit; the multi-stage gradient cooling unit is used to cool the impregnated composite according to a preset cooling rate curve, so as to control the crystallinity of polyether ether ketone resin and lock the fiber microstructure.

[0011] Compared with the prior art, the present invention has the following beneficial effects: 1. This system induces a thixotropic effect at the resin-fiber interface using a high-frequency vibration energy generator. Utilizing the shear-thinning properties of ultrasonic or mechanical vibration, it instantaneously reduces the apparent viscosity of high-viscosity polyether ether ketone melt at the microscale. This mechanism allows the resin to rapidly penetrate the dense gaps between carbon fiber monofilaments like a low-viscosity liquid, eliminating the need for the high macroscopic mechanical pressure required in traditional processes. This not only solves the problem of brittle carbon fiber fracture caused by excessive pressure but also overcomes the defects of incomplete wetting and dry spots caused by high resin flow resistance under low pressure, significantly improving the mechanical properties and structural integrity of ultrathin prepregs. 2. By introducing a rheological state control module, this system can calculate and precisely control the minimum vibration frequency and amplitude combination required for the resin to undergo shear thinning in real time based on the current production line speed and the preset rheological model. This feedforward adaptive control strategy ensures that the resin is always in the optimal low viscosity flow window, regardless of fluctuations in production speed. It effectively prevents poor wetting caused by insufficient vibration energy, avoids energy waste and resin thermal degradation risks caused by blindly increasing power, and ensures product uniformity in continuous production. 3. This system combines a melt impedance monitoring module and a wetting defect detection module, giving the equipment dual tactile and visual sensing capabilities. By monitoring the acoustic impedance or mechanical damping feedback of the melt in real time, the system can automatically sense and compensate for minute fluctuations in the molecular weight of the resin between batches. At the same time, by identifying minute dry spots through online visual inspection at the end, it can instantly generate power compensation commands. This dual closed-loop logic from process monitoring to final quality control enables the equipment to respond quickly and correct deviations, reducing the scrap rate to an extremely low level and achieving zero-defect delivery. 4. In terms of structural design, this system employs a wedge-shaped converging flow channel to establish the basic melt pressure and superimposes a high-frequency vibration energy field to form a pulsating shear stress field. Utilizing a mechanism similar to the ratchet effect, it unidirectionally drives the resin to penetrate efficiently, thereby increasing the impregnation depth. In terms of thermal management, the system combines the elimination of interfacial temperature difference thermal resistance in the preheating zone with a multi-level gradient cooling strategy in the crystallization and shaping zone to precisely control the crystallinity of polyetheretherketone and lock in the fiber microstructure. This systematic process optimization eliminates residual stress caused by uneven thermal shrinkage, ensuring that the ultra-thin prepreg product has excellent flatness and stable dimensional accuracy. Attached Figure Description

[0012] The present invention will be further explained below with reference to the accompanying drawings and embodiments: Figure 1 This is a structural diagram of the system of the present invention. Detailed Implementation

[0013] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0014] Example 1: Please see Figure 1 A production device for processing polyetheretherketone (PEEK) includes a precision fiber spreading and conveying unit, a preheating zone, a dynamic rheological impregnation coupling zone, and a crystallization and shaping zone. The preheating zone, the dynamic rheological impregnation coupling zone, and the crystallization and shaping zone are arranged sequentially along the conveying direction of the precision fiber spreading and conveying unit. The dynamic rheological impregnation coupling zone includes a melt flow channel mold and a high-frequency vibration energy generator arranged opposite to each other. The precision fiber spreading and conveying unit is used to convey the carbon fiber spreading band at a constant tension. The high-frequency vibration energy generator is configured to apply a mechanical vibration wave or ultrasonic wave of a specific frequency to the molten PEEK resin. The dynamic rheological impregnation coupling zone is used to induce a thixotropic effect at the contact interface between the PEEK resin and the carbon fiber spreading band using the mechanical vibration wave or ultrasonic wave, so as to instantaneously reduce the apparent viscosity of the PEEK resin and allow it to penetrate into the gaps between the monofilaments of the carbon fiber spreading band while keeping the macroscopic mechanical pressure on the carbon fiber spreading band below a preset damage threshold.

[0015] This embodiment provides a production equipment for processing polyetheretherketone (PEEK). Its core design concept is to break the physical paradox of high pressure causing fiber damage and low pressure causing poor impregnation in traditional hot-pressing processes. Rheological modification is achieved by introducing a dynamic energy field. A precision fiber spreading and conveying unit is configured to convey extremely thin carbon fiber spreading bands with constant tension. This unit uses a high-precision servo tension control system to ensure that the fiber band does not slack or break due to excessive tightness during transmission, providing a stable geometric base for subsequent micro-impregnation. The carbon fiber spreading band enters the dynamic rheological impregnation coupling zone, where mechanical vibration waves or ultrasound are used to contact the polyetheretherketone resin with the carbon fiber spreading band. Interface-induced thixotropic effect; in this process, the energy field generated by the high-frequency vibration energy generator applies high-frequency shear force to the resin molecules at the microscale, temporarily unwinding or relaxing the molecular chain entanglement network of the polymer melt, causing the fluid to exhibit non-Newtonian fluid characteristics with a sharp decrease in apparent viscosity as the shear rate increases; to instantaneously reduce the apparent viscosity of polyetheretherketone resin while keeping the macroscopic mechanical pressure on the carbon fiber bundle below a preset damage threshold, allowing the originally high-viscosity polyetheretherketone melt to rapidly penetrate into the dense monofilament gaps of the carbon fiber bundle like a low-viscosity liquid; wherein, the preset damage threshold is set to the tensile breaking strength of the carbon fiber bundle. - This value was obtained through offline monofilament tensile testing.

[0016] Example 2: It also includes a rheological state control module, which is electrically connected to a high-frequency vibration energy generator. The rheological state control module is used to calculate the vibration frequency and amplitude parameters required for the polyether ether ketone resin to undergo shear thinning based on a preset rheological model and the current production line speed, and to generate drive control commands based on the calculated vibration frequency and amplitude parameters. The high-frequency vibration energy generator is used to adjust the energy density of the output mechanical vibration wave or ultrasonic wave in response to the drive control commands.

[0017] This embodiment further introduces a rheological state control module, aiming to establish a quantitative mapping relationship between production speed and vibration energy to achieve intelligent closed-loop control of the impregnation process. Based on a preset rheological model and the current production line speed, the rheological state control module calculates the vibration frequency and amplitude parameters required for the polyetheretherketone resin to undergo shear thinning. This embodiment constructs the following modified dynamic rheological control model, which includes rheological prediction equations and permeation constraint inequalities: Define the current equivalent shear rate of the system. Compared with predicted apparent viscosity : Define the critical viscosity threshold that guarantees the resin will complete its penetration at the current linear velocity. : The control objective of the rheological state control module is: to regulate Make Established; in, The system calculates the predicted resin viscosity based on the current vibration parameters, in units of... ; Microscopic equivalent shear rate induced by high-frequency vibration, in units of ; The source is the preset value of the physical property parameters of the raw material, and the physical meaning is the zero shear viscosity of polyetheretherketone resin, with the unit being Pa·s; The source is material rheological test data, and its physical meaning is the relaxation time constant of the resin, with the unit being seconds. The source is the output frequency of the high-frequency vibration energy generator; its physical meaning is the vibration frequency parameter, and its unit is Hz. The source is the displacement amplitude of the vibration wave; its physical meaning is the amplitude parameter, and its unit is meters (m). The source is fiber geometric parameters, and its physical meaning is the characteristic gap scale between carbon fiber monofilaments. It is used to convert vibration velocity into equivalent shear rate and as a scale for penetration depth, with the unit being meters. The source is a material property library, and its physical meaning is the power law exponent in the Carreau-Yasuda model, which represents the sensitivity to shear thinning. The unit is dimensionless. The source is the fiber arrangement structure parameter, and its physical meaning is the dimensionless permeability shape factor, which typically ranges from... to The specific method for selecting this value is as follows: by performing cross-sectional microscopic analysis on the carbon fiber spread width, determine whether its actual micro-arrangement is hexagonal or tetragonal, and then look up the corresponding shape factor in the table. The unit is dimensionless. The source is based on theoretical calculations using the Yang-Laplace equation, and the calculation formula is as follows: in, The surface tension of the resin is expressed in units of 1000 ppm. ; This is the dynamic contact angle between the resin and the fiber; this model is applicable to... The wetting system, at this time When the value is positive, capillary pressure assists osmosis; The physical meaning is the capillary pressure that drives the natural permeation of resin, and the unit is Pa; The source is real-time feedback from the precision fiber spreading and conveying unit, and its physical meaning is the current production line speed, in m / s; The system further defines the control cost optimization function. This function does not directly calculate physical power consumption, but rather serves as a mathematical optimization metric for finding the minimum combination of parameters. and Here are the dimensionless normalized weighted coefficients, where The unit is , The unit is Used to eliminate and The difference in magnitude between them ensures that the optimization function is dimensionless, and its specific value is determined based on the transducer's electro-acoustic conversion efficiency and impedance characteristics. and ,in, The highest resonant frequency of the system design, in units of: , The maximum allowable displacement amplitude of the transducer, in units of: , and The preset dimensionless weighting factor is used to eliminate the order-of-magnitude difference between the frequency and amplitude terms and achieve normalization. The rheological state control module adopts a sequential quadratic programming (SQP) constrained optimization algorithm to find the objective function while satisfying the aforementioned viscosity inequality constraints. Minimize the optimal solution This calculation aims to find the minimum combination of vibrational energy required to ensure complete resin penetration at the current production rate, avoiding excessive energy that could lead to resin degradation. The system generates a set of... The high-frequency vibration energy generator responds to the drive control command by dynamically adjusting the energy density of the output mechanical vibration wave or ultrasonic wave. This embodiment ensures that the rheological state of polyetheretherketone resin in the contact area is always in the optimal low viscosity window, regardless of the fluctuation of the production line speed. This adaptive control strategy avoids incomplete wetting due to insufficient vibration energy and effectively prevents resin thermal degradation due to excessive vibration energy, achieving a perfect balance between energy efficiency and product quality in a dynamic production environment.

[0018] Example 3: It also includes a melt impedance monitoring module, which is installed inside the melt flow channel mold and electrically connected to the rheological state control module. The melt impedance monitoring module is used to collect the acoustic impedance feedback signal or mechanical damping feedback signal of polyetheretherketone resin to vibration waves in real time, and transmit the collected feedback signal to the rheological state control module. The rheological state control module is used to analyze the actual viscosity state of the current polyetheretherketone resin based on the feedback signal, and when the actual viscosity state is higher than the preset penetration threshold, it corrects the drive control command to increase the vibration energy density.

[0019] This embodiment further includes a melt impedance monitoring module to address model deviations caused by batch-to-batch resin characteristic fluctuations or environmental changes. This module can be a piezoelectric sensor or an ultrasonic probe embedded in the mold wall. The melt impedance monitoring module collects real-time acoustic impedance feedback signals or mechanical damping feedback signals of the polyetheretherketone resin to vibration waves. The acoustic impedance feedback signal is related to the density and sound velocity of the medium, while the sound velocity is highly correlated with the elastic modulus and viscosity state of the medium. The rheological state control module receives this signal and analyzes the actual viscosity state of the current polyetheretherketone resin based on a preset impedance-viscosity feature library. The impedance-viscosity feature library is constructed using the following empirical regression equation: in, Acoustic impedance modulus acquired by the melt impedance monitoring module, unit: MRayl. The fitting coefficients are obtained in advance through a joint calibration experiment using an offline rheometer and an ultrasonic probe. The system executes closed-loop correction logic based on the PID algorithm to calculate viscosity deviation. ,in, The preset permeation threshold is used; in response to the actual viscosity being higher than the preset permeation threshold, the rheological state control module calculates the correction increment of the vibration energy density. : in, These are preset proportional, integral, and differential gain coefficients, which have a dimension conversion function to convert viscosity error units. The dimensionless unit of the correction increment mapped to the control objective function; the system will use this increment... The adjustment amount is allocated to frequency or amplitude based on a sensitivity analysis strategy; the specific allocation logic is as follows: Step 1: Calculate the real-time sensitivity of frequency and amplitude to viscosity. and : Step 2: Calculate the normalized allocation weights and : Step 3: Based on the energy consumption objective function The gradient information is used to apply the gradient descent principle to the total energy increment according to the objective function. The partial derivatives of frequency and amplitude are inversely proportional to ensure that the growth rate of the cost function is minimized during the adjustment process; based on this principle, the final control increment is calculated: Based on the above calculations, the system prioritizes increasing the parameter that can cause a greater decrease in viscosity and a smaller increase in energy consumption, thereby modifying the drive control command to improve the vibration energy density. This embodiment introduces a real-time feedback mechanism for melt impedance and a PID closed-loop control algorithm, giving the production equipment tactile sensing capabilities so that it can sense and adaptively compensate. This mechanism is particularly crucial for handling the common batch-to-batch molecular weight fluctuations of high-performance resins, ensuring that a high degree of consistency in product quality can still be maintained even when there are slight changes in the characteristics of the raw materials.

[0020] Example 4: It also includes a wetting defect detection module, which is located between the dynamic rheological impregnation coupling zone and the crystallization shaping zone and is electrically connected to the rheological state control module. The wetting defect detection module is used to collect surface microscopic image data or transmitted light spot data of the carbon fiber spread width after impregnation treatment. The rheological state control module is used to identify whether there are dry spot areas in the carbon fiber spread width based on the surface microscopic image data or transmitted light spot data, and when a dry spot area is identified, it generates a compensation command to increase the output power of the high-frequency vibration energy generator.

[0021] This embodiment adds an impregnation defect detection module between the dynamic rheological impregnation coupling zone and the crystallization shaping zone, constructing the final product quality defense line. The impregnation defect detection module uses a high-resolution microscopic vision system or a laser transmission detection device to collect surface microscopic image data or transmitted light spot data of the carbon fiber after impregnation. The rheological state control module executes image processing algorithms based on the above data: for surface microscopic image data, the algorithm uses adaptive histogram equalization to enhance local image contrast and uses Otsu's maximum inter-class variance method for binarization segmentation to identify the reflective properties of the fiber bundle surface. Fibers not coated with resin usually exhibit different diffuse reflection characteristics. For transmitted light spot data, the algorithm analyzes the light intensity distribution after light penetrates the prepreg. Due to the different refractive indices of air and resin, dry spot areas can cause distortion or dark areas in the transmitted light spot. The system executes judgment logic: in response to the identification of dry spot areas, the system determines that the current vibration energy is insufficient to overcome the interfacial tension, and the rheological state control module then calculates the area ratio of the dry spot area within the field of view. And based on this proportion, a power compensation coefficient is generated. : in, The system uses the preset aggressive adjustment gain, employing the formula: The current energy consumption target value is revised, where, The objective function value at the current moment. The target value is the corrected value; the rheological state control module is based on the corrected value. Recalculate to satisfy the optimal energy efficiency ratio Combine and generate compensation commands to increase the output power of the high-frequency vibration energy generator; This embodiment realizes closed-loop control of online quality inspection and real-time correction. Unlike the traditional offline detection mode, this system can detect tiny impregnation defects within milliseconds and automatically increase vibration power for compensation. This rapid response mechanism minimizes the scrap rate of 0.01mm ultra-thin prepreg and ensures zero-defect delivery capability in continuous production processes.

[0022] Example 5: The high-frequency vibration energy generating device includes an ultrasonic transducer array, which is directly coupled to the mold wall of the melt flow channel mold or directly contacts the polyetheretherketone resin; the ultrasonic transducer array is used to generate an ultrasonic vibration field with a frequency between 20kHz and 100kHz, and the direction of action of the ultrasonic vibration field is perpendicular to the conveying direction of the carbon fiber spreading width or forms a preset angle with the conveying direction.

[0023] This embodiment defines the specific structure of the high-frequency vibration energy generating device, which includes an ultrasonic transducer array composed of multiple piezoelectric ceramic transducers arranged in a predetermined geometry. These transducers are configured to be directly coupled to the mold wall of the melt flow channel mold, or to directly contact the polyetheretherketone resin through an amplitude transformer, so as to generate an ultrasonic vibration field with a frequency between 20kHz and 100kHz. The selection of this frequency band is based on the fact that 20kHz-100kHz is the optimal frequency band for inducing cavitation and thixotropic effects in polymer melts. Below 20kHz, audible noise may be generated and the shearing efficiency is low, while above 100kHz, the energy decays too quickly. The direction of action of the ultrasonic vibration field is designed to be perpendicular to the conveying direction of the carbon fiber spreading width or to form a predetermined angle with the conveying direction. This embodiment adopts an array design to ensure uniform distribution of vibration energy across a wide width, effectively avoiding the occurrence of energy dead zones. At the same time, the vertical or angled vibration direction design maximizes the transmission and coupling efficiency of ultrasonic vibration energy in the fiber gaps. By utilizing the specific geometric relationship between the pulsating shear stress field induced by vibration and the fiber arrangement direction, resin molecules are more effectively driven to squeeze into the fiber monofilaments, improving the impregnation depth and uniformity.

[0024] Example 6: The melt flow channel mold is internally defined by a wedge-shaped converging flow channel, the cross-sectional area of ​​which gradually decreases along the conveying direction. The wedge-shaped converging flow channel is used to establish the basic melt pressure. The vibration energy field generated by the high-frequency vibration energy generator is superimposed on the basic melt pressure to form a pulsating shear stress field.

[0025] This embodiment optimizes the internal flow channel structure of the melt flow channel mold; the mold interior is defined by a wedge-shaped converging flow channel, and the cross-sectional area of ​​the flow channel gradually decreases along the conveying direction; utilizing the principle of fluid dynamics, as the flow channel narrows, the melt flow velocity increases, thereby establishing a basic melt pressure inside the mold, which serves as a static and fundamental driving force; the vibration energy field generated by the high-frequency vibration energy generator is superimposed on the basic melt pressure, and the two work together to form a pulsating shear stress field; This embodiment uses a superposition design of static pressure and dynamic pressure to form an impregnation mechanism similar to the ratchet effect. The base pressure ensures close contact between the resin and the fiber, while the superimposed high-frequency vibration is like a microscopic hammering, constantly breaking the surface tension balance of the resin at the entrance of the micropores, so that the resin can only penetrate into the fiber in one direction. This design greatly improves the impregnation efficiency, while avoiding the risk of fiber damage caused by relying solely on high static pressure.

[0026] Example 7: The preheating zone includes an infrared radiation heating unit or a hot air convection heating unit; the preheating zone is used to heat the carbon fiber spreading band to a preset temperature range close to the melting point of polyether ether ketone resin, so as to reduce the interfacial thermal resistance when the resin comes into contact with the fiber.

[0027] This embodiment describes in detail the composition of the preheating zone; the zone includes an infrared radiation heating unit or a hot air convection heating unit; the preheating zone starts the heating program to heat the carbon fiber spread band to a preset temperature range close to the melting point of polyether ether ketone resin; this step is designed to eliminate the instantaneous condensation shell that may form at the interface when the cold fiber comes into direct contact with the hot resin. This embodiment effectively reduces the interfacial temperature difference thermal resistance when the resin contacts the fiber through precise preheating control, so that the resin maintains a good melt flow state at the moment of contact. This optimized thermal environment, combined with the subsequent vibration energy field, achieves second-level wetting and prevents poor wetting caused by rapid cooling of the interface.

[0028] Example 8: The crystallization and shaping zone includes a multi-level gradient cooling unit; the multi-level gradient cooling unit is used to cool the impregnated composite according to a preset cooling rate curve in order to control the crystallinity of polyether ether ketone resin and lock the fiber microstructure.

[0029] This embodiment describes in detail the composition of the crystallization and shaping zone, which includes a multi-stage gradient cooling unit, such as three independently temperature-controlled cooling rollers or air-cooled sections. This unit receives the impregnated composite and cools it strictly according to a preset cooling rate curve. This process aims to precisely control the crystallinity of the polyether ether ketone resin within the optimal range while locking the fiber microstructure. This embodiment solves the problem of performance control of polyetheretherketone (PEEK), a semi-crystalline polymer, during the cooling process by adopting a multi-level gradient cooling strategy. This solution avoids the problems of low crystallinity and high-temperature dimensional instability caused by rapid cooling, and also prevents the material from becoming brittle due to slow cooling. At the same time, it effectively suppresses the internal residual stress caused by uneven thermal shrinkage, ensuring the flatness and excellent mechanical properties of the ultra-thin prepreg product.

[0030] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A production equipment for processing polyetheretherketone (PEEK), characterized in that, The device comprises a precision fiber broadening conveying unit, a preheating zone, a dynamic rheological immersion coupling zone and a crystallization setting zone, the preheating zone, the dynamic rheological immersion coupling zone and the crystallization setting zone are sequentially arranged along the conveying direction of the precision fiber broadening conveying unit; the dynamic rheological immersion coupling zone comprises a melt runner mold and a high-frequency vibration energy generating device arranged oppositely; the precision fiber broadening conveying unit is used to convey carbon fiber broadening strips with constant tension; the high-frequency vibration energy generating device is configured to apply mechanical vibration waves or ultrasonic waves of a specific frequency to the polyether ether ketone resin in a molten state; the dynamic rheological immersion coupling zone is used to induce a thixotropic effect at the contact interface between the polyether ether ketone resin and the carbon fiber broadening strips by using the mechanical vibration waves or ultrasonic waves, so as to instantaneously reduce the apparent viscosity of the polyether ether ketone resin and make it penetrate into the interfilament gap of the carbon fiber broadening strips while keeping the macroscopic mechanical pressure on the carbon fiber broadening strips below a preset damage threshold.

2. The apparatus for producing polyether ether ketone according to claim 1, wherein It also comprises a rheological state control module, which is electrically connected with the high-frequency vibration energy generating device; the rheological state control module is used to calculate the vibration frequency parameter and amplitude parameter required for the polyether ether ketone resin to shear thinning according to a preset rheological model and the current production line speed, and generate a driving control instruction based on the calculated vibration frequency parameter and amplitude parameter; the high-frequency vibration energy generating device is used to adjust the energy density of the output mechanical vibration waves or ultrasonic waves in response to the driving control instruction.

3. The apparatus for producing polyether ether ketone according to claim 2, wherein It also comprises a melt impedance monitoring module, which is arranged in the melt runner mold and electrically connected with the rheological state control module; the melt impedance monitoring module is used to collect acoustic impedance feedback signals or mechanical damping feedback signals of the polyether ether ketone resin to vibration waves in real time, and transmit the collected feedback signals to the rheological state control module; the rheological state control module is used to analyze the actual viscosity state of the current polyether ether ketone resin according to the feedback signals, and correct the driving control instruction to increase the vibration energy density when the actual viscosity state is higher than a preset penetration threshold.

4. The apparatus for producing polyether ether ketone according to claim 2, wherein It also comprises an immersion defect detection module, which is arranged between the dynamic rheological immersion coupling zone and the crystallization setting zone and electrically connected with the rheological state control module; the immersion defect detection module is used to collect surface microscopic image data or transmission light spot data of the carbon fiber broadening strips after immersion treatment; the rheological state control module is used to identify whether there is a dry spot area in the carbon fiber broadening strips based on the surface microscopic image data or transmission light spot data, and generate a compensation instruction for increasing the output power of the high-frequency vibration energy generating device when a dry spot area is identified.

5. The apparatus for producing polyether ether ketone according to claim 1, wherein The high-frequency vibration energy generating device comprises an ultrasonic transducer array directly coupled to the mold wall of the melt runner mold or directly contacting the polyether ether ketone resin; the ultrasonic transducer array is used to generate an ultrasonic vibration field with a frequency of 20 kHz to 100 kHz, and the action direction of the ultrasonic vibration field is perpendicular to the conveying direction of the carbon fiber spread band or forms a preset included angle with the conveying direction.

6. The apparatus for producing polyether ether ketone according to claim 1, wherein The melt runner mold is internally defined with a wedge-shaped converging runner, and the cross-sectional area of the wedge-shaped converging runner gradually decreases along the conveying direction; the wedge-shaped converging runner is used to establish a basic melt pressure, and the vibration energy field generated by the high-frequency vibration energy generating device is superimposed on the basic melt pressure to form a pulsating shear stress field.

7. The apparatus according to claim 1, wherein The preheating zone comprises an infrared radiation heating unit or a hot air convection heating unit; the preheating zone is used to heat the carbon fiber spread band to a preset temperature interval close to the melting point of the polyether ether ketone resin, so as to reduce the interfacial temperature difference thermal resistance when the resin contacts the fiber.

8. The apparatus for producing polyether ether ketone according to claim 1, wherein The crystallization setting zone comprises a multi-stage gradient cooling unit; the multi-stage gradient cooling unit is used to cool the impregnated composite according to a preset temperature decreasing rate curve, so as to control the crystallinity of the polyether ether ketone resin and lock the fiber microstructure.

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