Impregnation device and melt impregnation system

Abstract

The utility model relates to the technical field of prepreg tape processing, and discloses a dipping device and a melt dipping system.The dipping device comprises a mold with a dipping channel, a dipping inlet is formed in one end of the dipping channel, a dipping outlet is formed in the other end of the dipping channel, and at least one adjusting roller set is arranged in the dipping channel from the dipping inlet to the dipping outlet. Each adjusting roller set comprises a fixed roller, an adjusting rail located on the inner wall of the dipping channel, a movable roller in sliding connection with the adjusting rail and an adjusting and controlling mechanism, and the adjusting rails extend upwards or downwards in an inclined mode from the fixed rollers; each adjusting roller group can adjust the position of the movable roller in the adjusting track through a corresponding regulating and controlling mechanism so as to adjust the coating angle of the impregnated material on the adjusting roller group; and a resin injection opening is formed in the mold wall. The impregnation device can improve the impregnation degree of the thermoplastic fiber impregnation belt, reduces fiber damage and porosity, and is wide in application range.

Description

Technical Field

[0001] The utility model relates to the technical field of prepreg processing, and particularly relates to an impregnation device and a melt impregnation system including the impregnation device. Background Art

[0002] Continuous fiber reinforced thermoplastic composites have the advantages of high strength, good toughness, excellent resistance to heat and humidity, recyclability, short production cycle, easy storage, etc. Compared with traditional single materials, they have great development potential. However, the research on continuous fiber reinforced thermoplastic composites in China started relatively late, and the mechanical properties of the composites are restricted by their preparation process, making it difficult to form large-scale applications.

[0003] The thermoplastic fiber prepreg is processed by pultrusion, molding, winding, etc. to obtain continuous fiber reinforced thermoplastic composites, which can be made into products such as plates, ribs, sheets, etc., and are applied in the fields of civil engineering, transportation, aerospace, medical and health, etc. As an intermediate product for preparing continuous fiber reinforced thermoplastic composites, the performance of the thermoplastic fiber prepreg restricts the development and application of the composites to a great extent.

[0004] The existing thermoplastic fiber prepregs generally have the defects of high porosity and low impregnation degree. At the same time, there are also many problems in the melt impregnation process of thermoplastic fiber prepregs, mainly including: lack of a mature and systematic melt impregnation device, and the impregnation process flow is not yet clear; it is difficult to establish a stable impregnation pressure during the melt impregnation process of thermoplastic fiber prepregs, and the impregnation process is often accompanied by serious fiber damage, which destroys the continuity of the pultrusion process of thermoplastic fiber prepregs, and the quality of the corresponding products is also greatly affected; and a single impregnation die is difficult to meet the impregnation requirements of thermoplastic resins with different melt indexes. In response to the change of the melt index, multiple melt impregnation dies with different structures need to be matched, which greatly reduces the melt impregnation efficiency, and the preparation cost of thermoplastic fiber prepregs also increases accordingly. Summary of the Invention

[0005] The purpose of the utility model is to overcome the problems existing in the prior art, such as high porosity, low impregnation degree of thermoplastic fiber prepregs, and small application range of dies, and to provide an impregnation device and a melt impregnation system. The impregnation device can improve the impregnation degree of thermoplastic fiber impregnated tapes, reduce fiber damage and porosity, and has a wide application range.

[0006] To achieve the above object, a first aspect of the present utility model provides an impregnation device, which includes a mold having an impregnation channel. One end of the impregnation channel is provided with an impregnation inlet, and the other end is provided with an impregnation outlet. At least one set of adjusting roller groups is arranged in the impregnation channel from the impregnation inlet to the impregnation outlet. Each set of adjusting roller groups includes a fixed roller, an adjusting track located on the inner wall of the impregnation channel, a movable roller slidably connected to the adjusting track, and a control mechanism. The adjusting track extends obliquely upward or obliquely downward from the fixed roller. Each adjusting roller group can adjust the position of the movable roller in the adjusting track through the corresponding control mechanism to adjust the wrapping angle of the impregnating material on the adjusting roller group. A resin injection port is provided on the side wall of the impregnation channel.

[0007] Preferably, the control mechanism includes connecting shafts located on both sides of the movable roller and fasteners located outside the impregnation channel. The fasteners are arranged in one-to-one correspondence with the connecting shafts. The connecting shafts are slidably connected in the adjusting track and are connected to the corresponding fasteners.

[0008] Preferably, the radius of the movable roller and the radius R of the fixed roller are each independently less than or equal to 30 mm.

[0009] Preferably, the angle α between the adjusting track and the horizontal plane is 40° - 50°.

[0010] Preferably, the radius of the fixed roller and the radius of the movable roller in each adjusting roller group are the same;

[0011] The calculation formula for the wrapping angle of the impregnating material on each adjusting roller group is shown in formula (1):

[0012]

[0013] wherein, R represents the radius of the movable roller and the fixed roller in each adjusting roller group;

[0014] l represents the horizontal distance between the centers of the movable roller and the fixed roller in this adjusting roller group;

[0015] d represents the vertical distance between the centers of the movable roller and the fixed roller in this adjusting roller group;

[0016] If the adjusting track extends obliquely upward, H represents the distance between the lower tangent point of the movable roller and the upper tangent point of the fixed roller in this adjusting roller group;

[0017] If the adjusting track extends obliquely downward, H represents the distance between the upper tangent point of the movable roller and the lower tangent point of the fixed roller in this adjusting roller group.

[0018] Preferably, the change range of the wrapping angle of the impregnating material on the adjusting roller group is 20° < θ < 60°.

[0019] Preferably, when the movable roller slides to the end of the adjustment track away from the fixed roller, the horizontal distance l between the centers of the movable roller and the fixed roller is less than 100 mm, and the vertical distance d between the centers of the movable roller and the fixed roller in the adjustment roller set is less than 150 mm.

[0020] Preferably, multiple groups of the adjustment roller sets are provided, the horizontal heights of the fixed rollers in each group of the adjustment roller sets are the same, and the distance between the centers of the fixed rollers in adjacent adjustment roller sets is the same and less than 100 mm.

[0021] In a second aspect of the present invention, a melt impregnation system is provided, including the impregnation device described in the first aspect above.

[0022] Preferably, the melt impregnation system further includes a yarn rack, a pre-dispersion device, a preheating device, and a yarn spreading device connected in sequence along the impregnation material conveying direction. One end of the mold is connected to the yarn spreading device, the other end is connected to a calendering device, and an extruder is correspondingly arranged above the resin injection port.

[0023] Through the above technical solution, the impregnation device provided by the present invention adopts the cooperation of the fixed roller and the movable roller in at least one group of adjustment roller sets, changes the wrapping angle of the impregnation material in the resin injected into the resin injection port by changing the position of the movable roller, thereby changing the impregnation pressure, can significantly improve the impregnation degree of the thermoplastic fiber prepreg, reduce fiber damage and porosity, and has a wide application range.

[0024] Other features and advantages of the present invention will be described in detail in the subsequent specific implementation part. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the following specific implementation manners, they are used to explain the present invention, but do not constitute a limitation to the present invention. In the drawings:

[0026] Figure 1 is a front view of an embodiment of the impregnation device in the present invention;

[0027] Figure 2 is a schematic diagram of the first embodiment of the wrapping angle adjustment of the impregnation device in the present invention;

[0028] Figure 3 is a schematic diagram of the second embodiment of the wrapping angle adjustment of the impregnation device in the present invention;

[0029] Figure 4 is a schematic diagram of the third embodiment of the wrapping angle adjustment of the impregnation device in the present invention;

[0030] Figure 5 It is a schematic diagram of an implementation manner of the melt impregnation system in the present utility model.

[0031] Explanation of reference numerals

[0032] 1. Fiber bundle; 2. Yarn rack; 3. Pre-dispersion device; 4. Preheating device; 5. Yarn spreading device; 6. Die; 601. Movable roller; 602. Fixed roller; 603. Adjusting track; 604. Control mechanism; 605. Resin injection port; 7. Extruder; 8. Calendering device; 9. Cooling and cutting device; 10. Traction device; 11. Rewinding device; 12. Thermoplastic fiber prepreg tape. Specific implementation manner

[0033] The following will describe in detail the specific implementation manner of the present utility model with reference to the accompanying drawings. It should be understood that the specific implementation manner described herein is only for the purpose of illustrating and explaining the present utility model, and is not used to limit the present utility model.

[0034] In the description of the present utility model, it should be noted that unless otherwise clearly defined and limited, the terms "connected" and "coupled" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, it can be a butt joint, it can be the internal communication of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific situations.

[0035] It should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "inner", "outer", etc. is based on the direction or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the present utility model. In addition, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined with "first" and "second" may explicitly or implicitly include one or more of the said features.

[0036] In the first aspect of the present utility model, an impregnation device is provided, which includes a mold 6 having an impregnation channel. One end of the impregnation channel is provided with an impregnation inlet, and the other end is provided with an impregnation outlet. At least one set of adjusting roller groups is arranged in the impregnation channel from the impregnation inlet to the impregnation outlet. Each set of adjusting roller groups includes a fixed roller 602, an adjusting track 603 located on the inner wall of the impregnation channel, a movable roller 601 slidably connected to the adjusting track 603, and a regulating mechanism 604. The adjusting track 603 extends obliquely upward or obliquely downward from the fixed roller 602. Each adjusting roller group can adjust the position of the movable roller 601 in the adjusting track 603 through the corresponding regulating mechanism 604 to adjust the wrapping angle of the impregnating material on the adjusting roller group. A resin injection port 605 is provided on the side wall of the impregnation channel.

[0037] It should be noted that the above-mentioned movable roller 601 and fixed roller 602 are the structures of the movable roller 601 and fixed roller 602 commonly used in the prior art. A connecting shaft and an outer roller surface sleeved on the connecting shaft are arranged inside the movable roller 601 and the fixed roller 602, and the outer roller surface can rotate around the connecting shaft when driving the impregnating material. Two adjusting tracks 603 are correspondingly arranged for one movable roller 601, and the two adjusting tracks 603 are correspondingly arranged on the inner walls on both sides of the mold 6. The mold 6 is of an openable and closable structure, and can be opened and closed by using the structure of an upper mold and a lower mold, or an openable and closable structure can be adopted on the top plate of the mold 6. The impregnating liquid is injected from the resin injection port 605 and filled into the impregnation channel of the above-mentioned mold 6, so that the impregnating material is all or partially impregnated in the impregnating liquid. Heating plates are attached to the peripheral sides of the side walls outside the mold 6, and the heating plates are electrically connected to a thermocouple and a PLC temperature control regulator. The temperature of the heating plates is adjusted and controlled through the thermocouple and the PLC temperature control regulator to realize the heating and heat preservation of the mold 6 during the working process.

[0038] According to the present utility model, different types of impregnating materials and impregnating liquids require different impregnation pressures. The change of the wrapping angle can adjust the impregnation pressure. By adjusting the size of the wrapping angle, the impregnation pressure can be adjusted, the processing damage and porosity of the impregnating material can be reduced, and the impregnating material and the impregnating liquid can be better fused together. Exemplarily, when the impregnating material is carbon fiber CF and the resin is polyetheretherketone PEEK, the fiber wrapping angle is 35° - 45°; when the impregnating material is carbon fiber CF and the resin is nylon PA, the fiber wrapping angle is 30° - 35°; when the impregnating material is carbon fiber CF and the resin is polypropylene PP, the fiber wrapping angle is 30° - 35°; when the impregnating material is glass fiber GF and the resin is nylon PA, the fiber wrapping angle is 25° - 30°; when the impregnating material is glass fiber GF and the resin is polypropylene PP, the fiber wrapping angle is 25° - 35°.

[0039] When the impregnation device provided by the above basic embodiment of the present utility model works, taking the impregnating material as fibers and the impregnating liquid as molten resin as an example, the fibers pass through at least one set of adjusting roller sets arranged from the impregnation inlet to the impregnation outlet in the impregnation channel; each set of adjusting roller sets includes a stationary roller 602, an adjusting track 603 located on the inner wall of the impregnation channel, a movable roller 601 slidably connected to the adjusting track 603, and a control mechanism 604. The adjusting track 603 extends obliquely upward or obliquely downward from the stationary roller 602. Each set of adjusting roller sets can adjust the fixed position of the movable roller 601 in the adjusting track 603 according to the required wrapping angle of the fibers through the corresponding control mechanism 604. After the position of the movable roller 601 is fixed, the fibers are wound around the surfaces of the stationary roller 602 and the movable roller 601 in sequence. The resin is injected into the impregnation channel through the resin injection port 605, so that the fibers are fully contacted and fused with the molten resin and then pass out from the impregnation outlet.

[0040] For convenience of description, the multiple sets of adjusting roller sets arranged from the impregnation inlet to the impregnation outlet are respectively called the first adjusting roller set, the second adjusting roller set, the third adjusting roller set, the fourth adjusting roller set, the fifth adjusting roller set, etc., and can be distinguished according to the number of sets provided.

[0041] When four sets of adjusting roller sets are provided in the above impregnation device, see Figures 2 - 4 , when the adjusting track 603 extends obliquely upward from the stationary roller 602, taking the impregnating material as fibers and the impregnating liquid as molten resin as an example, when the impregnation device works, the fibers penetrate from the impregnation inlet and then pass through the first adjusting roller set, the second adjusting roller set, the third adjusting roller set, and the fourth adjusting roller set arranged in sequence from the impregnation inlet to the impregnation outlet in the impregnation channel; each set of adjusting roller sets includes a stationary roller 602, a set of adjusting tracks 603 located on the inner wall of the impregnation channel, a movable roller 601 slidably connected to the adjusting track 603, and a control mechanism 604. The fibers are wound from the lower tangent of the stationary roller 602 in the first adjusting roller set to the upper tangent of the movable roller 602, and then around the lower tangent of the stationary roller 602 in the second adjusting roller set, and then around the upper tangent of the movable roller 602. The above winding method is repeated in the third adjusting roller set and the fourth adjusting roller set, so that the fibers are wound around the surfaces of the stationary roller 602 and the movable roller 601 in the five sets of adjusting roller sets in sequence, forming a W-shaped distribution. The fixed position of the movable roller 601 in the adjusting track 603 is adjusted through the control mechanism 604 in each set of adjusting roller sets to adjust the wrapping angle of the fibers. After the position of the movable roller 601 is adjusted, the fibers are penetrated, and the resin is injected into the impregnation channel through the resin injection port 605, so that the fibers are fully contacted and fused with the molten resin and then pass out from the impregnation outlet.

[0042] When there are five sets of adjusting roller groups in the above impregnating device and the adjusting track 603 extends obliquely downward from the stationary roller 602, taking the impregnating material as fibers and the impregnating liquid as molten resin as an example, when the impregnating device works, the fibers penetrate from the impregnating inlet and then pass through the first adjusting roller group, the second adjusting roller group, the third adjusting roller group, the fourth adjusting roller group and the fifth adjusting roller group which are arranged in sequence from the impregnating inlet to the impregnating outlet in the impregnating channel. Each set of adjusting roller groups includes a stationary roller 602, a set of adjusting tracks 603 located on the inner wall of the impregnating channel, a movable roller 601 slidably connected to the adjusting track 603 and a regulating mechanism 604. The fibers are wound from the upper tangent plane of the stationary roller 602 in the first adjusting roller group to the lower tangent plane of the movable roller 602, and then around the upper tangent plane of the stationary roller 602 in the second adjusting roller group, and then to the lower tangent plane of the movable roller 602. The above winding method is repeated in the third adjusting roller group, the fourth adjusting roller group and the fifth adjusting roller group, so that the laid fibers are successively wound on the surfaces of the stationary roller 602 and the movable roller 601 to form a W-shaped distribution. The fixed position of the movable roller 601 in the adjusting track 603 is adjusted by the regulating mechanism 604 in each adjusting roller group to adjust the wrapping angle of the fibers. After adjusting the position of the movable roller 601, the fibers are penetrated, and the resin is injected into the impregnating channel through the resin injection port 605, so that the fibers are fully contacted and fused with the molten resin and then pass out from the impregnating outlet.

[0043] The impregnating device provided by the utility model can change the wrapping angle of the impregnating material on the movable roller 601 in the resin injected from the resin injection port 605 by adjusting the position of the movable roller 601, thereby changing the impregnating pressure, significantly improving the impregnation degree of the thermoplastic fiber prepreg tape, reducing fiber damage and porosity, and having a wide application range.

[0044] In a specific embodiment of the present utility model, the regulating mechanism 604 includes connecting shafts located on both sides of the movable roller 601 and fasteners located outside the impregnation channel. The fasteners are arranged in one-to-one correspondence with the connecting shafts. The connecting shafts are slidably connected in the adjusting track 603 and are connected to the corresponding fasteners. The inventor found that by reserving the adjusting track 603 for the movable roller 601 on both sides inside the mold 6, both ends of the movable roller 601 are connected to the connecting shafts, and the movable roller 601 can slide in the adjusting track 603 through the connecting shafts, and then the position of the connecting shafts is fixedly connected by the fasteners passing through the side wall of the impregnation channel. Exemplarily, the fasteners include adjusting screws and nuts cooperating with the adjusting screws. The lower end of the adjusting screw passes through the side wall of the impregnation channel and is slidably connected to the connecting shaft, and the upper end of the adjusting screw passes through the side wall of the impregnation channel and is screwed and fixed on the side wall by the nut. When the nut is screwed clockwise, the gap between the screw and the nut decreases, and the movable roller 601 is fixed; when the nut is screwed counterclockwise, the gap between the screw and the nut increases, and the movable roller 601 can slide. Adjusting the position of the movable roller 601 can change the wrapping angle of the impregnating material on the movable roller 601, thereby changing the impregnation pressure, which can significantly improve the impregnation degree of the thermoplastic fiber prepreg, reduce fiber damage and porosity, and has a wide application range.

[0045] In a specific embodiment of the present utility model, the radius of the movable roller 601 and the radius R of the stationary roller 602 are each independently less than or equal to 30 mm. The inventor found that when R is less than or equal to 30 mm, by adjusting the position of the movable roller 601 to change the wrapping angle of the impregnating material on the movable roller 601, thereby changing the impregnation pressure, the impregnation degree of the thermoplastic fiber prepreg can be significantly improved, and fiber damage and porosity can be reduced.

[0046] In a specific embodiment of the present utility model, the angle α between the adjusting track 603 and the horizontal plane is 40° - 50°. The inventor found that when the angle between the adjusting track 603 and the horizontal plane is within the above range, by adjusting the position of the movable roller 601, the adjustment range of the wrapping angle of different impregnating materials can be satisfied, and the application range of the impregnation device is wider.

[0047] In a specific embodiment of the present utility model, the radius of the stationary roller 602 and the movable roller 601 in each adjusting roller group is the same. The inventor found that when the radii of the stationary roller 602 and the movable roller 601 in each adjusting roller group are different, there will be errors when adjusting the position of the movable roller 601 during the processing of different batches of impregnating materials, which will affect the impregnation effect; preferably, when the radii of the stationary roller 602 and the movable roller 601 are the same, when adjusting the position of the movable roller 601 during the processing of different batches of impregnating materials, the adjustment error is smaller, which can improve the stability of the processing performance of the impregnation device and expand the application range.

[0048] In a specific embodiment of the present utility model, the calculation formula for the wrapping angle of the impregnating material on each adjusting roll group is shown in Formula (1):

[0049]

[0050] Wherein, R represents the radii of the movable roll 601 and the fixed roll 602 in each adjusting roll group; l represents the horizontal distance between the centers of the movable roll 601 and the fixed roll 602 in this adjusting roll group; d represents the vertical distance between the centers of the movable roll 601 and the fixed roll 602 in this adjusting roll group; if the adjusting track 603 extends obliquely upward, H represents the distance between the lower tangent point of the movable roll 601 and the upper tangent point of the fixed roll 602 in this adjusting roll group; if the adjusting track 603 extends obliquely downward, H represents the distance between the upper tangent point of the movable roll 601 and the lower tangent point of the fixed roll 602 in this adjusting roll group. The inventor found that the wrapping angles in the processing of different impregnating materials satisfy the formula of Formula (1). When replacing different impregnating materials, the position of the movable roll 601 can be adjusted according to Formula (1) and the range of the wrapping angle, so as to change the wrapping angle of the impregnating material on the movable roll 601, and further change the impregnation pressure, which can significantly improve the impregnation degree of the thermoplastic fiber prepreg tape, reduce fiber damage and porosity, and has a wide application range.

[0051] In a specific embodiment of the present utility model, the change range of the wrapping angle of the impregnating material on the adjusting roll group is 20° < θ < 60°. The inventor found that when the movable roll 601 and the adjacent two fixed rolls 602 are distributed in an isosceles triangle, the change range of the wrapping angle can meet the impregnation requirements of different impregnating liquids. Exemplarily, the impregnating liquid is a molten resin, specifically it can be polyether ether ketone resin, polyarylether ketone resin, polyphenylene sulfide resin, polypropylene resin and nylon resin. Further preferably, when the movable roll 601 and the adjacent two fixed rolls 602 are distributed in an isosceles right triangle, the wrapping angle reaches the maximum range. Exemplarily, when l = 90 mm, d = 100 mm, R = 20 mm in the above Formula (1) and H > 2R, θ = 68.4° is calculated according to the formula; when 0 < H < 2R, θ = 111.6° is calculated according to the formula. It can meet the impregnation requirements of polyether ether ketone resins, polyarylether ketone resins, polyphenylene sulfide resins, polypropylene resins and nylon resins with different melt indexes. The impregnation device has a wide application range and can reduce fiber damage and porosity.

[0052] In a specific embodiment of the present utility model, when the movable roller 601 slides to the end point of the adjustment track 603 away from the fixed roller 602, the horizontal distance l between the centers of the movable roller 601 and the fixed roller 602 is less than 100 mm, and the vertical distance d between the centers of the movable roller 601 and the fixed roller 602 in the adjustment roller group is less than 150 mm. The inventor found that when the distance between the centers of adjacent movable rollers 601 and fixed rollers 602 is within the above range, the adjustment range of the movable roller 601 is larger, which can meet the processing requirements of more types of fibers and resins, can significantly improve the impregnation degree of the thermoplastic fiber prepreg tape, reduce fiber damage and porosity, and has a wide application range.

[0053] In a specific embodiment of the present utility model, multiple groups of adjustment roller groups are provided. The horizontal heights of the fixed rollers 602 in each group of adjustment roller groups are the same, and the distance between the centers of the fixed rollers 602 in adjacent adjustment roller groups is the same and less than 100 mm. The inventor found that when the fixed rollers 602 are arranged in the above positions, the cooperation between adjacent adjustment roller groups is more continuous and smooth. Exemplarily, when adjusting the positions of the movable rollers 601 in each adjustment roller group, the positions of the movable rollers 601 can be adjusted to the same position, or the positions of the movable rollers 601 can be slightly different, but they are all within the wrapping angle range of the impregnating material. The wrapping angle range can be slightly reduced or increased to change the wrapping angle of the impregnating material on the movable roller 601, thereby changing the impregnation pressure, so that the impregnation pressure of the impregnating material in each group of adjustment roller groups is the same or similar, which can significantly improve the impregnation degree of the thermoplastic fiber prepreg tape, reduce fiber damage and porosity, and has a wide application range.

[0054] The second aspect of the present utility model provides a melt impregnation system, including the impregnation device of the first aspect above. A resin injection port 605 is provided on the side wall of the impregnation channel in the melt impregnation system. In addition, the melt impregnation system further includes an extruder 7, which is correspondingly arranged above the resin injection port 605. The flow rate of the extruder 7 is adjusted according to different impregnating liquids, which is matched with the adjustment range of the wrapping angle in the mold 6, so that the impregnating liquid is evenly coated on the surface of the impregnating material, which can significantly improve the impregnation degree of the thermoplastic fiber prepreg tape, reduce fiber damage and porosity, and has a wide application range.

[0055] In a specific embodiment of the present utility model, it further includes a yarn rack 2, a pre-dispersion device 3, a preheating device 4, a yarn spreading device 5, a die 6, and a calendering device 8 arranged in sequence along the conveying direction of the impregnating material. An extruder 7 is correspondingly arranged above the die 6. The above-mentioned devices or equipment are conventional devices used in the art and can be obtained through commercial purchase. Exemplarily, taking the impregnating material as the fiber bundle 1, the fiber bundle 1 is placed on the yarn rack 2, and the pre-tension applied to the fiber bundle 1 can be adjusted by the knob on the yarn rack 2; the pre-dispersion device 3 is placed behind the yarn rack 2 to orderly arrange the fiber bundle 1 drawn out from the yarn rack 2; the preheating device 4 is placed behind the pre-dispersion device 3, and the sizing agent in the fiber bundle 1 gradually decomposes and is removed at a temperature of 200 - 350 °C; the yarn spreading device 5 is placed behind the pre-dispersion device 3. Under the reciprocating vibration of multiple hot rollers in the yarn spreading device 5, the fiber bundle 1 is split into single fiber filaments and evenly spreads on the surface of the hot rollers; the die 6 is placed behind the yarn spreading device 5, and the single fiber filaments after the dispersion of the fiber bundle 1 are in full contact with the surfaces of the movable roller 601 and the stationary roller 602 in the die 6; the single fiber filaments penetrate into the die 6 through the impregnation inlet; the single fiber filaments penetrate into the die 6 from the impregnation inlet and exit from the impregnation outlet; by adjusting the flow rate of the extruder 7 correspondingly arranged with the die 6, the resin in the extruder 7 is injected into the die 6 and spreads on the surface of the single fiber filaments. After the melted and impregnated single fiber filaments and the resin are fully fused, they exit from the impregnation outlet. After being processed by the calendering device 8 placed behind the die 6, the thickness and surface morphology of the impregnated thermoplastic fiber prepreg 12 are further optimized under the pressure of multiple calendering rollers. The impregnation pressure of the single fiber filaments inside the die 6 is adjusted and set according to the single fiber filaments, which can significantly improve the impregnation degree of the thermoplastic fiber prepreg, reduce fiber damage and porosity, and has a wide application range.

[0056] In a specific embodiment of the present utility model, the melt impregnation system further includes a cooling and cutting device 9, a traction device 10, and a winding device 11. The cooling and cutting device 9 is placed behind the calendering device 8 to obtain prepreg 12 products with different widths by cutting and trimming both sides of the thermoplastic fiber prepreg 12; the traction device 10 is placed behind the cooling and cutting device 9 to provide an adjustable traction speed and provide power for the entire pultrusion device; the winding device 11 is placed behind the traction device 10 to complete the sorting and storage of the thermoplastic fiber prepreg 12 products. By adjusting the position of the movable roller 601 to change the wrapping angle of the impregnating material on the movable roller 601, and thus changing the impregnation pressure, the impregnation degree of the thermoplastic fiber prepreg 12 can be significantly improved, fiber damage and porosity can be reduced, and it has a wide application range.

[0057] As a relatively preferred specific embodiment of the present utility model, refer to Figure 1 、 Figure 2 and Figure 5, provided is an impregnation device, including a mold 6 having an impregnation channel, one end of the impregnation channel is provided with an impregnation inlet, the other end is provided with an impregnation outlet, and 4 groups of adjusting roller sets are arranged in the impregnation channel from the impregnation inlet to the impregnation outlet; each group of adjusting roller sets includes a fixed roller 602, two adjusting tracks 603 located on the inner wall of the impregnation channel, a movable roller 601 slidably connected to the adjusting track 603, and a control mechanism 604. The adjusting track 603 extends obliquely upward from the fixed roller 602, and the angle α between the adjusting track 603 and the horizontal plane is 45°; the control mechanism 604 includes connecting shafts located on both sides of the movable roller 601 and fasteners located outside the impregnation channel. The fasteners are arranged in one-to-one correspondence with the connecting shafts. The connecting shafts are slidably connected in the adjusting track 603 and are connected to the fasteners penetrating through the side wall of the impregnation channel. The radii of the fixed roller 602 and the movable roller 601 in each group of adjusting roller sets are the same; each group of adjusting roller sets can be fixed after adjusting the position of the movable roller 601 in the adjusting track 603 according to the required coating angle of the impregnating material by the corresponding fastener; a resin injection port 605 is provided on the side wall of the impregnation channel.

[0058] When the above-mentioned impregnation device is working, it is used together with a yarn rack 2, a pre-dispersion device 3, a preheating device 4, a yarn spreading device 5, a calendering device 8, a cooling and cutting device 9, a traction device 10, and a winding device 11 arranged in sequence along the conveying direction of the impregnation material. One end of the die 6 is connected to the yarn spreading device 5, and the other end is connected to the calendering device 8. An extruder 7 is correspondingly arranged above the resin injection port 605. Taking the impregnation material as the fiber bundle 1 as an example, the fiber bundle 1 is placed on the yarn rack 2, and the pre-tension force received by the fiber bundle 1 can be adjusted through the knob on the yarn rack 2; the pre-dispersion device 3 is placed behind the yarn rack 2 to arrange the fiber bundle 1 drawn out by the yarn rack 2 in an orderly manner; the preheating device 4 is placed behind the pre-dispersion device 3, and the sizing agent in the fiber bundle 1 is gradually decomposed and removed at a temperature of 200-350 °C; the yarn spreading device 5 is placed behind the pre-dispersion device 3. Under the reciprocating vibration of the multi-stage hot rollers in the yarn spreading device 5, the fiber bundle 1 is split into single fiber filaments and evenly spreads on the surface of the hot rollers; the die 6 is placed behind the yarn spreading device 5, and the dispersed single fiber filaments of the fiber bundle 1 are in full contact with the surfaces of the movable roller 601 and the fixed roller 602 in the die 6; the single fiber filaments penetrate into the die 6 through the impregnation inlet; the single fiber filaments pass through 4 groups of adjusting roller groups arranged from the impregnation inlet to the impregnation outlet in the longitudinal impregnation channel; the single fiber filaments are wound around the surfaces of the fixed roller 602 and the movable roller 601 in sequence and then pass out from the impregnation outlet. The single fiber filaments show a "W"-shaped distribution inside the die 6; adjust the flow rate of the extruder 7 correspondingly arranged with the die 6, inject the resin in the extruder 7 into the die 6 and spread it on the surface of the single fiber filaments. After the molten-impregnated single fiber filaments and the resin are fully fused, they pass out from the impregnation outlet. After being processed by the calendering device 8 placed behind the die 6, the thickness and surface morphology of the impregnated thermoplastic fiber pre-impregnated tape 12 are further optimized under the pressure of the multi-stage calendering rollers. The cooling and cutting device 9 is placed behind the calendering device 8. By cutting and trimming both sides of the thermoplastic fiber pre-impregnated tape 12, pre-impregnated tape 12 products with different widths are obtained; the traction device 10 is placed behind the cooling and cutting device 9 to provide an adjustable traction speed and provide power for the whole pultrusion device; the winding device 11 is placed behind the traction device 10 to complete the sorting and storage of the thermoplastic fiber pre-impregnated tape 12 products.

[0059] Using the impregnation device provided by the above-mentioned preferred implementation method, as Figure 1 Figure 2 and Figure 5 shown, the thermoplastic fiber pre-impregnated tape 12 is respectively processed using carbon fiber CF and polyether ether ketone PEEK, carbon fiber CF and nylon PA, carbon fiber CF and polypropylene PP, glass fiber GF and nylon PA, and glass fiber GF and polypropylene PP as raw materials.

[0060] Adjust the position of the movable rollers 601 in the mold 6 according to different fibers and resins so that the setting range of the fiber wrapping angle after the four movable rollers 601 are fixed, the traction speed of the traction device 10, the set temperature of the preheating device 4, the set temperature of the mold 6, and the set temperature of the calendering device 8 meet the processing requirements of the corresponding fiber bundle 1 and resin. The specific process parameter settings for preparing the thermoplastic fiber prepreg with different fiber bundles 1 and resins are shown in Table 1.

[0061] Table 1

[0062]

[0063] Perform performance tests on the porosity, impregnation degree, tensile strength, and tensile modulus of the five thermoplastic fiber prepregs prepared above; the porosity is the ratio of the pore volume in the prepreg per unit volume to the total volume of the prepreg. Among them, the pore volume is the prepreg volume minus the resin volume and the fiber volume. The total volume of the prepreg is calculated from the prepreg mass and the actual density of the prepreg. The fiber volume is calculated from the fiber density and mass. The resin volume is calculated from the resin density and mass. The measurement of the impregnation degree of the prepreg is to observe the cross-section of the prepreg using a super-depth-of-field microscope (model: DSX-500, manufacturer: OLYMPUS, Japan). The impregnation degree of the prepreg is the ratio of the number of completely impregnated fiber roots per unit area to the total number of fiber roots. Five regions are randomly selected from each group of prepregs to measure the impregnation degree and the average value is taken as the impregnation degree of the prepreg. The measurement of the tensile strength and modulus is to first make the thermoplastic fiber prepreg into a measurement standard part specified in ASTM D3039 and measure it on a universal testing machine (DHY-10080). The performance test results of the above five thermoplastic fiber prepregs 12 are shown in Table 2.

[0064] Table 2

[0065] Fiber bundle / resin Porosity / % Impregnation degree / % Tensile strength / MPa Tensile modulus / GPa CF / PEEK 3-8 85-90 1500-2100 150-170 CF / PA 2-5 90-95 1600-2000 150-160 CF / PP 2-5 90-95 1500-2000 150-160 GF / PA 1-3 92-96 1500-1800 120-160 GF / PP 1-3 92-96 1500-1800 120-160

[0066] Compared with the thermoplastic fiber prepreg products with a porosity of 9%-10% prepared by traditional impregnation molds, the performance of the thermoplastic fiber prepregs processed by the impregnation device provided by the present utility model has been greatly improved in terms of the performance of the thermoplastic fiber prepregs processed from different fiber bundles 1 and resins in Table 2.

[0067] The impregnation device provided by the present utility model can significantly improve the impregnation degree of the thermoplastic fiber prepreg, reduce fiber damage and porosity by changing the wrapping angle by changing the position of the movable rollers, and has a wide application range.

[0068] The preferred embodiments of the present utility model have been described in detail above. However, the present utility model is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present utility model, various simple modifications can be made to the technical solutions of the present utility model, and these simple modifications all fall within the protection scope of the present utility model.

[0069] In addition, it should be noted that, in the various specific technical features described in the above specific embodiments, they can be combined in any appropriate manner without contradiction. To avoid unnecessary repetition, the present utility model will not separately describe various possible combination methods.

[0070] Furthermore, any combination can be made between various different embodiments of the present utility model, as long as it does not violate the idea of the present utility model, and it should also be regarded as the content disclosed by the present utility model.

Claims

1. An impregnation device, comprising a mold (6) having an impregnation channel, wherein one end of the impregnation channel is provided with an impregnation inlet and the other end is provided with an impregnation outlet, characterized in that: At least one group of adjusting roller groups is arranged in the impregnation channel from the impregnation inlet to the impregnation outlet, and each group of the adjusting roller groups includes a stationary roller (602), an adjusting track (603) located on the inner wall of the impregnation channel, a movable roller (601) slidably connected to the adjusting track (603), and a regulating mechanism (604), the adjusting track (603) extending obliquely upward or obliquely downward from the stationary roller (602), and each of the adjusting roller groups can adjust the position of the movable roller (601) in the adjusting track (603) through the corresponding regulating mechanism (604) to adjust the wrapping angle of the impregnating material on the adjusting roller group; a resin injection port (605) is provided on the side wall of the impregnation channel.

2. The impregnation device according to claim 1, characterized in that The regulating mechanism (604) comprises connecting shafts located on both sides of the movable roller (601) and fasteners located outside the impregnation channel, wherein the fasteners are arranged in a one-to-one correspondence with the connecting shafts, and the connecting shafts are slidably connected in the regulating track (603) and connected to the corresponding fasteners.

3. The impregnation device according to claim 1, characterized in that The radius R of the movable roller (601) and the radius R of the stationary roller (602) are each independently less than or equal to 30 mm.

4. The impregnation device according to claim 1, characterized in that The included angle α between the adjustment track (603) and the horizontal plane is 40°-50°.

5. The impregnation device according to any one of claims 1 to 4, characterized in that The radius of the stationary roller (602) and the movable roller (601) in each adjusting roller group is the same; The calculation formula of the covering angle of the impregnating material on each of the adjusting roller groups is shown in formula (1): Wherein, R represents the radius of the movable roller (601) and the fixed roller (602) in each adjustment roller group; l represents the horizontal distance between the center of the movable roller (601) and the center of the fixed roller (602) in the adjusting roller group; d represents the vertical distance between the center of the movable roller (601) and the center of the fixed roller (602) in the adjusting roller group; If the adjustment track (603) extends upwardly at an angle, H represents the distance between the lower tangent point of the movable roller (601) and the upper tangent point of the fixed roller (602) in the adjustment roller group; If the adjustment track (603) extends downwardly at an angle, H represents the distance between the upper tangent point of the movable roller (601) and the lower tangent point of the stationary roller (602) in the adjustment roller group.

6. The impregnation device according to claim 5, characterized in that The coverage angle of the impregnating material on the adjusting roller set varies in the range of 20°<θ<60°.

7. The impregnation device according to any one of claims 1 to 4, characterized in that When the movable roller (601) slides to the end point of the adjustment track (603) away from the stationary roller (602), the horizontal distance l between the center of the movable roller (601) and the center of the stationary roller (602) is less than 100 mm, and the vertical distance d between the center of the movable roller (601) and the center of the stationary roller (602) in the adjustment roller group is less than 150 mm.

8. The impregnation device according to any one of claims 1 to 4, characterized in that There are multiple groups of adjusting roller groups, the horizontal heights of the stationary rollers (602) in each group of adjusting roller groups are the same, and the distances between the centers of the stationary rollers (602) in adjacent adjusting roller groups are the same and less than 100 mm.

9. A melt impregnation system, characterized in that: The impregnation device comprises the impregnation device according to any one of claims 1 to 8.

10. The melt impregnation system according to claim 9, characterized in that The melt impregnation system also includes a yarn rack (2), a pre-dispersing device (3), a preheating device (4), and a yarn spreading device (5) which are connected in sequence along the conveying direction of the impregnating material; one end of the mold (6) is connected to the yarn spreading device (5) and the other end is connected to the calendering device (8); an extruder (7) is correspondingly arranged above the resin injection port (605).

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