Preparation device of continuous fiber reinforced thermoplastic resin composite material

Abstract

The utility model relates to a device for preparing a continuous fiber reinforced thermoplastic resin composite material. The device comprises a traction unit, a solution dipping unit, a pressure applying unit and a drying unit, the traction unit comprises a continuous fiber leading-in end and a composite material leading-out end which are oppositely arranged; under the action of the continuous fiber leading-in end, continuous fibers can be sequentially subjected to dipping treatment through the dipping unit, extrusion treatment through the pressure applying unit and drying treatment through the drying unit. According to the preparation device of the continuous fiber reinforced thermoplastic resin composite material disclosed by the embodiment of the utility model, the continuous fiber reinforced thermoplastic resin composite material with high fiber content and better mechanical property can be prepared.

Description

TECHNICAL FIELD

[0001] The utility model relates to the preparation device of high molecule composite material especially continuous fiber reinforced thermoplastic resin composite material's preparation device. BACKGROUND

[0002] In recent years, continuous fiber reinforced thermoplastic composite (CFRTP) as a kind of high-performance composite material has been rapidly developed. It is to use continuous fiber as reinforcing material, thermoplastic resin as matrix, and use the process of thermoplastic resin melting impregnation fiber to prepare high-strength, high-rigidity, high-toughness composite material. Continuous fiber includes continuous glass fiber, carbon fiber, aramid fiber and basalt fiber and other reinforcing materials, and thermoplastic resin mainly includes PP (polypropylene), PE (polyethylene), PA6 (polyamide 6), PET (polyethylene terephthalate) and other thermoplastic resins. Compared with traditional thermosetting composite material, CFRTP has the advantages of easy forming, light weight, high strength and toughness, recyclability, heat resistance, creep resistance and excellent dimensional stability, which can meet the requirements of various practical applications on material performance, and has wide application prospect in automobile industry, construction, aerospace, military industry and other fields.

[0003] At present, the preparation process of continuous fiber reinforced thermoplastic composite prepreg in China basically adopts the method of thermoplastic resin melting impregnation fiber. The adopted impregnation method is resin melting coating impregnation. This impregnation method is simple and convenient to clean, but for PEI (polyetherimide), PPS (polyphenyl sulfide), PES (polyether sulfone resin), PSF (polysulfone), PEEK (polyether ether ketone resin) and high-melting temperature and high-processing viscosity thermoplastic resin such as high-temperature-resistant PA (polyamide), it is difficult to obtain resin-dispersed, impregnated prepreg through this method. Because the viscosity of molten resin is high, its fluidity and permeability are poor, and the fiber is difficult to be fully impregnated, which is easy to produce dry yarn, so that the fiber content of continuous fiber reinforced composite material is low, and the mechanical properties are poor, thereby limiting the application of matrix resin in continuous fiber reinforced composite material. SUMMARY

[0004] In order to overcome at least one defect of the prior art, in a first aspect, an embodiment of the utility model provides a kind of preparation device of continuous fiber reinforced thermoplastic resin composite material, including traction unit, solution impregnation unit, pressure applying unit and drying unit;The traction unit includes the continuous fiber introduction end and the composite material exit end of opposite arrangement;Under the action of the continuous fiber introduction end, continuous fiber can be impregnated in sequence through the impregnation unit, be extruded through the pressure applying unit, and be dried through the drying unit.

[0005] According to an embodiment of the present application, the solution impregnation unit comprises an impregnation box and at least one yarn spreading roller arranged in the impregnation box, the yarn spreading roller being used to apply tension to the continuous fiber.

[0006] According to an embodiment of the present application, a heat circulation structure for heating the impregnation solution is arranged in the impregnation box; and / or,

[0007] A vibration structure is arranged on the yarn spreading roller.

[0008] According to an embodiment of the present application, the impregnation box comprises a box body and a sealing cover which is openably and closably connected to the box body.

[0009] According to an embodiment of the present application, at least one guide roller is arranged on the box body, for guiding the movement of the continuous fiber in the impregnation box.

[0010] According to an embodiment of the present application, the pressure applying unit comprises at least two extrusion rollers, each two of the extrusion rollers being oppositely and spacedly arranged, and the continuous fiber being capable of passing between the oppositely arranged two extrusion rollers.

[0011] According to an embodiment of the present application, recesses and protrusions capable of being mutually engaged are respectively arranged on the oppositely arranged two extrusion rollers.

[0012] According to an embodiment of the present application, the drying unit comprises a drying box and a heating structure, the heating structure being used to adjust the temperature of the drying box; and / or,

[0013] The preparation device further comprises a solution recovery unit, the solution recovery unit being oppositely arranged with the pressure applying unit, for collecting the solution from the pressure applying unit.

[0014] According to an embodiment of the present application, a solvent recovery tank and a vacuum pump are arranged on the drying box; and / or,

[0015] At least one guide wheel is arranged in the drying box, and the continuous fiber passes through the guide wheel.

[0016] According to an embodiment of the present application, opposite ends of the solution recovery unit are respectively in communication with the solution impregnation unit and the drying unit.

[0017] The preparation device for the continuous fiber reinforced thermoplastic resin composite material according to an embodiment of the present application can prepare the continuous fiber reinforced thermoplastic resin composite material with high fiber content and relatively excellent material mechanical properties. BRIEF DESCRIPTION OF DRAWINGS

[0018] The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this invention.

[0019] in:

[0020] Figure 1 This is a schematic diagram of the apparatus for preparing continuous fiber reinforced thermoplastic resin composite material according to one embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the traction unit, solution impregnation unit, pressure application unit, and drying unit according to one embodiment of the present invention.

[0022] Figure 3 This is a schematic diagram of the apparatus for preparing a continuous fiber reinforced thermoplastic resin composite material according to another embodiment of the present invention.

[0023] Figure 4 This is a schematic diagram of the traction unit, solution impregnation unit, pressure application unit, drying unit, and solution recovery unit according to one embodiment of the present invention.

[0024] The annotations in the attached figures are explained as follows:

[0025] 001, Continuous fiber inlet end; 002, Composite material outlet end; 003, Input guide roller; 004, Output guide roller; 100, Solution impregnation unit; 200, Pressure application unit; 300, Drying unit; 400, Solution recovery unit; 101, Impregnation tank; 102, Spreading roller; 201, Upper extrusion roller; 202, Lower extrusion roller; 301, Drying box; 302, Guide roller; 303, Solvent recovery tank; 304, Vacuum pump; 401, Glue splicing tank. Detailed Implementation

[0026] Typical embodiments embodying the features and advantages of this utility model will be described in detail in the following description. It should be understood that this utility model can have various variations in different embodiments, all of which do not depart from the scope of this utility model, and the description herein is essentially for illustrative purposes and not intended to limit this utility model. Identical components are denoted by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the drawings. The terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0027] Reference Figure 1As shown, one embodiment of this utility model provides a preparation device for a continuous fiber reinforced thermoplastic resin composite material, including a traction unit, a solution impregnation unit 100, a pressure application unit 200, and a drying unit 300; wherein, the traction unit includes a continuous fiber inlet end 001 and a composite material outlet end 002 arranged opposite to each other; the continuous fiber passes sequentially from the continuous fiber inlet end 001 through the solution impregnation unit 100, the pressure application unit 200, the drying unit 300, and the composite material outlet end 002.

[0028] In one embodiment, the traction unit is used to traction the continuous fiber between the continuous fiber inlet end 001 and the composite material outlet end 002, and to make the continuous fiber pass through the solution impregnation unit 100, the pressure application unit 200 and the drying unit 300 in sequence.

[0029] In one embodiment, continuous fibers enter the solution impregnation unit 100 from the continuous fiber inlet end 001. The solution impregnation unit 100 is used to impregnate the continuous fibers with a solution to obtain continuous fibers (or impregnated fibers) with the solution attached. The solution is a resin solution.

[0030] In one embodiment, a resin solution may be provided in the solution impregnation unit 100 for solution impregnation. The resin solution includes a thermoplastic resin (e.g., polyamide) and a solvent. Further, the resin solution may also include other raw materials, such as additives, including one or more of flame retardants, nucleating agents, reinforcing agents, and other auxiliaries.

[0031] In one embodiment, the pressure unit 200 is used to squeeze the impregnated fiber so that the solution is uniformly attached to the continuous fiber and to remove excess resin solution to obtain the impregnated and pressed fiber.

[0032] In one embodiment, the drying unit 300 is used to dry the impregnated and pressed fibers so that the continuous fibers and the solution (the impregnated and pressed fibers) form an integral structure of continuous fiber reinforced thermoplastic resin composite material, and the resulting composite material is output from the lead-out end 002.

[0033] In one embodiment, the aforementioned apparatus for preparing continuous fiber reinforced thermoplastic resin composite materials is used to prepare continuous fiber reinforced thermoplastic composite materials via solution impregnation. Specifically, a resin solution of a certain concentration is prepared by mixing thermoplastic resin and solvent. When the continuous fibers pass through the solution impregnation unit 100, the thermoplastic resin is uniformly adhered to the continuous fibers. Excess resin solution is then removed by the pressure application unit 200, and the solvent is removed by the drying unit 300, thereby obtaining a composite material in which the resin is uniformly distributed throughout the continuous fibers. The use of this apparatus or method is of great significance for reducing the resin viscosity during the impregnation process, increasing the glass fiber content of the composite material, and improving the mechanical properties of the composite material.

[0034] In one implementation, reference Figure 2 As shown, the solution impregnation unit 100 includes an impregnation tank 101 and a spreading roller 102.

[0035] In one embodiment, the solution impregnation unit 100 includes an impregnation tank 101 and at least one spreading roller 102 disposed within the impregnation tank 101. The spreading roller 102 applies tension to the continuous fibers, thereby tightening the continuous fibers and preventing them from agglomerating in the resin solution. A thermal circulation structure may be provided within the impregnation tank 101 to control the temperature of the solution within the impregnation unit, resulting in better impregnation of the continuous fibers.

[0036] In one embodiment, the spreading roller 102 is detachably connected to the impregnation tank 101, and during operation, the spreading roller 102 is located in the impregnation solution.

[0037] In one embodiment, there are multiple spreading rollers 102, which are staggered (or offset) within the impregnation tank 101 along the direction of continuous fiber movement. Adjacent spreading rollers 102 have a certain gap to allow for adjustment during production. Preferably, the multiple spreading rollers 102 are arranged in two rows: an upper spreading roller located above and a lower spreading roller located below. The upper and lower spreading rollers are staggered, and during operation, the continuous fiber sequentially passes over the upper spreading roller and then over the lower spreading roller.

[0038] In one embodiment, the thermal circulation structure includes, but is not limited to, a hydrothermal circulation structure, such as a circulating water pipe installed on the impregnation tank 101, which uses water as a medium to heat or cool the resin solution.

[0039] In one embodiment, a temperature display structure is provided inside the impregnation tank 101, which can acquire the temperature of the resin solution inside the impregnation tank 101 in real time; the temperature display structure is used in conjunction with the heat circulation structure to keep the resin solution inside the impregnation tank 101 within a suitable temperature range.

[0040] In one embodiment, a stirring structure is provided inside the impregnation tank 101. The stirring structure can keep the concentration of the resin solution in the impregnation tank 101 uniform, so as to obtain a better impregnation effect for the continuous fibers.

[0041] In one embodiment, a yarn guiding structure is provided inside the impregnation tank 101. The yarn guiding structure and the yarn spreading roller 102 are both connected to the inner wall of the impregnation tank 101 to adjust the height of the yarn spreading roller 102.

[0042] In one embodiment, a vibration structure is provided on the yarn spreading roller 102, which can enhance the vibration amplitude and frequency of the yarn spreading roller 102, thereby further improving the yarn spreading effect.

[0043] In one embodiment, the material of the spreading roller 102 includes one or more of 316 stainless steel, 316L stainless steel, 2205 stainless steel and Hastelloy, preferably 316L stainless steel.

[0044] In one embodiment, the impregnation tank 101 includes a tank body and a sealing cover closable on the tank body. The tank body is used to contain the resin solution, and the sealing cover is closable on the tank body to enable opening and closing of the tank body. When the sealing cover is open, it facilitates operation by personnel, such as adding resin solution. When the sealing cover is closed, it effectively prevents the odor of the resin solution from spreading to the outside and prevents impurities in the air from entering the resin solution, avoiding contamination. It also prevents the solvent in the resin solution from evaporating too quickly, which would increase the viscosity of the resin solution and affect the impregnation effect of continuous fibers.

[0045] In one embodiment, a sealing cover is provided on the body of the impregnation tank 101 to seal the opening of the tank as a whole. The sealing cover can be partially opened, or a through hole is provided on the sealing cover to guide the continuous fibers in and out, so that the continuous fibers can enter and exit the impregnation tank 101.

[0046] In another embodiment, the impregnation tank 101 has two through holes on its body to guide continuous fibers in and out, and a sealing cover is used to seal the through holes.

[0047] In one embodiment, at least one guide roller is provided on the box body along the direction of continuous fiber movement. Adjacent guide rollers have a certain gap to allow for adjustment during production. The guide rollers guide the movement of the continuous fiber within the impregnation box 101 so that the continuous fiber can pass through the impregnation box 101 effectively and achieve sufficient impregnation.

[0048] In one embodiment, there are multiple guide rollers, which are staggered in the impregnation tank 101 (i.e., around the perimeter) along the direction of continuous fiber movement, with a certain gap between adjacent guide rollers to allow for adjustment during production.

[0049] In one implementation, reference Figure 4 As shown, there are two guide rollers, namely input guide roller 003 and output guide roller 004. Input guide roller 003 and output guide roller 004 are respectively set at opposite ends of the impregnation tank 101 along the continuous fiber movement direction. Input guide roller 003 is used to introduce the continuous fiber into the impregnation tank 101, and output guide roller 004 is used to lead the impregnated fiber out of the impregnation tank 101.

[0050] In one embodiment, the guide roller is made of one or more of the following materials: 316 stainless steel, 316L stainless steel, 2205 stainless steel, 304 stainless steel, Hastelloy, PE, PP and PTFE, preferably 316L stainless steel or PP.

[0051] In one embodiment, the pressure application unit 200 includes at least two extrusion rollers, each pair of rollers being disposed opposite to and spaced apart from each other, and respectively disposed on opposite sides of the continuous fiber. The continuous fiber coated with resin solution is passed between the two extrusion rollers to remove excess resin solution from the continuous fiber. This process can also be used to control the thickness of the resin solution on the continuous fiber, thereby controlling the thickness of the continuous fiber reinforced thermoplastic resin composite material.

[0052] Reference Figure 2 , 4 As shown, in one embodiment, the number of extrusion rollers can be adjusted according to the length of the continuous fiber. The longer the continuous fiber, the more extrusion rollers are used, with a minimum of two. Each pair of extrusion rollers forms a group, located on opposite sides of the continuous fiber. The extrusion roller located above the continuous fiber is the upper extrusion roller 201, and the extrusion roller located below the continuous fiber is the lower extrusion roller 202. There is a certain distance between the upper extrusion roller 201 and the lower extrusion roller 202, which can be 0.1 to 2 mm.

[0053] In one embodiment, the material of the extrusion roller includes one or more of 316 stainless steel, 316L stainless steel, 2205 stainless steel, 304 stainless steel, Hastelloy, PE, PP and PTFE, preferably 316L stainless steel or PP.

[0054] In one embodiment, grooves and protrusions that can mesh with each other are provided on two oppositely arranged extrusion rollers. The grooves and protrusions extend along the axial direction of the extrusion rollers. After impregnation, the fibers pass through the extrusion rollers with grooves and protrusions, which further plays a role in separating and evenly distributing the yarn, preventing the accumulation of impregnated fibers and avoiding uneven quality of subsequent products.

[0055] In one embodiment, the surfaces of the upper extrusion roller 201 and the lower extrusion roller 202 are respectively provided with interlocking grooves and protrusions along the axial direction.

[0056] In one embodiment, the drying unit 300 includes a drying chamber 301 and a heating structure. A solvent recovery tank 303 and a vacuum pump 304 are installed on the drying chamber 301. The heating structure regulates the temperature inside the drying chamber 301, and the vacuum pump 304 maintains a relative vacuum environment in the drying chamber 301, allowing the heating process of the continuous fibers by the drying unit 300 to be carried out under vacuum conditions, thereby improving the heat treatment quality. The solvent recovery tank 303 can be located at the top or upper-middle part of the drying chamber 301. During the drying process, solvent evaporates, and the evaporated solvent is recovered through the solvent recovery tank 303 for subsequent use.

[0057] In one embodiment, the heating structure is disposed within the drying chamber 301. The heating structure includes one or more of the following: an oil bath heating structure, an infrared heating structure, and an electric heating structure. For example, an oil bath heating structure is used, in which multiple uniformly distributed metal conduits are arranged within the drying chamber 301, and circulating heat-conducting oil is used to heat the metal conduits, drying the impregnated and pressed fibers through heat convection. Using an oil bath heating structure for drying results in uniform heating and a good drying effect.

[0058] In one embodiment, at least one guide roller 302 is provided inside the drying chamber 301, through which continuous fibers pass. The guide roller 302 is used to guide the direction of the continuous fibers. By adding the guide roller 302, the moving distance of the continuous fibers in the drying chamber 301 can be extended, the drying time can be increased, and thus the drying rate can be improved.

[0059] In one embodiment, there are multiple guide rollers 302, which are staggered along the direction of continuous fiber movement within the drying chamber 301. Adjacent guide rollers 302 have a certain gap to allow for adjustment during production. The impregnated and pressed fibers pass sequentially through the guide rollers 302 and are reciprocated within the drying chamber 301, increasing the drying time.

[0060] In one embodiment, a ceramic layer or a self-lubricating layer is provided on at least one surface of the guide wheel 302. The ceramic or self-lubricating material has low frictional force, and the impregnated fibers contact the ceramic layer or self-lubricating layer of the guide wheel 302, thereby reducing friction in the drying device. Other coatings with frictional forces comparable to those of the ceramic layer may also be provided on the surface of the guide wheel 302.

[0061] In one embodiment, the guide wheel 302 is made of one or more of the following materials: 316 stainless steel, 316L stainless steel, 2205 stainless steel, 304 stainless steel, Hastelloy, PE, PP and PTFE. It may also be made of ceramic or self-lubricating materials.

[0062] In one implementation, reference Figure 3As shown, the apparatus for preparing continuous fiber reinforced thermoplastic resin composites includes a traction unit, a solution impregnation unit 100, a pressure application unit 200, a drying unit 300, and a recovery unit 400.

[0063] In one embodiment, the solution recovery unit 400 is disposed opposite to the pressure unit 200, that is, the solution recovery unit 400 is located below the pressure unit 200. The solution recovery unit 400 can receive excess resin solution squeezed out from the continuous fiber by the pressure unit 200 for reuse.

[0064] In one embodiment, the solution recovery unit 400 is connected to the solution impregnation unit 100 and the drying unit 300 at opposite ends, respectively. That is, the solution recovery unit 400 is located between the drying chamber 301 and the impregnation chamber 101, with one end connected to the drying chamber 301 and the other end connected to the impregnation chamber 101. A solvent recovery tank 303 is provided on the drying chamber 301 to recover the resin solution volatilized in the drying chamber 301 and transport it to the solution recovery unit 400. All the collected resin solution can be transported to the impregnation chamber 101 through the solution recovery unit 400 for recycling.

[0065] In one implementation, reference Figure 4 As shown, the solution recovery unit 400 includes a glue receiving tank 401.

[0066] In one embodiment, the glue receiving tank 401 is inclinedly disposed between the drying chamber 301 and the impregnation chamber 101, and is located below (e.g., directly below) the pressure application unit 200; the two ends of the glue receiving tank 401 are respectively connected to the drying chamber 301 and the impregnation chamber 101, and the end connected to the drying chamber 301 is higher than the end connected to the impregnation chamber 101, so that the resin solution in the glue receiving tank 401 can enter the impregnation chamber 101 by its own weight.

[0067] In one embodiment, the glue receiving tank 401 has an opening with a slope. The opening of the glue receiving tank 401 is connected to the impregnation tank 101 without gap. The resin solution squeezed out by the upper extrusion roller 201 and the lower extrusion roller 202 can flow into the glue receiving tank 401 along the slope of the opening of the glue receiving tank 401 and finally return to the impregnation tank 101 for recycling.

[0068] According to one embodiment of the present invention, a preparation apparatus for a continuous fiber reinforced thermoplastic resin composite material is described. During operation, continuous fibers enter the solution impregnation unit 100 through the continuous fiber inlet end 001 and enter the impregnation tank 101 through the input guide roller 003. After solution impregnation in the impregnation tank 101, impregnated fibers are obtained. The impregnated fibers are then led out of the impregnation tank 101 through the output guide roller 004. Then, the impregnated fibers are squeezed by the upper extrusion roller 201 and the lower extrusion roller 202 to obtain impregnated and pressed fibers. After that, the impregnated and pressed fibers are introduced into the drying oven 301 for vacuum heating and drying. Finally, under the traction of the guide roller 302, they enter the composite material outlet end 002 to obtain a continuous fiber reinforced thermoplastic resin prepreg yarn.

[0069] One embodiment of this utility model provides a method for preparing a continuous fiber reinforced thermoplastic resin composite material, comprising the following steps:

[0070] Continuous fibers are impregnated in a resin solution to obtain impregnated fibers.

[0071] The impregnated fibers are extruded to obtain impregnated and bonded fibers; and

[0072] The fibers that have been impregnated and pressed are dried to obtain a continuous fiber reinforced thermoplastic resin composite material.

[0073] The method for preparing a continuous fiber-reinforced thermoplastic resin composite material according to one embodiment of this utility model can be implemented using the above-described preparation apparatus. Further, the impregnation treatment can be performed in the solution impregnation unit 100, the extrusion treatment can be performed in the pressure application unit 200, and the drying treatment can be performed in the drying unit 300.

[0074] In one embodiment, the resin solution used for impregnating the continuous fibers comprises a polyamide resin, wherein the mass content of the polyamide resin in the resin solution can be 3 to 25 wt%, more preferably 8 to 15 wt%, for example 4 wt%, 5 wt%, 9 wt%, 10 wt%, 11 wt%, 12 wt%, 13 wt%, 14 wt%, 15 wt%, 18 wt%, 20 wt%, 21 wt%, or 22 wt%.

[0075] In one embodiment, the resin solution includes a polyamide resin and optional additives, which may be one or more of flame retardants, nucleating agents, and reinforcing agents.

[0076] In one embodiment, the monomers for preparing the polyamide resin contained in the resin solution include a diamine and a diacid. The diamine may be an aliphatic diamine containing 4 to 6 carbon atoms, and the diacid may include one or more of an aliphatic diacid containing 6 to 8 carbon atoms and an aromatic diacid containing 8 to 10 carbon atoms.

[0077] In one embodiment, the diamine used to prepare the polyamide resin may be pentanediamine.

[0078] In one embodiment, the aromatic dicarboxylic acid used to prepare the polyamide resin may be one or more of terephthalic acid, phthalic acid, and isophthalic acid.

[0079] In one embodiment, the polyamide resin can be one or more of PA56T resin, PA56 resin, PA56TI resin, and PA5T66 resin. Specifically, PA56T resin is obtained by copolymerizing pentanediamine, adipic acid, and terephthalic acid; PA56 resin is obtained by copolymerizing pentanediamine and adipic acid; PA56TI resin is obtained by copolymerizing pentanediamine, adipic acid, terephthalic acid, and isophthalic acid; and PA5T66 resin is obtained by copolymerizing pentanediamine, hexamethylenediamine, terephthalic acid, and adipic acid.

[0080] In one embodiment, the relative viscosity of the polyamide resin can be 2.0 to 2.6, more preferably 2.2 to 2.5, for example 2.2, 2.3, 2.4, 2.5.

[0081] In one embodiment, the melting point of the polyamide resin can be 200-300°C, and more specifically 250-270°C, for example 210°C, 230°C, 255°C, 258°C, 260°C, 262°C, 265°C, 268°C, 290°C, 295°C, or 297°C.

[0082] In one embodiment, during the preparation of the continuous fiber reinforced thermoplastic resin composite material, the temperature of the impregnation tank 101 of the solution impregnation unit 100, or the temperature at which the continuous fibers are solution impregnated, can be 18–45°C, more specifically 35–40°C, for example, 20°C, 25°C, 30°C, 36°C, 37°C, or 38°C. Maintaining the impregnation temperature within the above range ensures good uniformity of the resin solution, thereby resulting in more uniform impregnation of the fibers.

[0083] In one embodiment, during the preparation of the continuous fiber reinforced thermoplastic resin composite material, the continuous fibers are sequentially subjected to impregnation, extrusion, and drying treatments by the traction action of the traction unit. The traction speed of the traction unit is 2–150 m / min, and can be further 2–120 m / min, for example 4 m / min, 9 m / min, 10 m / min, 11 m / min, 15 m / min, 19 m / min, 20 m / min, 21 m / min, 25 m / min, 29 m / min, 30 m / min, 31 m / min, 35 m / min, 39 m / min, 40 m / min, 41 m / min, 44 m / min, 45 m / min, 46 m / min, 80 m / min, 85 m / min, 90 m / min, 110 m / min, 115 m / min, 120 m / min, 130 m / min, and 140 m / min.

[0084] In one embodiment, during the preparation of the continuous fiber reinforced thermoplastic resin composite material, the temperature of the drying unit 300 or the temperature at which the impregnated and pressed fibers are dried can be 170 to 225°C, for example, 175°C, 185°C, 195°C, 205°C, 215°C, or 220°C.

[0085] In one embodiment, the continuous fiber reinforced thermoplastic resin composite material can be a continuous fiber reinforced thermoplastic resin prepreg yarn.

[0086] In one embodiment, the continuous fiber used for impregnation with the resin solution can be glass fiber.

[0087] In one embodiment, the continuous fiber used to prepare the continuous fiber reinforced thermoplastic resin composite material is glass fiber, and the mass content of glass fiber in the composite material can be 70-97%, more preferably 80-90%, for example 72%, 73%, 75%, 79%, 82%, 84%, 85%, 86%, 87%, 88%, 91%, 93%, 94%, and 95%.

[0088] In one embodiment, the flexural modulus of the continuous fiber reinforced thermoplastic resin composite material can be 40-65 GPa, for example 43 GPa, 44 GPa, 45 GPa, 46 GPa, 50 GPa, 53 GPa, 54 GPa, 55 GPa, 56 GPa, 57 GPa, 58 GPa, 60 GPa, 61 GPa, 62 GPa, or 63 GPa.

[0089] In one embodiment, the flexural strength of the continuous fiber reinforced thermoplastic resin composite material can be 880–1330 MPa, for example, 880 MPa, 886 MPa, 890 MPa, 900 MPa, 950 MPa, 952 MPa, 953 MPa, 956 MPa, 957 MPa, 1000 MPa, 1020 MPa, 1021 MPa, 1022 MPa, 1030 MPa, 1063 MPa, 1064 MPa, 1100 MPa, 1200 MPa, 1262 MPa, 1263 MPa, 1270 MPa, 1287 MPa, 1288 MPa, 1300 MPa, 1310 MPa, 1313 MPa, 1314 MPa, 1327 MPa, and 1328 MPa.

[0090] In one embodiment, the glass fiber content deviation of the continuous fiber reinforced thermoplastic resin composite is less than 2.5 wt%, and more preferably less than 2 wt%.

[0091] In one embodiment, the flexural modulus of the continuous fiber reinforced thermoplastic resin composite material is above 40 GPa, and more particularly above 50 GPa.

[0092] In one embodiment, the flexural strength of the continuous fiber reinforced thermoplastic resin composite material is above 880 MPa, and more particularly above 1000 MPa.

[0093] One embodiment of this utility model provides the application of the above-mentioned continuous fiber reinforced thermoplastic resin composite material in the preparation of pultruded products.

[0094] In one embodiment, a pultruded product is obtained by pultruding a raw material, the raw material including the aforementioned continuous fiber-reinforced thermoplastic resin composite material. Further, the pultruded product can be a hollow or shaped article.

[0095] In one embodiment, the pultrusion process (or pultrusion process) can be an existing process, such as forming and curing prepreg yarn through an extrusion die under traction.

[0096] Existing technologies use melt impregnation to prepare continuous fiber reinforced thermoplastic composites. However, due to the high melting temperature and high viscosity of thermoplastic resins, the resulting continuous fiber reinforced composites typically have low fiber content and poor mechanical properties. One embodiment of this invention provides an apparatus / method for preparing continuous fiber reinforced thermoplastic resin composites. The method involves preparing the composite material through solution impregnation (or a solution impregnation unit), allowing the thermoplastic resin to adhere uniformly to the continuous fibers. Excess resin solution is then removed by a pressure unit (or extrusion treatment), and the solvent is removed by a drying unit (or drying treatment), resulting in a composite material with resin uniformly distributed throughout the continuous fibers. Furthermore, this method is significant for reducing resin viscosity during impregnation, increasing the glass fiber content of the composite material, and improving its mechanical properties.

[0097] The preparation of a continuous fiber reinforced thermoplastic composite material (continuous glass fiber / thermoplastic polyamide resin prepreg yarn) according to one embodiment of the present invention will be further described below with reference to the accompanying drawings and specific embodiments. In Example 1, a method using... Figure 4 The preparation apparatus shown prepares continuous glass fiber / thermoplastic polyamide resin prepreg yarn; the continuous fiber used in Example 1 and Comparative Example 1 is continuous glass fiber with a linear density of 1200 tex.

[0098] The test methods involved in Example 1 and Comparative Example 1 are as follows:

[0099] Test method

[0100] 1. Bending performance test

[0101] The full performance of fiber-reinforced plastics was tested according to GB / T 1449-2005 Test Method for Bending Properties. The impregnated yarn sheet sample was prepared according to the method. In the three-point bending test, the sample size was 80mm×10mm×4mm (length×width×thickness) and the test span was 64mm. The sample showed interlaminar shear failure. The sample with obvious internal defects or failure beyond the middle third should be discarded. There should be no less than 5 valid samples in the same batch.

[0102] 2. Glass fiber content test

[0103] The glass fiber content was tested according to the calcination method of ISO 1172: the glass fiber content was obtained by calculating the difference between the mass of the calcined sample and the mass of the dried sample. The specific process was as follows: weigh the clean and dry crucible, and record the mass in grams as m1; place the sample in the crucible and dry it in a ventilated drying oven at 105℃ to a constant mass, cool it to room temperature in a desiccator and weigh it again and record the mass as m2; calcine it at a constant temperature of 700℃ for 120 min in a muffle furnace, and then cool the residue and the crucible together in a desiccator to room temperature and weigh it as m3. Each group of test samples had at least two samples, the mass of the samples was in the range of 2 to 10 g, and the difference between the measured values ​​was less than 5%. The glass fiber content M of each sample was calculated using equation (1). glass .

[0104]

[0105] When testing the glass fiber content of the prepreg yarn obtained in Example 1 or Comparative Example 1, samples were taken every 50m from the initial winding of the prepreg yarn, resulting in 20 sets of samples. The length of the prepreg yarn in each sample was 10±0.5m. The standard deviation σ of the glass fiber content of the prepreg yarn was calculated using equation (2), which represents the stability of the glass fiber content of the prepreg yarn. Where M i The glass fiber content value for each group of samples. is the average glass fiber content of all samples, and n is the number of sampling groups.

[0106]

[0107] 3. Relative viscosity (ηr) test of resin

[0108] Ubbelohde viscometer concentrated sulfuric acid method: Accurately weigh 0.5±0.0002g of dried polyamide resin sample, add 50mL of concentrated sulfuric acid (96%) to dissolve it to obtain a polyamide solution, measure and record the flow time t0 of concentrated sulfuric acid and the flow time t of polyamide solution in a constant temperature water bath at 25℃.

[0109] Relative viscosity calculation formula:

[0110] The relative viscosity ηr = t / t0.

[0111] Example 1

[0112] (1) A certain mass of polyamide resin (PA56T resin, melting point 260℃, relative viscosity 2.35) was dissolved in 85wt% formic acid aqueous solution and stirred thoroughly to obtain a polyamide resin solution with a polyamide content of 10wt%.

[0113] (2) Add the polyamide resin solution prepared in step (1) into the impregnation tank 101 of the solution impregnation unit 100 and set the temperature of the impregnation tank to 37°C; start pulling the continuous fiber from the inlet end 001, and sequentially pass through the solution impregnation unit 100, the pressure unit 200 and the drying unit 300 for corresponding treatment, and finally output it from the composite material outlet end 002 to prepare continuous glass fiber / thermoplastic polyamide resin prepreg yarn.

[0114] The impregnation tank 101 is equipped with two sets of spreading rollers 102, each set of spreading rollers 102 consisting of an upper spreading roller and a lower spreading roller; during the preparation process, the height of the liquid level in the impregnation tank 101 is always controlled to exceed the spreading rollers 102, the traction unit pulls the continuous fiber (or pre-impregnated yarn) at a speed of 10 m / min, and the drying temperature of the drying unit 300 is 180℃.

[0115] Comparative Example 1

[0116] (1) Bisphenol A epoxy resin, curing agent dicyandiamide and active thickener polyetheramine are mixed and stirred at 40°C in a mass ratio of 10:1:1. The stirring speed is 150 rpm and the stirring time is 20 min to obtain a uniform and stable mixture. The mixture is cooled to room temperature to obtain a low-temperature curing epoxy resin system.

[0117] (2) Place the low-temperature curing epoxy resin system obtained in step (1) into the glue tank of the coating machine and heat it to 40°C. At this temperature, the viscosity of the resin system is 16 Pa·s. Lay the release paper required for preparing the adhesive film, adjust the gap between the coating rollers to 0.02 mm, and the areal density of the resin film is 25 g / m³. 2 The epoxy resin coating machine is started to prepare epoxy resin film using the above epoxy resin system. The thickness of the film is detected by infrared ray instrument, cooled, and wound up to obtain resin film with release paper on both sides.

[0118] (3) The above-mentioned adhesive film is drawn out from the upper and lower adhesive film rollers of the prepreg machine, and the glass fiber is drawn out from the yarn rack. The glass fiber is located between the two layers of adhesive film and passes through 2 to 3 sets of hot rollers at a temperature of 45°C on the prepreg machine in sequence, so that the resin adhesive film and glass fiber are fully impregnated. Then, after cooling, film coating (polyethylene film), winding and other steps, a fiber epoxy resin low-temperature curing prepreg with a glass fiber content of about 77% is obtained.

[0119] The composite materials obtained in Example 1 and Comparative Example 1 were tested for glass fiber content, bending properties, etc., according to the aforementioned method. The results are shown in Table 1.

[0120] Table 1

[0121]

[0122] Comparative Example 1 uses prepreg to prepare low-temperature curing composite materials. The main problem with this method is that typical low-temperature curing resin systems have a shelf life of only a few hours. Therefore, the prepreg cures quickly, failing to meet the time requirements of certain components for prepreg, cutting, and lamination processes. In contrast, the thermoplastic resin-based impregnated yarn preparation apparatus of this embodiment is simpler, more convenient to produce, more stable, and eliminates storage difficulties, demonstrating significant advantages in promoting the use of impregnated yarns.

[0123] As can be seen from the data in Table 1, compared with Comparative Example 1, the continuous glass fiber / thermoplastic polyamide resin prepreg yarn (i.e., continuous fiber reinforced thermoplastic resin composite material) prepared in Example 1 of this utility model has a higher glass fiber content, a lower glass fiber content deviation, and higher flexural modulus and flexural strength. Therefore, the continuous fiber reinforced thermoplastic resin composite material prepared by the preparation apparatus of one embodiment of this utility model has a higher glass fiber content and superior mechanical properties.

[0124] Unless otherwise specified, the terms used in this utility model have the meanings commonly understood by those skilled in the art.

[0125] The embodiments described in this utility model are for illustrative purposes only and are not intended to limit the scope of protection of this utility model. Those skilled in the art can make various other substitutions, changes and improvements within the scope of this utility model. Therefore, this utility model is not limited to the above embodiments, but is only defined by the claims.

Claims

1. An apparatus for preparing continuous fiber-reinforced thermoplastic resin composite materials, characterized in that, It includes a traction unit, a solution impregnation unit, a pressure application unit, and a drying unit; the traction unit includes a continuous fiber inlet end and a composite material outlet end arranged opposite to each other; under the action of the continuous fiber inlet end, the continuous fiber can be sequentially impregnated by the impregnation unit, extruded by the pressure application unit, and dried by the drying unit.

2. The preparation apparatus according to claim 1, characterized in that, The solution impregnation unit includes an impregnation tank and at least one spreading roller disposed within the impregnation tank, the spreading roller being used to apply tension to the continuous fibers.

3. The preparation apparatus according to claim 2, characterized in that, The impregnation tank is provided with a thermal circulation structure for heating the impregnation solution; and / or, A vibration structure is provided on the yarn spreading roller.

4. The preparation apparatus according to claim 2, characterized in that, The impregnation tank includes a tank body and a sealing cover that can be opened and closed and connected to the tank body.

5. The preparation apparatus according to claim 4, characterized in that, At least one guide roller is provided on the box body to guide the movement of the continuous fibers within the impregnation box.

6. The preparation apparatus according to claim 1, characterized in that, The pressure unit includes at least two compression rollers, each pair of compression rollers being arranged opposite to each other and spaced apart, and the continuous fiber being able to pass between the two oppositely arranged compression rollers.

7. The preparation apparatus according to claim 6, characterized in that, The two opposing extrusion rollers are respectively provided with grooves and protrusions that can mesh with each other.

8. The preparation apparatus according to claim 1, characterized in that, The drying unit includes a drying chamber and a heating structure, the heating structure being used to regulate the temperature of the drying chamber; and / or, The preparation apparatus further includes a solution recovery unit, which is disposed opposite to the pressure application unit and is used to collect the solution from the pressure application unit.

9. The preparation apparatus according to claim 8, characterized in that, The drying oven is equipped with a solvent recovery tank and a vacuum pump; and / or, At least one guide roller is provided inside the drying chamber, through which the continuous fibers pass.

10. The preparation apparatus according to claim 8, characterized in that, The solution recovery unit is connected to the solution impregnation unit and the drying unit at opposite ends, respectively.

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