Continuous pultrusion method, forming die and forming equipment

Abstract

The invention discloses a continuous pultrusion method, a forming die and forming equipment, and relates to the technical field of profile machining, the continuous pultrusion method comprises the following steps: S1, laying a fiber material in a pre-forming cavity of a pre-forming die to form a fiber bundle body with a target section shape; s2, the core mold is placed in an inner cavity of the fiber bundle body, and a preformed body is formed; s3, the preformed body wrapped with the core mold is placed in a closed cavity of a forming mold, and the core mold and the closed cavity jointly extrude the preformed body for shaping; s4, in the forming mold, the preformed body is cured and shaped into a continuous profile; and S5, a traction device is used for linearly pulling out the continuous profile from the interior of the forming mold. Through preforming guiding, core mold supporting and joint constraint of the inner mold and the outer mold, the quality problem of a multi-cavity structure in the resin flowing infiltration, curing shrinkage and demolding processes is avoided, fiber distribution of a continuous profile is uniform, the structure is complete, the size is stable, and therefore the structural reliability is improved.

Description

Technical Field

[0001] This invention relates to the field of profile processing technology, and in particular to a continuous pultrusion molding method, molding die and molding equipment. Background Technology

[0002] In rail vehicles, floor beams are installed at the bottom of the cargo compartment floor. As the main load-bearing components, their function is to effectively transfer the weight of the cargo and the floor load to the vehicle body structure. The lateral span of the floor beams is usually large, and their cross-sectional shape needs to be specially designed and optimized to ensure sufficient structural strength under load conditions.

[0003] Traditional floor beams are mostly made of triangular aluminum alloy profiles. While structurally stable, they suffer from problems such as heavy weight and poor corrosion resistance, making it difficult to meet the lightweight requirements of fields like rail transportation and aerospace. To address these challenges, using composite materials to replace traditional metal materials has become the mainstream development direction for achieving lightweight structures.

[0004] Due to limitations in existing processes, current floor beams are mostly limited to flat plates or single-cavity structures. If designed as complex multi-cavity structures, the intricate internal geometry can easily lead to problems such as poor resin flow and uneven fiber distribution during pultrusion molding, resulting in defects such as porosity or dry spots. These defects directly weaken the bonding strength of the composite material interface, thereby affecting the structural reliability of the floor beams. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a continuous pultrusion molding method, molding die and molding equipment, which precisely controls the final cross-sectional shape by preforming guidance, core mold support and joint constraint of inner and outer molds, to ensure the structural integrity of the continuous profile, thereby improving the structural reliability and solving the technical problem of low structural reliability of existing floor beams.

[0006] To achieve the above objectives, the present invention provides a continuous pultrusion molding method, comprising the following steps:

[0007] S1. The fiber material is laid in the preforming cavity of the preforming mold to form a fiber bundle with the target cross-sectional shape;

[0008] S2. Place the core mold into the internal cavity of the fiber bundle to form a preform;

[0009] S3. Place the preform containing the core mold into the closed cavity of the molding die. The core mold and the closed cavity together compress the preform to shape it.

[0010] S4. The preform is solidified and shaped into a continuous profile within the molding die;

[0011] S5. Use a traction device to pull the continuous profile out of the forming mold along a linear path.

[0012] In some embodiments, step S1 includes:

[0013] S11. The unwinding mechanism releases the rolled fiber material at a set speed;

[0014] S12. Use a guiding mechanism to guide the fiber material to move along a preset path;

[0015] S13. Use a yarn guide frame to bundle and combine the fiber materials and arrange them in a set order;

[0016] S14. Feed the arranged fiber material into the preforming cavity;

[0017] S15. Lay the fiber material and attach it to the inner wall of the preformed cavity.

[0018] In some embodiments, step S2 includes:

[0019] S21. Move the core mold to the entrance of the internal cavity;

[0020] S22. Use the guide mechanism to adjust the position of the core mold so that the center line of the core mold coincides with the center line of the internal cavity;

[0021] S23. Push the core mold into the internal cavity along the axial direction with a set pressure so that the outer surface of the core mold fits against the fiber arm of the internal cavity.

[0022] S24. When the core mold is inserted to a set depth, the core mold is controlled to stop moving according to the signal fed back by the ranging mechanism.

[0023] In some embodiments, step S3 includes:

[0024] S31. Open the upper forming mold of the forming mold;

[0025] S32. Adjust the position of the preform to ensure that the preform is aligned with the lower forming groove of the lower forming mold.

[0026] S33. Place the preform containing the core mold onto the lower forming mold of the forming mold, so that the preform falls into the lower forming groove.

[0027] S34. Close the upper forming mold and the lower forming mold together, and the upper forming groove of the upper forming mold and the lower forming groove of the lower forming mold together to form a closed cavity;

[0028] S35. Apply a preset pressure to at least one of the upper and lower forming molds using a pressurizing device, and extrude and shape the preform through a closed cavity.

[0029] In some embodiments, step S4 includes:

[0030] S41. Pressurize the inside of the closed cavity to the specified pressure;

[0031] S42. Inject the matrix material into the closed cavity through the injection port of the molding die, so that the matrix material completely fills the fiber gaps of the preform under the specified pressure.

[0032] S43. Heat the molding die to the set temperature to allow the preform to solidify and set.

[0033] In some embodiments, step S5 includes:

[0034] S51. At the exit end of the forming mold, the continuous profile is clamped by the clamping mechanism and passed through the centering mechanism.

[0035] S52. The clamping mechanism is driven by the drive mechanism to move linearly away from the forming mold at a preset speed.

[0036] S53. Determine whether the clamping mechanism has reached the target position. If yes, control the drive mechanism to drive the clamping mechanism to continue moving in a straight line; if no, control the drive mechanism to stop moving.

[0037] In some embodiments, the method further includes: step S6, cutting the continuous profile using a cutting device; step S6 includes:

[0038] S61. Use a length detection device to detect the output length of continuous profiles;

[0039] S62. Determine whether the output length has reached the set length. If yes, control the cutting device to cut the continuous profile; otherwise, control the cutting device to remain stationary.

[0040] The present invention also provides a molding die for use in the above-described continuous pultrusion molding method, comprising:

[0041] The upper forming mold has an upper forming groove;

[0042] The lower forming mold is opposite to the upper forming mold. The lower forming mold has a lower forming groove. The lower forming groove and the upper forming groove interlock to form a closed cavity. The internal contour shape of the closed cavity matches the external contour shape of the continuous profile.

[0043] The core mold is inserted into the internal cavity of the fiber bundle to work with the closed cavity to extrude the preform for shaping.

[0044] In some embodiments, it also includes:

[0045] A fixed support is fixed at the entrance of the closed cavity. The fixed support is provided with a guide hole for guiding the mandrel into the internal cavity of the fiber bundle.

[0046] The sealing structure is fixed at both ends of the closed cavity to prevent the base material from leaking from the gap between the core mold and the closed cavity.

[0047] The present invention also provides a molding apparatus, comprising the above-mentioned molding die, including:

[0048] The injection device injects the matrix material into the closed cavity through the injection port provided in the upper molding die, so that the matrix material completely fills the fiber gaps of the preform under a specified pressure.

[0049] Heating device, used to heat the molding die to a set temperature, so that the preform is heated and solidified;

[0050] A traction device is used to pull a continuous profile out of a forming mold along a linear path.

[0051] A cutting device is used to cut continuous profiles.

[0052] Compared with the prior art, the continuous pultrusion molding method of the present invention includes the following steps: S1, laying fiber material in the preforming cavity of a preforming mold to form a fiber bundle with a target cross-sectional shape; S2, placing a mandrel in the internal cavity of the fiber bundle to form a preform; S3, placing the preform containing the mandrel in the closed cavity of a molding die, and the mandrel and the closed cavity jointly extruding the preform for shaping; S4, solidifying and shaping the preform into a continuous profile in the molding die; S5, using a traction device to pull the continuous profile linearly out of the molding die.

[0053] This invention first utilizes a pre-forming mold to orderly bundle and initially shape the fiber material, allowing the fiber material to be laid out in a regular pattern to form a fiber bundle with a target cross-sectional shape. By constraining the laying pattern of the fiber material, it effectively avoids fiber disorder or uneven distribution during the molding process. Furthermore, this invention also inserts a core mold into the internal cavity of the fiber bundle. The core mold provides effective support, resisting resin pressure and shrinkage stress, preventing the fiber bundle from collapsing, shifting, or deforming at the interface, thus ensuring the geometric integrity and dimensional stability of the multi-cavity structure during molding. Even further, this invention places the pre-formed body with the core mold inside the molding die. The core mold supports the cavity structure from the inside, while the molding die constrains the overall contour from the outside. Through this dual constraint, the pre-formed body is cured and shaped, ultimately resulting in a continuous profile with precise internal and external contours after curing.

[0054] This invention achieves precise control over fiber placement, cavity morphology evolution, and final cross-sectional shape through preforming guidance, core mold support, and joint constraint of inner and outer molds. This avoids quality problems such as cavity collapse, uneven thickness, and fiber wrinkles in multi-cavity structures during resin flow and wetting, curing shrinkage, and demolding. As a result, the continuous profile has uniform fiber distribution, complete structure, and stable dimensions, thereby improving structural reliability. Attached Figure Description

[0055] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0056] Figure 1 This is a flowchart of a continuous pultrusion molding method provided in a specific embodiment of the present invention;

[0057] Figure 2 This is a schematic diagram of a molding die provided in a specific embodiment of the present invention;

[0058] Figure 3 for Figure 1 A schematic diagram of the injection port;

[0059] Figure 4 for Figure 1 Schematic diagram of the traction device;

[0060] Figure 5 for Figure 1 A schematic diagram of a continuous profile.

[0061] The attached figures are labeled as follows:

[0062] Preform 01 and continuous profile 02;

[0063] Upper forming mold 1, lower forming mold 2, core mold 3, and traction device 4;

[0064] Upper molding groove 11 and injection port 12;

[0065] Lower forming groove 21. Detailed Implementation

[0066] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0067] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0068] This invention discloses a continuous pultrusion molding method, as shown in the attached figure. Figure 1 As shown, the steps include:

[0069] S1. The fiber material is laid in the preforming cavity of the preforming mold to form a fiber bundle with the target cross-sectional shape. The preforming mold is used to orderly bundle and initially shape the fiber material, so that the fiber material is laid out in a regular manner to form a fiber bundle with the target cross-sectional shape. By constraining the laying pattern of the fiber material, it is ensured that the preform 01 can tightly fit into the closed cavity of the molding mold in the subsequent process. This effectively avoids defects such as uneven pressure, uncontrolled thickness, or fiber wrinkles caused by fiber accumulation or gaps during the molding process, thereby improving molding accuracy and product quality.

[0070] It is particularly important to note that the fiber material in this invention can be reinforcing fiber bundles and multiaxial warp-knitted fiber fabrics, but is not limited to these.

[0071] S2. The mandrel 3 is placed in the internal cavity of the fiber bundle to form a preform 01. This invention also ensures the geometric integrity and dimensional stability of the multi-cavity structure during molding by placing the mandrel 3 inside the internal cavity of the fiber bundle. The mandrel 3 provides effective support, resists resin pressure and shrinkage stress, and prevents the fiber bundle from collapsing, shifting, or deforming at the interface.

[0072] Considering that the cross-section of the continuous profile 02 contains multiple independent triangular cavities, the cross-section of the core mold 3 is preferably triangular to ensure that the outer surface shape of the core mold 3 is completely consistent with the shape of the internal cavity of the continuous profile 02, so that the core mold 3 fits evenly with the internal cavity of the continuous profile 02 and provides reliable rigid support. When the cross-section of the continuous profile 02 contains multiple parallel triangular cavities, multiple independent triangular core molds 3 are used, and each core mold 3 is inserted into its corresponding internal cavity, so that the internal cavity of the continuous profile 02 is independently supported, preventing the multi-cavity structure of the continuous profile 02 from interfering with each other or experiencing uneven stress during the molding process. The multi-core mold 3 support design of the present invention can not only effectively prevent local collapse, uneven wall thickness, or fiber displacement of the continuous profile 02 during the molding process, but also facilitate the uniform flow of the matrix material in multiple parallel cavities, improving the molding quality of the complex cross-section of the continuous profile 02.

[0073] S3. The preform 01 containing the core mold 3 is placed in the closed cavity of the molding die. The core mold 3 and the closed cavity together compress the preform 01 for shaping. In this invention, the preform 01 with the core mold 3 is placed in the molding die. The core mold 3 supports the cavity structure from the inside, and the molding die constrains the overall contour from the outside. Through the dual constraint of the inside and outside, the preform 01 is cured and shaped, which ultimately makes the inner and outer contours of the cured continuous profile 02 accurate. This prevents defects such as uneven wall thickness and cavity collapse caused by material shrinkage or deformation during the curing process, and improves the mechanical properties and geometric consistency of the continuous profile 02.

[0074] S4. Within the molding die, the preform 01 is cured and shaped into a continuous profile 02. Specifically, the preform 01, already placed in the core mold 3, is placed in the closed cavity of the molding die. After mold closing, heating and pressurization work synergistically on the preform 01 to achieve dynamic balance during the curing process, avoiding problems such as local overheating, insufficient curing, or over-curing. This ensures stable product quality during continuous production, effectively reduces the scrap rate, and improves the production quality of the continuous profile 02. The purpose of heating is to raise the temperature of the molding die to the curing temperature range of the matrix material, ensuring that the matrix material undergoes a cross-linking reaction. The purpose of pressurization is to apply uniform pressure to the preform 01 through the joint action of the core mold 3 and the molding die, ensuring that the fiber material is tightly compacted, the matrix material flows fully, and internal gases are expelled, reducing the porosity of the continuous profile 02.

[0075] S5. Using the traction device 4, the continuous profile 02 is pulled linearly out of the forming mold, as shown in the attached figure. Figure 5 As shown, uninterrupted production is beneficial to improving production efficiency.

[0076] This invention achieves precise control over fiber placement, cavity morphology evolution, and final cross-sectional shape through preforming guidance, core mold 3 support, and joint constraint of inner and outer molds. This avoids quality problems such as cavity collapse, uneven thickness, and fiber wrinkles in multi-cavity structures during resin flow and wetting, curing shrinkage, and demolding. As a result, the continuous profile 02 has uniform fiber distribution, complete structure, and stable dimensions, thereby improving structural reliability.

[0077] In a preferred embodiment, step S1 includes:

[0078] S11. The unwinding mechanism releases the rolled fiber material at a set speed. The unwinding mechanism releases the material with constant tension, ensuring a stable supply of fiber material for subsequent impregnation, cutting, or laying processes, thus preventing process defects caused by unstable material supply. Furthermore, the constant speed of the unwinding mechanism ensures the consistency of the fiber material arrangement and the uniformity of impregnation for each layer, directly reducing material stretching, wrinkling, or breakage caused by speed fluctuations, lowering the scrap rate, and thereby improving product quality.

[0079] S12. The guiding mechanism guides the fiber material to move along a preset path. The fiber material released from the unwinding mechanism is precisely guided to a preset spatial position and trajectory, providing an accurate spatial path for subsequent weaving, laying, winding, or sewing processes. By controlling the movement of the guiding mechanism, the path of the fiber material can be dynamically changed, thereby weaving a preform 01 with a complex cross-section.

[0080] S13. Using a yarn guide frame, the fiber material is bundled and arranged in a predetermined order to construct a preform 01 with a specific fiber orientation, layered structure, and cross-sectional shape. The orderly arrangement avoids fiber crossing, overlapping, or uneven spacing, ensuring the uniformity of subsequent impregnation, reducing product defects caused by fiber distribution problems, and effectively improving product quality.

[0081] S14. The arranged fiber material is fed into the preforming cavity. Specifically, with the help of a robotic arm or conveyor belt, the preformed body 01, arranged in a predetermined order, is accurately placed into the preforming cavity. In addition, during the feeding process, negative pressure adsorption, flexible clamping, or synchronous conveying are used to ensure that the interlayer structure of the preformed body 01 does not misalign and the fibers do not bend during transfer, maintaining the layup sequence and fiber orientation of the fiber material, ensuring the accuracy of the product dimensions of the continuous profile 02, and effectively improving product quality.

[0082] S15. Lay and adhere the fiber material to the inner wall of the preforming cavity. Using vacuum adsorption or airbag pressurization, the fiber material fed into the preforming cavity is tightly spread onto the inner wall, ensuring complete adhesion and transforming the fiber material from a loose to a compact state. During the laying and compaction process, it is necessary to effectively eliminate interlayer air in the fiber material, reduce wrinkles and redundant gaps, improve the uniformity of the fiber material, ensure the dimensional accuracy of the preform 01, and improve the product quality of the continuous profile 02.

[0083] In a preferred embodiment, step S2 includes:

[0084] S21. Move the core mold 3 to the entrance of the internal cavity. Specifically, using a robotic arm or lifting cylinder, accurately move the core mold 3 to the entrance of the preforming mold to ensure accurate positioning of the core mold 3 and guarantee the relative positional accuracy between the core mold 3 and the preforming mold. When the core mold 3 enters the preforming mold and closes, the pre-positioning directly determines the uniformity of the compaction of the fiber material between the core mold 3 and the forming mold, thereby ensuring the uniformity of the wall thickness of the continuous profile 02 and the accuracy of the internal cavity dimensions, avoiding defects such as off-center cores or uneven thickness in certain areas. By laying the fiber first and then introducing the core mold 3, interference with the core mold 3 during fiber laying is effectively avoided, protecting the flatness and structural order of the already laid fiber layer, preventing airflow disturbance of the fiber layer due to violent movements, and ensuring the quality of fiber layup.

[0085] S22. Adjust the position of the core mold 3 using a guiding mechanism to align its centerline with the centerline of the internal cavity. Specifically, the guiding mechanism can be a laser alignment device, a visual locator, etc. By detecting and dynamically adjusting the spatial position of the core mold 3 in real time, it aligns the centerline of the core mold 3 with the centerline of the internal cavity of the preform mold, eliminating initial positional deviations caused by processing errors, thermal deformation, or mechanical clearances, and providing a benchmark for improving mold closing accuracy. Precise alignment prevents the core mold 3 from accidentally scraping or colliding with the inner wall of the forming mold during subsequent insertion or mold closing, ensuring smooth mold closing.

[0086] S23. Using a set pressure, push the core mold 3 axially into the internal cavity, ensuring that the outer surface of the core mold 3 adheres to the fiber arm of the internal cavity, thus compacting the preform 01. The set pressure mentioned above is a key process parameter controlling the density and cured thickness of the preform 01. The tight fit achieved through pressure greatly reduces flow resistance during subsequent impregnation, avoids flow channels caused by poor adhesion, and ensures uniform heat transfer during the curing stage, which is beneficial to improving product quality.

[0087] S24. When the core mold 3 is inserted to the set depth, the core mold 3 is controlled to stop moving based on the signal fed back by the ranging mechanism. The insertion stroke of the core mold 3 is detected in real time by a ranging mechanism such as a laser rangefinder, grating ruler, or encoder. When the core mold 3 reaches the set depth, the drive mechanism is controlled to automatically stop, ensuring that the core mold 3 can accurately stop on the same axial coordinate, thereby guaranteeing the accuracy of the mold closing state. This invention, through closed-loop control with ranging feedback, eliminates the cumulative positional error caused by factors such as mechanical transmission errors or temperature drift, ensuring that the dimensions of the continuous profile 02 meet tolerance requirements and ensuring that the core mold 3 achieves precise positioning.

[0088] In a preferred embodiment, step S3 includes:

[0089] S31. Open the upper forming mold 1 of the forming mold. That is to say, the forming mold adopts a split design, including the upper forming mold 1 and the lower forming mold 2 which are set opposite each other, so as to facilitate demolding.

[0090] S32. Adjust the position of the preform 01 to ensure that the preform 01 is aligned with the lower forming groove 21 of the lower forming mold 2. Before mold closing, fine-tune the position of the upper forming mold 1 using visual positioning and mechanical probes to ensure precise alignment of the upper forming mold 1 and the lower forming mold 2. This eliminates positional deviations caused by placement or deformation of the preform 01, preventing edge pressing or folding during mold closing due to misalignment of the preform 01. Precise positioning of the preform 01 before molding provides conditions for high-quality mold closing.

[0091] S33. Place the preform 01 containing the core mold 3 onto the lower forming mold 2 of the forming mold, so that the preform 01 falls into the lower forming groove 21. By using a robot or lifting mechanism, the preform 01 is placed onto the lower forming mold 2, reducing the difficulty of mold closing, shortening the mold closing time, and improving production efficiency.

[0092] S34. The upper forming mold 1 and the lower forming mold 2 are closed, and the upper forming groove 11 and the lower forming groove 21 of the upper forming mold 1 enclose a closed cavity. The closed environment after mold closing isolates the molding process from the external environment, prevents dust contamination, and helps improve production quality.

[0093] S35. A preset pressure is applied to at least one of the upper forming mold 1 and the lower forming mold 2 using a pressurizing device, and the preform 01 is extruded and shaped through a closed cavity. The pressurizing device can be a hydraulic mechanism, etc. By controlling the pressure, it is ensured that each product can be shaped under the same mechanical state, thus guaranteeing the consistency of product quality during mass production.

[0094] In a preferred embodiment, step S4 includes:

[0095] S41. Pressurize the sealed cavity to the specified pressure. Specifically, by controlling the pressure within the sealed cavity, the pressure is uniformly applied to all surfaces of the preform 01, forcing the internal fiber network to further densify, causing the resin to generate micro-flow to completely fill the fiber gaps and expel residual gas. The specified pressure directly determines the core performance indicators of the final product, such as fiber volume fraction, porosity, interlayer bonding strength, and dimensional stability. By creating a high-pressure environment, the vaporization of volatiles during resin curing is effectively suppressed, preventing bubble formation and ensuring the uniformity within the continuous profile 02. The entire pressurization process also promotes uniform heat conduction within the cavity, optimizes curing reaction kinetics, and ultimately strengthens the fiber-resin interface bond at the molecular scale, enabling the product to achieve fatigue life and environmental durability.

[0096] S42. Inject the matrix material into the closed cavity through the injection port 12 of the molding die, so that the matrix material completely fills the fiber gaps of the preform 01 under a specified pressure. The high-pressure injection forces the matrix material (such as resin) with a specific viscosity to quickly penetrate the intricate pore network inside the preform 01, effectively expelling air from the fiber gaps and eliminating pore defects. Continuous pressure holding and flow under a specified pressure ensures that the resin fully coats the preform 01, optimizes the interfacial bonding strength and stress transfer efficiency between the fiber material and the matrix material, and achieves uniform distribution of the matrix material in three-dimensional space. Through the coordinated control of pressure, temperature, and time, the curing and cross-linking kinetics of the resin are precisely adjusted, ultimately obtaining a composite material product with a constant fiber volume fraction, extremely low porosity, and uniform internal structure.

[0097] S43. Heat the molding die to the set temperature to allow the preform 01 to heat-cur and set. By controlling the heating temperature, uniform heat transfer is ensured in the molding die, maintaining a stable temperature field in the preform 01 and ensuring that the matrix material undergoes a full polymerization reaction to form a stable network structure. Temperature control not only regulates the curing reaction rate, avoiding internal stress concentration, microcracks, or deformation caused by excessively high exothermic peaks, and ensuring that the resin fully wets the fibers, effectively reducing the porosity of the preform 01 and improving product quality, but also shortens the curing cycle and increases production efficiency.

[0098] In a preferred embodiment, step S5 includes:

[0099] S51. At the exit end of the forming mold, a clamping mechanism is used to clamp the continuous profile 02 and pass it through the centering mechanism. Specifically, the clamping mechanism is used to grip the end of the continuous profile 02 to ensure that slippage or surface damage does not occur during traction. During traction, the clamping mechanism, in conjunction with the centering mechanism, dynamically adjusts the positional offset and angular deviation of the clamping mechanism in the direction of travel through real-time detection and feedback to ensure that the continuous profile 02 maintains linear movement. The centering mechanism effectively eliminates profile bending or deformation caused by mold wear, uneven temperature, or material shrinkage differences, ensuring the dimensional stability of the continuous profile 02.

[0100] S52. The driving mechanism drives the clamping mechanism to move linearly away from the forming mold at a preset speed, achieving uniform traction of the continuous profile 02 and precisely controlling the production cycle and product performance. Specifically, the driving mechanism can be a servo motor or a hydraulic cylinder, causing the clamping mechanism to move linearly at a constant speed, thereby applying a continuous axial tension to the continuous profile 02. This ensures the profile maintains a stable forming state at the mold exit, effectively avoiding defects such as uneven dimensions, surface ripples, or structural delamination caused by speed fluctuations.

[0101] S53. Determine whether the clamping mechanism has reached the target position. If so, control the drive mechanism to continue the clamping mechanism's linear movement; otherwise, control the drive mechanism to stop. The displacement of the clamping mechanism is monitored in real time via an encoder, laser rangefinder, or position sensor, and compared with the preset target position to form a closed-loop feedback control. If the target position is not reached, the drive mechanism is immediately stopped to prevent overstretching of the continuous profile 02, abnormal mold stress, or failure of subsequent process connections due to overshoot or positioning deviation, thus improving production safety. If the target position has been reached, the drive mechanism is triggered to continue linear movement at a preset speed, ensuring the continuity of the traction action and the accuracy of the production rhythm.

[0102] In a preferred embodiment, the continuous pultrusion molding method further includes step S6, which involves cutting the continuous profile 02 using a cutting device to achieve a fixed-length cut. The cutting device can be a high-speed saw blade, laser, or water jet, etc., which rapidly cuts the continuous profile 02 at a preset position, ensuring a clean cut and minimizing burrs, delamination, or fiber pull-out. The cutting process is dynamically synchronized with the traction speed, completing the cut while forming a uniform motion, avoiding product deformation or internal damage caused by vibration or sudden stress changes.

[0103] In a preferred embodiment, step S6 includes:

[0104] S61. The output length of the continuous profile 02 is detected by a length detection device. The output length is monitored in real time during the forming process, providing a basis for production control and quality management. The length detection device can be an encoder, laser rangefinder, or vision measurement device that accumulates the output length of the continuous profile 02 in real time, achieving precise feedback on the production process. When the length detection device detects that the output length of the continuous profile 02 has reached the set length, the length detection device sends out a fixed-length cutting command to ensure that the output length is controlled within a strict range.

[0105] S62. Determine if the output length has reached the set length. If yes, control the cutting device to cut the continuous profile 02; otherwise, control the cutting device to remain stationary. By comparing the output length with the set length in real time, when the length meets the standard, immediately send an instruction to the cutting device to execute the cutting operation, ensuring that the length of each product segment strictly conforms to the design tolerance and meets standardized assembly requirements; if the length does not meet the standard, maintain the cutting device in standby mode to avoid material waste due to miscutting. This invention controls the operating status of the cutting device in real time according to the output length, not only synchronizing the cutting action with the production process and ensuring accurate cutting position, but also improving the continuity of the production process through automated decision-making and manual intervention, thereby improving production efficiency.

[0106] The present invention also provides a molding die for use in the above-mentioned continuous pultrusion molding method, as shown in the attached figure. Figure 2As shown, it includes an upper forming mold 1, a lower forming mold 2, and a core mold 3. The upper forming mold 1 has an upper forming groove 11. The lower forming mold 2 is opposite to the upper forming mold 1 and has a lower forming groove 21. The lower forming groove 21 and the upper forming groove 11 are interlocked to form a closed cavity. The internal contour shape of the closed cavity matches the external contour shape of the continuous profile 02. The core mold 3 is used to be inserted into the internal cavity of the fiber bundle to cooperate with the closed cavity to extrude the preform 01 for shaping.

[0107] During the mold closing process, the outer mold shaping and inner mold support are combined. The closed cavity and the core mold 3 simultaneously apply radial and axial composite pressure to the preform 01, forcing the fiber bundle to be uniformly compressed in three dimensions, effectively eliminating interlayer gas, reducing porosity, and improving the mechanical properties of the continuous profile 02.

[0108] It should be noted that the upper forming mold 1 and the lower forming mold 2 are provided with mutually cooperating positioning pins and positioning holes, so that the upper forming mold 1 and the lower forming mold 2 are precisely aligned and repeatedly positioned, eliminating product defects caused by mold misalignment, ensuring that the contours of the upper forming groove 11 and the lower forming groove 21 are completely aligned, avoiding uneven wall thickness caused by lateral misalignment or angular deviation, which is conducive to improving product quality.

[0109] In a preferred embodiment, the molding die also includes a fixed support and a sealing structure. The fixed support is fixed at the entrance of the closed cavity and has a guide hole for guiding the core mold 3 into the internal cavity of the fiber bundle, avoiding fiber damage, cavity destruction, or uneven wall thickness caused by misaligned insertion, thus effectively improving production quality. As a rigid installation reference, the fixed support ensures that each insertion of the core mold 3 begins at the same coordinate origin, greatly reducing the need for manual adjustment or visual alignment, making it particularly suitable for automated continuous production scenarios, shortening cycle time, and improving production efficiency.

[0110] The sealing structures are fixed at both ends of the closed cavity to prevent the base material from leaking from the gap between the core mold 3 and the closed cavity. This not only prevents the base material from overflowing and reduces material waste, but also ensures that the injected base material is precise and controllable. Furthermore, it ensures that the molding process is carried out in a completely sealed high-pressure environment, so that the closed cavity maintains stable pressure and the base material fully impregnates the preform 01.

[0111] The present invention also provides a molding apparatus, including the above-mentioned molding die, comprising an injection device, a heating device, a traction device 4, and a cutting device. (See attached diagram) Figure 2 and 3 As shown, the injection device injects the matrix material into the closed cavity through the injection port 12 of the upper molding die 1, so that the matrix material completely fills the fiber gaps of the preform 01 under a specified pressure. The heating device is used to heat the molding die to a set temperature, so that the preform 01 is heated and solidified. (See attached diagram) Figure 4 As shown, the traction device 4 is used to pull the continuous profile 02 linearly out of the forming mold. The cutting device is used to cut the continuous profile 02.

[0112] The injection unit and heating unit work together to control and adjust the viscosity and curing start time of the matrix material, achieving efficient connection between the rapid charging and curing stages and providing stable and reliable composite conditions for mass production. The traction device 4 can be equipped with multiple clamping mechanisms to traction the continuous profile 02 in segments, meeting the production requirements of continuous profiles 02 of different lengths. The cutting device performs fixed-length cutting of the continuous profile 02. The cutting device is equipped with a moving mechanism, which can be adjusted to adapt to cutting continuous profiles 02 of different lengths by changing the position of the cutting device.

[0113] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.

[0114] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A continuous pultrusion molding method, characterized in that the steps include... include: S1. The fiber material is laid in the preforming cavity of the preforming mold to form a fiber bundle with the target cross-sectional shape; S2. Place the core mold in the internal cavity of the fiber bundle to form a preform; S3. The preform containing the core mold is placed in the closed cavity of the molding die, and the core mold and the closed cavity together compress the preform to shape it. S4. The preform is solidified and shaped into a continuous profile within the molding die; S5. The continuous profile is pulled out of the forming mold along a linear path using a traction device.

2. The continuous pultrusion molding method according to claim 1, characterized in that, Step S1 includes: S11. The unwinding mechanism releases the rolled fiber material at a set speed; S12. The fiber material is guided to move along a preset path using a guiding mechanism; S13. The fiber material is bundled and arranged in a set order using a yarn guide frame; S14. The arranged fiber material is fed into the preforming cavity; S15. Lay the fiber material and attach it to the inner wall surface of the preformed cavity.

3. The continuous pultrusion molding method according to claim 1, characterized in that, Step S2 includes: S21. Move the core mold to the entrance of the internal cavity; S22. Adjust the position of the core mold using the guide mechanism so that the center line of the core mold coincides with the center line of the internal cavity; S23. The core mold is pushed axially into the internal cavity with a set pressure, so that the outer surface of the core mold fits against the fiber arm of the internal cavity. S24. When the core mold is inserted to a set depth, the core mold is controlled to stop moving according to the signal fed back by the ranging mechanism.

4. The continuous pultrusion molding method according to claim 1, characterized in that, Step S3 includes: S31. Open the upper forming mold of the forming mold; S32. Adjust the position of the preform to ensure that the preform is aligned with the lower forming groove of the lower forming mold of the forming mold; S33. Place the preform containing the core mold onto the lower molding mold of the molding mold, so that the preform falls into the lower molding groove; S34. The upper molding mold and the lower molding mold are closed together, and the upper molding groove of the upper molding mold and the lower molding groove are enclosed to form the closed cavity; S35. Apply a preset pressure to at least one of the upper molding die and the lower molding die using a pressurizing device, and extrude and shape the preform through the closed cavity.

5. The continuous pultrusion molding method according to claim 1, characterized in that, Step S4 includes: S41. Pressurize the inside of the closed cavity to a specified pressure; S42. Inject the matrix material into the closed cavity through the injection port of the molding die, so that the matrix material completely fills the fiber gaps of the preform under the specified pressure. S43. Heat the molding die to a set temperature to heat and solidify the preform.

6. The continuous pultrusion molding method according to claim 1, characterized in that, Step S5 includes: S51. At the outlet end of the forming mold, the continuous profile is clamped by a clamping mechanism and passed through the centering mechanism. S52. The clamping mechanism is driven by the driving mechanism to move linearly at a preset speed in a direction away from the molding die. S53. Determine whether the clamping mechanism has reached the target position. If yes, control the driving mechanism to drive the clamping mechanism to continue moving in a straight line; if no, control the driving mechanism to stop moving.

7. The continuous pultrusion molding method according to any one of claims 1 to 6, characterized in that, It also includes: step S6, cutting the continuous profile using a cutting device; step S6 includes: S61. Detect the output length of the continuous profile using a length detection device; S62. Determine whether the output length has reached the set length. If yes, control the cutting device to cut the continuous profile. If no, control the cutting device to remain stationary.

8. A molding die, characterized in that, The continuous pultrusion molding method according to any one of claims 1 to 7 includes: Upper forming mold, wherein the upper forming mold has an upper forming groove; The lower forming mold is opposite to the upper forming mold. The lower forming mold has a lower forming groove. The lower forming groove and the upper forming groove are interlocked to form a closed cavity. The internal contour shape of the closed cavity matches the external contour shape of the continuous profile. A core mold is used to insert into the internal cavity of the fiber bundle to cooperate with the closed cavity to extrude the preform for shaping.

9. The molding die according to claim 8, characterized in that, Also includes: A fixed support is fixed at the entrance of the closed cavity. The fixed support is provided with a guide hole for guiding the mandrel into the internal cavity of the fiber bundle. A sealing structure is fixed at both ends of the closed cavity to prevent the base material from leaking from the gap between the core mold and the closed cavity.

10. A molding device, characterized in that, The molding die according to any one of claims 8 and 9 includes: An injection device injects matrix material into the closed cavity through an injection port provided in the upper molding die, so that the matrix material completely fills the fiber gaps of the preform under a specified pressure. A heating device is used to heat the molding die to a set temperature, so that the preform is heated and solidified. A traction device for pulling the continuous profile linearly out of the forming mold; A cutting device for cutting the continuous profile.

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