Printing-thermal synergistic composite processing method for nylon-carbon fiber layered composite board

Abstract

The invention discloses a printing-thermal synergistic composite processing method for a nylon-carbon fiber laminated composite board, which is characterized in that lamination of high-strength nylon and carbon fiber prepreg cloth is realized through a composite process under the action of laser heating and roller pressing, namely a nylon-carbon fiber composite workpiece with higher carbon fiber content is realized. Through nylon-carbon fiber layered composite board surface printing-thermal synergistic compounding, the bonding strength of the composite material is improved, the generation of micropores in the hot pressing process is reduced, and meanwhile, the processing procedures and the operation steps are greatly reduced.

Description

Technical Field

[0001] This invention relates to a nylon-carbon fiber layered composite material, and in particular to a nylon-carbon fiber layered composite board surface printing-thermal synergistic composite processing method, which manufactures nylon-carbon fiber composite boards with high bonding strength and adjustable load-bearing capacity. Background Technology

[0002] Carbon fiber reinforced resin matrix composites, due to their superior specific strength, specific modulus, excellent fatigue resistance, and designability, have become key materials for achieving structural lightweighting in aerospace, new energy vehicles, and high-end equipment manufacturing. Based on the type of matrix resin, they are mainly divided into two categories: thermosetting (such as epoxy resin) and thermoplastic (such as nylon, i.e., polyamide). Thermosetting carbon fiber composite technology is relatively mature, but it suffers from inherent limitations such as high brittleness, insufficient impact resistance, and the inability to recycle and reprocess after curing. In contrast, thermoplastic matrices, represented by nylon, are considered a more promising next-generation lightweight material due to their good toughness, impact resistance, chemical corrosion resistance, recyclability, and rapid thermoplastic molding capabilities.

[0003] To prepare high-performance fiber-reinforced resin matrix composites, various processes have been developed in the industry. For example, invention patent CN121379134A proposes a carbon fiber reinforced nylon composite material and its preparation method. This method modifies carbon fibers through high-energy electron irradiation, forming polar groups on their surface to enhance the interfacial bonding with the nylon matrix. However, such methods are cumbersome, and the pretreatment effect may diminish during subsequent high-temperature processing, posing a challenge to the stability of interfacial properties. Simultaneously, during hot pressing, the high-viscosity melt is difficult to completely wet the fibers, easily generating defects such as porosity. Invention patent CN103847166A proposes a composite material with enhanced interlayer bonding strength and its preparation method. This method significantly improves the mechanical properties of the composite material in various directions by controlling the fiber layup direction and optimizing the interlayer interface structure. By precisely adjusting the layup direction, the tensile strength and compressive strength of the composite material are improved, and the interlayer bonding strength is also enhanced. However, in mass production, it is not possible to freely adjust the layup angle to achieve higher interlayer bonding strength and a more uniform layup effect.

[0004] Therefore, this patent employs a nylon-carbon fiber layered composite board surface printing-thermal synergistic composite processing method. After each layer of carbon fiber fabric is laid, its interface with the nylon matrix is ​​immediately strengthened. Simultaneously, an integrated thermosetting and rolling press is used, allowing the hot-pressing process to occur concurrently, reducing the formation of micropores. Furthermore, the nylon layers are stacked using surface printing. By adjusting the printing path, the orientation of the nylon filaments can be aligned with the fiber orientation in the carbon fiber prepreg, resulting in higher bonding strength and a more uniform laying effect. Summary of the Invention

[0005] The purpose of this invention is to provide a printing-thermal synergistic composite processing method for nylon-carbon fiber layered composite panels, which can produce lightweight nylon-carbon fiber layered composite panels with higher carbon fiber content, higher bonding strength and adjustable load-bearing capacity, suitable for the manufacture of lightweight and high-rigidity structural components for drone fuselages, automated equipment, etc.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides a method for printing and thermo-coordinated composite processing of nylon-carbon fiber layered composite plates, comprising the following steps:

[0008] S1. Preparation of the nylon layer:

[0009] The nylon layer thickness is designed to be 0.5~1mm, and a nylon-carbon fiber composite consumable with a carbon fiber content of 20%~40% is selected. Three-dimensional printing is performed using a printhead in a thermal deposition laser layup device, starting from the edge of the heated bed. The printhead parameters are set as follows: nozzle temperature 260~320℃, printing speed 40~60mm / s, layer height 0.1~0.2mm, and infill density 15%~25%.

[0010] S2, Preparation of carbon fiber layers:

[0011] Carbon fiber prepreg fabric is mounted onto two feeding rollers, and a laser is mounted onto the feeding nozzle. After the nylon layer is printed, the large feeding roller moves outside the heated bed and lowers a certain amount of carbon fiber prepreg fabric. The left hydraulic pump pushes out the left baffle to fix the carbon fiber prepreg fabric to the side of the heated bed, and then the large feeding roller moves from left to right to the other side of the heated bed. After the first layer of carbon fiber prepreg fabric is laid, the feeding nozzle moves outside the heated bed and lowers a certain amount of carbon fiber prepreg fabric. The width of the second layer of carbon fiber prepreg fabric is preset to be 5-10 mm. The right hydraulic pump pushes the right baffle to fix the prepreg fabric to the side of the heated bed, and the feeding nozzle moves from right to left. At the same time, the laser head is activated, focusing the laser spot onto the upper and lower surfaces of the two layers of carbon fiber prepreg fabric. The rectangular spot is 5-10 mm long and 2 mm wide, with the length of the rectangular spot matching the width of the prepreg fabric to be laminated. Different laser powers are used to irradiate the nylon layers depending on their carbon fiber content. While the laser scans across the carbon fiber prepreg, the rollers on the feeding nozzle press down on the laser-heated area, with a pressing amount set to 0.1~0.5mm. This continues until the feeding nozzle moves to the other side of the heated bed, at which point the cutter presses down and cuts the two layers of carbon fiber prepreg.

[0012] Preparation of S3 Nylon-carbon fiber layered composite plate

[0013] After the S2 layered composite board is prepared, a new nylon layer is printed on the surface of the carbon fiber prepreg using a printing nozzle. Then, step S2 is repeated, and nylon layers and carbon fiber prepreg are alternately stacked in sequence to finally produce a multi-layered nylon-carbon fiber layered composite board.

[0014] S4. Surface treatment:

[0015] After the composite board is prepared to the predetermined thickness, the excess carbon fiber prepreg on the side surface of the layered composite board is cut and recycled.

[0016] Furthermore, in step S1, the orientation of the nylon filament during the surface printing process should be coordinated with the fiber orientation of the carbon fiber prepreg in an angle between 0 and 90°. For example, if the nylon-carbon fiber composite board requires better unidirectional stress effect and bonding strength, the angle between the two should be 0°. If a more uniform stress effect is required, it can be prepared at a 90° angle.

[0017] Furthermore, in step S2, the laser beam in the laser head irradiates the nylon layer at a specific angle (30°~45°).

[0018] Furthermore, in step S2, the laser power is set to 200~350W to accommodate nylon carbon fiber filaments with different carbon fiber contents.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] This invention patent utilizes a printing-thermal synergistic composite processing method for nylon-carbon fiber layered composite panels. The arrangement of fibers in the nylon filaments and carbon fiber prepreg effectively enhances the bonding strength and load-bearing capacity in different directions of the nylon-carbon fiber layered composite panel. Simultaneously, the integrated thermosetting and roll forming equipment design allows for simultaneous hot pressing during processing, effectively reducing the generation of micropores in the composite panel and shortening the production cycle by reducing production steps. Attached Figure Description

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] Figure 1 This is a diagram illustrating the fused deposition modeling apparatus used in this invention;

[0023] Figure 2 The diagram shows the laying device and clamping device for the first layer of carbon fiber prepreg fabric used in this invention.

[0024] Figure 3 The illustration shows the laying device and clamping device of the second layer of carbon fiber prepreg fabric used in this invention.

[0025] Figure 4 The illustration shows the laser curing device and the roller pressing device used in this invention;

[0026] Figure 5 This is a schematic diagram of the overall frame of the invention using surface printing-thermal synergy;

[0027] The meanings of the labels in the diagram are as follows: Printing nozzle 11, feeding nozzle 12, heated bed 2, large feeding roller 31, small feeding roller 32, right baffle 41, left baffle 42, left hydraulic pump 51, right hydraulic pump 52, laser head 6, roller 7, cutter 8. Detailed Implementation

[0028] 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.

[0029] Example 1

[0030] This invention discloses a method for printing and thermo-coordinated composite processing of nylon-carbon fiber layered composite plates, comprising the following steps:

[0031] S1. Preparation of the nylon layer:

[0032] The nylon layer thickness is designed to be 0.5mm. Nylon-carbon fiber composite consumables with a carbon fiber content of 20% are selected. The printing nozzle 11 in the hot melt deposition laser laying device performs three-dimensional printing starting from the edge of the heated bed. The preset angle between the nylon layer filament and the fibers in the prepreg is 90°. The printing nozzle parameters are set as follows: nozzle temperature 260℃, printing speed 60mm / s, layer height 0.2mm, and filling density 25%.

[0033] S2, Preparation of carbon fiber layers:

[0034] The carbon fiber prepreg is mounted onto two feeding rollers, and the laser head 6 is mounted onto the feeding nozzle 12, with a preset included angle of 30°. After the nylon layer is printed, the large feeding roller 31 moves outside the heated bed 2 and lowers a certain amount of carbon fiber prepreg. The left hydraulic pump 51 pushes out the left baffle 41 to fix the carbon fiber prepreg on the side of the heated bed 2. Then, the large feeding roller 31 moves from left to right to the other side of the heated bed 2 to complete the laying of the first layer of carbon fiber prepreg. After the first layer of carbon fiber prepreg is laid, the feeding nozzle 12 moves to the outside of the heated bed 2, simultaneously lowering a certain amount of carbon fiber prepreg for suspension. The width of the second layer of carbon fiber prepreg is preset to 10mm. The right hydraulic pump 52 pushes the right baffle 42 to fix the prepreg on the side of the heated bed 2. The feeding nozzle 12 moves from right to left to lay the second layer of carbon fiber prepreg on the surface of the first layer. At the same time, the laser head 6 is activated, focusing the laser spot onto the upper and lower surfaces of the two layers of carbon fiber prepreg. The rectangular spot is 10mm long and 2mm wide, with the length of the rectangular spot matching the width of the prepreg to be laminated. The laser power is set to 200W. While the laser sweeps across the carbon fiber prepreg, the roller 7 on the feeding nozzle 12 rolls the laser-heated area, with a pressing amount set to 0.1mm. This continues until the feeding nozzle 12 moves to the other side of the heated bed 2, where the cutter 8 presses down to cut the two layers of carbon fiber prepreg.

[0035] Preparation of S3 Nylon-carbon fiber layered composite plate

[0036] After the S2 layered composite board is prepared, a new nylon layer is printed on the surface of the carbon fiber prepreg using the printing nozzle 11. Then, step S2 is repeated, and the nylon layer and the carbon fiber prepreg are alternately stacked in sequence to finally produce a multi-layered nylon-carbon fiber layered composite board.

[0037] S4. Surface treatment after completion:

[0038] After the composite board is prepared to the predetermined thickness, the excess carbon fiber prepreg on the side surface of the layered composite board is cut and recycled.

[0039] Through shear tests, the interlaminar bond strength of the above-mentioned nylon (20%)-carbon fiber layered composite plate is 65.2 MPa.

[0040] Example 2

[0041] This invention discloses a method for printing and thermo-coordinated composite processing of nylon-carbon fiber layered composite plates, comprising the following steps:

[0042] S1. Preparation of the nylon layer:

[0043] The nylon layer thickness is designed to be 0.7mm. A nylon-carbon fiber composite material with a carbon fiber content of 30% is selected. Three-dimensional printing is performed using a printhead in a thermal deposition laser layup device, starting from the edge of the heated bed. The preset angle between the nylon layer filaments and the fibers in the prepreg is 45°. The printhead parameters are set as follows: nozzle temperature 290℃, printing speed 50mm / s, layer height 0.15mm, and infill density 20%.

[0044] S2, Preparation of carbon fiber layers:

[0045] The carbon fiber prepreg is mounted onto two feeding rollers, and the laser head 6 is mounted onto the feeding nozzle 12, with a preset included angle of 30°. After the nylon layer is printed, the large feeding roller 31 moves outside the heated bed 2 and lowers a certain amount of carbon fiber prepreg. The left hydraulic pump 51 pushes out the left baffle 41 to fix the carbon fiber prepreg on the side of the heated bed 2. Then, the large feeding roller 31 moves from left to right to the other side of the heated bed 2 to complete the laying of the first layer of carbon fiber prepreg. After the first layer of carbon fiber prepreg is laid, the feeding nozzle 12 moves to the outside of the heated bed 2, simultaneously lowering a certain amount of carbon fiber prepreg for suspension. The width of the second layer of carbon fiber prepreg is preset to 10mm. The right hydraulic pump 52 pushes the right baffle 42 to fix the prepreg on the side of the heated bed 2. The feeding nozzle 12 moves from right to left to lay the second layer of carbon fiber prepreg on the surface of the first layer. At the same time, the laser head 6 is activated, focusing the laser spot onto the upper and lower surfaces of the two layers of carbon fiber prepreg. The rectangular spot is 10mm long and 2mm wide, with the length of the rectangular spot matching the width of the prepreg to be laminated. The laser power is set to 275W. While the laser sweeps across the carbon fiber prepreg, the roller 7 on the feeding nozzle 12 rolls the laser-heated area, with a pressing amount set to 0.3mm. This continues until the feeding nozzle 12 moves to the other side of the heated bed 2, where the cutter 8 presses down to cut the two layers of carbon fiber prepreg.

[0046] Preparation of S3 Nylon-carbon fiber layered composite plate

[0047] After the S2 layered composite board is prepared, a new nylon layer is printed on the surface of the carbon fiber prepreg using the printing nozzle 11. Then, step S2 is repeated, and the nylon layer and the carbon fiber prepreg are alternately stacked in sequence to finally produce a multi-layered nylon-carbon fiber layered composite board.

[0048] S4. Surface treatment:

[0049] After the composite board is prepared to the predetermined thickness, the excess carbon fiber prepreg on the side surface of the layered composite board is cut and recycled.

[0050] Through shear tests, the interlaminar bond strength of the above-mentioned nylon (30%)-carbon fiber layered composite plate is 68.5 MPa.

[0051] Example 3

[0052] This invention discloses a method for printing and thermo-coordinated composite processing of nylon-carbon fiber layered composite plates, comprising the following steps:

[0053] S1. Preparation of the nylon layer:

[0054] The nylon layer thickness is designed to be 1mm, and a nylon-carbon fiber composite material with a carbon fiber content of 40% is selected. Three-dimensional printing is performed using a printhead in a thermal deposition laser layup device, starting from the edge of the heated bed. The preset angle between the nylon layer filaments and the fibers in the prepreg is 0°. The printhead parameters are set as follows: nozzle temperature 320℃, printing speed 40mm / s, layer height 0.1mm, and infill density 15%.

[0055] S2, Preparation of carbon fiber layers:

[0056] The carbon fiber prepreg is mounted onto two feeding rollers, and the laser head 6 is mounted onto the feeding nozzle 12 at a preset angle of 45°. After the nylon layer is printed, the large feeding roller 31 moves outside the heated bed 2 and lowers a certain amount of carbon fiber prepreg. The left hydraulic pump 51 pushes out the left baffle 41 to fix the carbon fiber prepreg on the side of the heated bed 2. Then, the large feeding roller 31 moves from left to right to the other side of the heated bed 2 to complete the laying of the first layer of carbon fiber prepreg. After the first layer of carbon fiber prepreg is laid, the feeding nozzle 12 moves to the outside of the heated bed 2, simultaneously lowering a certain amount of carbon fiber prepreg for suspension. The width of the second layer of carbon fiber prepreg is preset to 5mm. The right hydraulic pump 52 pushes the right baffle 42 to fix the prepreg on the side of the heated bed 2. The feeding nozzle 12 moves from right to left to lay the second layer of carbon fiber prepreg on the surface of the first layer. At the same time, the laser head 6 is activated, focusing the laser spot onto the upper and lower surfaces of the two layers of carbon fiber prepreg. The rectangular spot is 5mm long and 2mm wide, with the length of the rectangular spot matching the width of the prepreg to be laminated. The laser power is set to 350W. While the laser sweeps across the carbon fiber prepreg, the roller 7 on the feeding nozzle 12 rolls the laser-heated area, with a pressing amount set to 0.5mm. This continues until the feeding nozzle 12 moves to the other side of the heated bed 2, where the cutter 8 presses down to cut the two layers of carbon fiber prepreg.

[0057] Preparation of S3 Nylon-carbon fiber layered composite plate

[0058] After the S2 layered composite board is prepared, a new nylon layer is printed on the surface of the carbon fiber prepreg using the printing nozzle 11. Then, step S2 is repeated, and the nylon layer and the carbon fiber prepreg are alternately stacked in sequence to finally produce a multi-layered nylon-carbon fiber layered composite board.

[0059] S4. Surface treatment:

[0060] After the composite board is prepared to the predetermined thickness, the excess carbon fiber prepreg on the side surface of the layered composite board is cut and recycled.

[0061] Through shear tests, the interlaminar bond strength of the above-mentioned nylon (40%)-carbon fiber layered composite plate was 71.8 MPa.

[0062] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for printing-thermal synergistic composite processing of nylon-carbon fiber layered composite panels, characterized in that, Includes the following steps: S1. Preparation of the nylon layer: The nylon layer thickness is designed to be 0.5~1mm, and a nylon-carbon fiber composite consumable with a carbon fiber content of 20%~40% is selected. Three-dimensional printing is performed using a printhead in a thermal deposition laser layup device, starting from the edge of the heated bed. The printhead parameters are set as follows: nozzle temperature 260~320℃, printing speed 40~60mm / s, layer height 0.1~0.2mm, and infill density 15%~25%. 2.S2, Preparation of carbon fiber layers: The carbon fiber prepreg is mounted onto two feeding rollers, and the laser is mounted onto the feeding nozzle. After the nylon layer is printed, the large feeding roller moves outside the heated bed and lowers a certain amount of carbon fiber prepreg. The left hydraulic pump pushes out the left baffle to fix the carbon fiber prepreg to the side of the heated bed, and then the large feeding roller moves from left to right to the other side of the heated bed. After the first layer of carbon fiber prepreg is laid, the feeding nozzle moves outside the heated bed and lowers a certain amount of carbon fiber prepreg. The width of the second layer of carbon fiber prepreg is preset to be 5-10mm. The right hydraulic pump pushes the right baffle to fix the prepreg to the side of the heated bed, and the feeding nozzle moves from right to left. At the same time, the laser head is activated, focusing the laser spot onto the upper and lower surfaces of the two layers of carbon fiber prepreg. The rectangular spot is 5-10mm long and 2mm wide, and the length of the rectangular spot is the same as the width of the prepreg to be laminated. Depending on the nylon layers with different carbon fiber contents, lasers of varying power are used for irradiation. Simultaneously, rollers on the feeding nozzle press down on the laser-heated area, with a pressing amount set to 0.1~0.5mm. This continues until the feeding nozzle moves to the other side of the heated bed, at which point a cutter presses down and cuts the two layers of carbon fiber prepreg.

3. Preparation of S3 Nylon-carbon fiber layered composite plates After the S2 layered composite board is prepared, a new nylon layer is printed on the surface of the carbon fiber prepreg using a printing nozzle. Then, step S2 is repeated, and nylon layers and carbon fiber prepreg are alternately stacked in sequence to finally produce a multi-layered nylon-carbon fiber layered composite board. 4.S4 Surface Treatment: After the composite board is prepared to the predetermined thickness, the excess carbon fiber prepreg on the side surface of the layered composite board is cut and recycled.

5. The method for preparing nylon-carbon fiber layered composite plates by laser curing and roll forming according to claim 1, characterized in that, In step S1, the direction of the nylon filament during the surface printing process should be coordinated with the angle between the fiber direction of the carbon fiber prepreg and the nylon filament in the direction of the fiber ...

6. The method for preparing nylon-carbon fiber layered composite plates by laser curing and roll forming according to claim 1, characterized in that, In step S2, the laser beam in the laser head irradiates the nylon layer at a specific angle (30°~45°).

7. The method for preparing nylon-carbon fiber layered composite plates by laser curing and roll forming according to claim 1, characterized in that, In step S2, the laser power is set to 200~350W to accommodate nylon carbon fiber filaments with different carbon fiber contents.

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