Knitted carbon fiber base material cutting wire

Abstract

The utility model belongs to the field of hard and brittle material cutting machining tools, and particularly relates to a woven carbon fiber base material cutting wire which comprises a carbon fiber base material and a solid woven rope formed by weaving a plurality of carbon fiber rope strands in a staggered mode, and each carbon fiber rope strand is composed of a plurality of carbon fiber monofilaments. The surface of the carbon fiber base material is coated with the coating layer, and the coating layer sequentially comprises a base layer, a transition layer and an abrasive layer from inside to outside. Compared with a multifilament single-bundle structure, the carbon fiber cutting filament has the advantages that loosening is avoided, combination is firmer, breakage of the carbon fiber monofilaments due to uneven stress is avoided, and high strength of the carbon fiber cutting filament is kept. Meanwhile, the carbon fiber base material can be coated and shaped by adopting the base layer and the transition layer, the structural stability of the carbon fiber base material in the cutting process is enhanced, the loosening condition is avoided, meanwhile, conditions are provided for coating the carbon fiber base material with the abrasive material layer, and abrasive materials in the abrasive material layer directly participate in cutting, so that the cutting efficiency is improved. And the cutting capability and the service life of the cutting wire are effectively improved.

Description

Technical Field

[0001] This application belongs to the field of cutting and processing tools for hard and brittle materials, and specifically relates to a method for weaving cutting filaments for carbon fiber substrates. Background Technology

[0002] Diamond wire cutting is a commonly used machining tool for cutting hard and brittle materials such as photovoltaic crystalline silicon. Electroplated diamond wire has diamond particles embedded in its base, which directly participate in the cutting process as abrasives. Currently, the base of commonly used diamond wire cutting is mainly high-carbon steel wire, but it is difficult to further improve the wire diameter and tensile strength. Therefore, tungsten wire diamond wire, with its higher strength at the same wire diameter, may become a preferred alternative to diamond wire. However, the high price of tungsten wire and the low yield rate of wire drawing limit its use.

[0003] Carbon fiber is a microcrystalline carbon material with a carbon content of over 90%, typically with a diameter of 6-8 μm. It is lightweight, has high tensile strength (2-7 GPa), high tensile modulus (200-500 GPa), good electrical conductivity, and low thermal conductivity. The diameter of the single carbon filaments used is generally within 8 μm. Due to the extremely small diameter of the single filaments, the microscopic breaking force is too small to be used directly as a cutting wire matrix; they are always present in multifilament bundles. If the single filaments in multifilament bundles are not treated, they will interact with each other during cutting, causing single filament breakage and resulting in a decrease in the overall tensile strength of the cutting wire. Carbon fiber is usually coated with resin to form a carbon fiber resin composite material, but the bond between the resin and carbon fiber is not strong. During cutting, the single filaments within the bundle will still move relative to each other under stress, causing the coating to peel off. How to effectively produce carbon fiber cutting wire without degrading fiber properties is a problem that needs to be solved. Utility Model Content

[0004] To address the technical problem in existing technologies where the interaction between individual filaments in multifilament single-bundle carbon fibers causes filament breakage during cutting, resulting in a decrease in the overall tensile strength of the cutting wire, this application provides a braided carbon fiber substrate cutting wire.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is a braided carbon fiber substrate cutting filament, comprising...

[0006] The carbon fiber substrate is composed of a solid braided rope made of multiple carbon fiber strands interlaced and woven together, wherein the carbon fiber strands are composed of multiple carbon fiber monofilaments.

[0007] The coating layer covers the surface of the carbon fiber substrate and includes, from the inside out, a base layer, a transition layer, and an abrasive layer.

[0008] In some embodiments, the carbon fiber rope strand is formed by interlacing at least two carbon fiber bundles, and the carbon fiber bundle is composed of multiple carbon fiber monofilaments.

[0009] In some embodiments, the carbon fiber monofilament is a continuous filament with a circular cross-section and a cross-sectional diameter of 5-8 μm.

[0010] In some embodiments, the tensile strength of the carbon fiber monofilament is above 6000 MPa.

[0011] In some embodiments, the carbon fiber substrate comprises 30-99 carbon fiber monofilaments.

[0012] In some embodiments, the base layer is a nickel plating layer, the transition layer is a copper plating layer, and the abrasive layer is a nickel-diamond composite plating layer.

[0013] In some embodiments, the total thickness of the covering layer is 10-30 μm, and the total thickness of the base layer and the transition layer is no more than 2 μm.

[0014] In some embodiments, the abrasive layer contains 200-1000 diamond particles / mm.

[0015] Beneficial Effects: This invention uses interlaced carbon fibers to form a solid braided rope structure to create the carbon fiber substrate. Compared to a multifilament single-bundle structure, this avoids loosening and, by not using conventional adhesive bonding, results in a stronger bond, preventing uneven stress on the individual carbon fiber filaments and thus maintaining the high strength of the carbon fiber cutting wire. Simultaneously, the use of a base layer and transition layer effectively coats and shapes the carbon fiber substrate, enhancing its structural stability during cutting and preventing loosening. Furthermore, it provides conditions for the abrasive layer to coat the carbon fiber substrate, allowing the abrasive particles in the abrasive layer to directly participate in cutting, effectively improving the cutting ability and service life of the cutting wire. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the woven carbon fiber substrate cutting filament structure of this utility model;

[0017] Figure 2 A schematic diagram of a carbon fiber rope strand structure formed by interlacing weave;

[0018] In the figure: 1. Carbon fiber substrate, 10. Carbon fiber strand, 11. Carbon fiber bundle, 2. Base layer, 3. Transition layer, 4. Abrasive layer, 41. Diamond particles. Detailed Implementation

[0019] The present application will be further described below with reference to specific embodiments. Obviously, the described embodiments are only a part of the embodiments of the present application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without making creative changes are within the protection scope of the present application.

[0020] Carbon fiber's high strength is attracting increasing attention across various fields. However, due to its thin filament diameter, it cannot be used directly as a cutting filament matrix. Multiple carbon fiber filaments need to be combined to form carbon fiber bundles for use. However, because carbon fiber has a high tensile modulus and is not easily deformed, it springs back during twisting, making it impossible to twist into ropes like steel wire. Furthermore, when multiple carbon fiber filaments are cured and shaped with resin, the bond between the resin and the carbon fiber is not strong, leading to resin detachment. Moreover, resin is not conductive, making it impossible to electroplate an abrasive layer onto the substrate using electroplating methods.

[0021] like Figure 1 and 2 As shown, the solution adopted in this application is as follows: a braided carbon fiber substrate cutting filament, comprising a carbon fiber substrate 1, which is composed of a solid braided rope formed by interlacing multiple carbon fiber strands 10, wherein the carbon fiber strands 10 are composed of multiple carbon fiber monofilaments; a covering layer, which covers the surface of the carbon fiber substrate 1, and includes, from the inside to the outside, a base layer 2, a transition layer 3 and an abrasive layer 4.

[0022] In this application, multiple carbon fiber monofilaments are combined to form a carbon fiber rope strand 10. The carbon fiber rope strand 10 is then interwoven to form a solid braided rope structure. The interwoven structure shapes the carbon fiber and ensures a strong bond. Compared to a carbon fiber substrate 1 in the form of a single bundle of unbraided multifilaments, this braided rope, as the carbon fiber substrate 1, will not loosen during use, and the monofilaments will not interact with each other during cutting, making it less likely for the monofilaments to break.

[0023] Specifically, in one embodiment, such as Figure 2As shown, the carbon fiber rope strand 10 is formed by interlacing at least two carbon fiber bundles 11, each bundle consisting of multiple carbon fiber monofilaments. Due to the small diameter of carbon fiber monofilaments, existing weaving equipment presents significant challenges in weaving them. In this embodiment, multiple carbon fiber monofilaments are used to form a carbon fiber bundle 11, which is unwoven. The cross-sectional size of the carbon fiber bundle 11 is relatively large, allowing for subsequent operations using weaving equipment. At least two carbon fiber bundles 11 are then interlaced to form the carbon fiber rope strand 10. Finally, multiple carbon fiber rope strands 10 are interlaced again to form the woven rope structure. The interlaced weaving structure restricts the movement of the carbon fiber rope strands 10, resulting in greater stability and preventing springback. More specifically, in this embodiment, four carbon fiber monofilaments can be arranged to form a carbon fiber bundle 11, and three carbon fiber bundles 11 can be interlaced to form the carbon fiber rope strand 10. Similarly, three carbon fiber rope strands 10 can be interlaced to form a solid woven rope structure. The cross-section of the woven rope structure is circular or approximately circular.

[0024] The type and number of carbon fiber monofilaments can be selected according to the actual cutting requirements. In some embodiments, the carbon fiber monofilaments are continuous filaments with a circular cross-section and a diameter of 5-8 μm. The tensile strength of the carbon fiber monofilaments is above 6000 MPa, and the carbon fiber substrate 1 contains 30-99 carbon fiber monofilaments.

[0025] In one embodiment, T1100 carbon fiber is selected, with a cross-sectional area of ​​6 μm and a tensile strength of 7000 MPa for each carbon fiber filament. Referring to the diameter and breaking force of a 33 μm tungsten wire, calculations show that 30 or more carbon fiber filaments are sufficient to meet the breaking force requirement of the cutting wire.

[0026] like Figure 1 As shown, in some embodiments, the base layer 2 in the coating layer is a nickel plating layer, the transition layer 3 is a copper plating layer, and the abrasive layer 4 is a nickel-diamond composite plating layer. First, a nickel plating layer is electroplated onto the surface of the carbon fiber. This nickel plating layer, serving as the base layer 2, is easier to electroplat, facilitating the subsequent electroplating of the transition layer 3 and the abrasive layer 4. Then, a copper plating layer is electroplated onto the nickel plating layer as the transition layer 3. The copper plating layer buffers and releases the stress generated during the weaving of the carbon fiber substrate 1, serving to shape the carbon fiber substrate 1 and ensuring that the plating layer does not peel off during cutting, thus enhancing the structural stability of the carbon fiber substrate 1 during the cutting process. Finally, a nickel-diamond composite plating layer is formed on the surface of the process layer as the abrasive layer 4. Diamond particles 41 are embedded in the nickel in the abrasive layer 4, directly participating in the cutting process.

[0027] Specifically, in some embodiments, the total thickness of the coating layer is 10-30 μm, and the total thickness of the base layer 2 and the transition layer 3 is no greater than 2 μm. The abrasive layer 4 contains 200-1000 diamond particles 41 per mm.

[0028] While the disclosure is as stated above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of this disclosure, and all such changes and modifications will fall within the scope of protection of this application.

Claims

1. A woven carbon fiber base material cut thread, characterized by: Comprising A carbon fiber substrate (1) composed of a solid braided rope interlaced by a plurality of carbon fiber strands (10) composed of a plurality of carbon fiber filaments; A coating layer coated on the surface of the carbon fiber substrate (1) and sequentially comprising a base layer (2), a transition layer (3) and an abrasive layer (4) from inside to outside.

2. The braided carbon fiber base material cut filament of claim 1, wherein: The carbon fiber strands (10) are interlaced by at least two carbon fiber tows (11) composed of a plurality of carbon fiber filaments.

3. The braided carbon fiber base material cut filament of claim 1, wherein, The carbon fiber filaments are continuous filaments with a circular cross-section and a cross-sectional diameter of 5-8 μm.

4. The braided carbon fiber base material cut filament of claim 1, wherein, The carbon fiber filaments have a tensile strength of 6000 MPa or more.

5. The braided carbon fiber base material cut thread according to any one of claims 1 to 4, characterized by, The carbon fiber substrate (1) contains 30-99 carbon fiber filaments.

6. The braided carbon fiber base material cut filament of claim 1, wherein, The base layer (2) is a nickel plating layer, the transition layer (3) is a copper plating layer, and the abrasive layer (4) is a nickel-diamond composite plating layer.

7. The braided carbon fiber base material cut filament according to claim 1 or 6, characterized by, The total thickness of the coating layer is 10-30 μm, and the total thickness of the base layer (2) and the transition layer (3) is not more than 2 μm.

8. The braided carbon fiber base material cut filament of claim 5, wherein, The abrasive layer (4) contains 200-1000 diamond particles (41) per mm.

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