Process equipment for preparing amorphous polyaryletherketone carbon fiber prepreg by solution method

Abstract

The utility model discloses process equipment for preparing amorphous polyaryletherketone carbon fiber prepreg by a solution method, which comprises a microwave solvent removing device which comprises a solvent removing cavity and a plurality of groups of glue scraping rollers arranged in the solvent removing cavity, the multiple sets of glue scraping rollers are sequentially arranged in the solvent removing cavity in the conveying direction of the carbon fibers, and the height of the glue scraping roller close to an inlet of the solvent removing cavity in the vertical direction is larger than or equal to the height of the adjacent glue scraping roller close to an outlet of the solvent removing cavity in the vertical direction. A plurality of groups of glue scraping rollers are designed at the same time, so that the retention time of the prepreg in the microwave solvent removing device is controllable, a solvent is fully volatilized, the height of the glue scraping rollers in the vertical direction is limited, redundant resin on the prepreg flows and is enriched, certain pressure is applied through the glue scraping rollers, the redundant resin is removed, the resin content is controllable, and the resin content is improved. Meanwhile, the combination with fibers is tighter, and the quality of the prepreg is obviously improved.

Description

Technical Field

[0001] This utility model relates to the field of composite materials, specifically to a process and equipment for preparing amorphous polyaryletherketone carbon fiber prepreg by solution method. Background Technology

[0002] Thermoplastic carbon fiber prepreg has been widely used in numerous fields due to its inherent advantages. In terms of mechanical properties, compared to traditional materials, it possesses higher specific strength and specific modulus, enabling it to maintain good load-bearing capacity while reducing structural weight. In the aerospace industry, it is commonly used to manufacture some secondary load-bearing structural components of aircraft, such as landing gear doors, contributing to aircraft weight reduction, lower fuel consumption, and improved flight performance. In the automotive manufacturing industry, it can be used to produce some exterior parts, such as roof racks, reducing the overall weight of the vehicle while maintaining sufficient strength, thus improving fuel economy. In the sporting goods industry, it is used to manufacture high-performance bicycle frames, golf clubs, and other products, giving them better strength and toughness, and significantly extending their service life.

[0003] However, current thermoplastic carbon fiber prepregs have many problems in terms of performance and preparation process. Commonly used thermoplastic resins such as polyetheretherketone (PEEK) have high strength, can withstand huge external forces without easily deforming or being damaged, have good toughness, strong impact resistance, and good wear resistance. However, processing requires high temperatures and pressures, placing high demands on processing equipment, increasing processing difficulty and production costs, resulting in relatively high product prices. Polyphenylene sulfide (PPS) has high mechanical strength, high rigidity, good creep resistance under load, high hardness, and good wear resistance. However, its toughness is poor, and it is prone to brittle fracture under large impact forces, limiting its application in some fields. From the perspective of preparation process, the commonly used melt impregnation method suffers from poor resin flowability, making it difficult to fully and uniformly impregnate carbon fibers, resulting in insufficient interfacial bonding strength between the fiber and resin, ultimately seriously affecting the overall stability and reliability of the composite material. How to improve the interfacial bonding strength between the fiber and resin, and reduce processing difficulty and production costs, remains an urgent technical problem to be solved. Utility Model Content

[0004] The purpose of this invention is to provide a process and equipment for preparing amorphous polyaryletherketone carbon fiber prepreg by solution method, so as to solve the problems of high cost of existing equipment, poor fiber impregnation effect and insufficient performance of existing thermoplastic resins.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is: a process equipment for preparing amorphous polyaryletherketone carbon fiber prepreg using a solution method, comprising a microwave solvent removal device. The microwave solvent removal device includes a solvent removal chamber and multiple sets of scraper rollers disposed within the solvent removal chamber. The multiple sets of scraper rollers are arranged sequentially along the carbon fiber conveying direction within the solvent removal chamber, and the scraper roller closest to the inlet of the solvent removal chamber has a vertical height greater than or equal to the vertical height of its adjacent scraper roller closest to the outlet of the solvent removal chamber. The inlet of the solvent chamber is the entrance for the carbon fiber into the solvent removal chamber, and the outlet of the solvent chamber is the exit for the carbon fiber from the solvent removal chamber.

[0006] Furthermore, the included angle formed between two adjacent sets of the scraper rollers is α, where α = 0° or 30° to 60°.

[0007] Furthermore, the included angle α formed by the two sets of scraper rollers located at the entrance of the solvent removal chamber is 30° to 60°.

[0008] Furthermore, the two sets of scraper rollers with an included angle α=0° and the two sets of scraper rollers with an included angle α=30°~60° are arranged alternately.

[0009] Furthermore, four sets of scraper rollers are provided: the angle α formed by scraper roller one and scraper roller two is 30° to 60°, the angle α formed by scraper roller two and scraper roller three is 0°, and the angle α formed by scraper roller three and scraper roller four is 30° to 60°.

[0010] By designing four sets of scraper rollers with relative positions, excess resin on the prepreg flows and accumulates. Then, a certain pressure is applied by the scraper rollers to remove the excess resin, making the resin content controllable and allowing it to bond more tightly with the fiber, thus significantly improving the quality of the prepreg.

[0011] Furthermore, a microwave generator is provided inside the solvent removal chamber, and a resin collector is provided below the scraper roller.

[0012] Furthermore, the microwave solvent removal device also includes a second vacuum pump, which is connected to the solvent removal chamber and the prepreg storage tank via a solvent evaporation pipe.

[0013] Furthermore, it also includes an ultrasonic impregnation device, which includes an impregnation tank and an ultrasonic generator disposed inside the impregnation tank.

[0014] Furthermore, the ultrasonic impregnation device also includes a pre-impregnation liquid storage tank, which is connected to the impregnation tank.

[0015] Furthermore, the ultrasonic impregnation device also includes a first vacuuming component, which is connected to the impregnation tank and the pre-impregnation liquid storage tank. The first vacuuming component is used to recover the solvent that evaporates in the impregnation tank into the pre-impregnation liquid storage tank.

[0016] Furthermore, it also includes a carbon fiber frame, a yarn spreading device, a sizing agent removal device, and a heating device arranged in sequence for surface treatment of carbon fibers.

[0017] The beneficial effects of this utility model are:

[0018] 1) In the microwave solvent removal device, by designing multiple sets of scraper rollers simultaneously, the residence time of the prepreg in the microwave solvent removal device can be controlled, allowing the solvent to fully evaporate. Furthermore, by limiting the vertical height of the scraper rollers, excess resin on the prepreg flows and accumulates. Then, by applying a certain pressure to the scraper rollers, the excess resin is removed, making the resin content controllable and allowing for a tighter bond with the fiber, thus significantly improving the quality of the prepreg.

[0019] 2) By setting an ultrasonic generator in the ultrasonic impregnation device, the resin solution can be used to penetrate into the carbon fiber fabric, thereby improving the impregnation effect. This solves the technical problem of uneven and insufficient resin distribution inside the carbon fiber bundle and achieves a higher resin loading capacity.

[0020] 3) By setting up the first and second vacuum components, the organic solvents are used in a closed environment. After use, the solvent is transported to the pre-impregnation liquid storage tank for recycling through condensation and reflux, which greatly saves costs, avoids solvent volatilization, produces no waste, is environmentally friendly, and meets the requirements of modern chemical technology for safe, efficient and controllable preparation process. Attached Figure Description

[0021] The accompanying drawings, which form part of this application, are used to provide a further understanding of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention.

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the process equipment for preparing amorphous polyaryletherketone carbon fiber prepreg by solution method according to an embodiment of the present invention.

[0024] Figure 2This is a schematic diagram of a microwave solvent removal device according to an embodiment of the present invention.

[0025] In the diagram: 1. Carbon fiber frame; 2. Yarn spreading device; 3. Sizing agent removal device; 4. Heating device; 5. Ultrasonic impregnation device; 51. Ultrasonic generator; 52. First vacuuming device; 53. Prepreg storage tank; 6. Microwave solvent removal device; 61. Squeegee roller; 611. Squeegee roller one; 612. Squeegee roller two; 613. Squeegee roller three; 614. Squeegee roller four; 62. Resin collector; 63. Microwave generator; 64. Solvent evaporation pipe; 65. Second vacuuming device; 7. Hot press roller; 81. Cooling device; 82. Cutting device; 9. Winding device. Detailed Implementation

[0026] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0027] See appendix Figure 1 and attached Figure 2 As shown in this embodiment, a process device for preparing amorphous polyaryletherketone carbon fiber prepreg by solution method is used to impregnate carbon fiber with resin, improve the interfacial bonding strength between carbon fiber and resin, and enhance the stability and reliability of composite materials obtained by impregnating carbon fiber with resin.

[0028] The continuous impregnation equipment includes a carbon fiber rack 1, a yarn spreading device 2, a sizing agent removal device 3, and a heating device 4 arranged in sequence, for treating the surface of carbon fibers. Specifically, the carbon fibers located on the carbon fiber rack 1 are passed through the yarn spreading device 2 and then drawn into the hot solvent of the sizing agent removal device 3 to remove the sizing agent from the surface of the carbon fibers, and then dried by the heating device 4.

[0029] In some embodiments, the equipment for preparing amorphous polyaryletherketone (PAEK) carbon fiber prepreg by solution method includes an ultrasonic impregnation device 5 disposed on one side of the heating device 4. The ultrasonic impregnation device 5 is used to hold a resin solution. The surface-treated carbon fiber passes through the ultrasonic impregnation device 5, and the resin solution inside the ultrasonic impregnation device 5 impregnates the carbon fiber. The resin solution is obtained by dissolving phenolphthalein-based amorphous PAEK powder in an organic solvent at room temperature.

[0030] The ultrasonic impregnation device 5 includes an impregnation tank and an ultrasonic generator 51 disposed inside the impregnation tank. The surface-treated carbon fibers are drawn into the ultrasonic impregnation device 5, and the ultrasonic generator 51 is activated. Ultrasonic waves and microjets are generated, allowing the resin to fully dissolve and disperse in the solvent, ensuring thorough contact with the carbon fibers and better impregnation. By incorporating the ultrasonic generator 51, ultrasound can be used to penetrate the resin solution into the carbon fiber fabric, improving the impregnation effect and solving the technical problem of uneven and insufficient distribution of polyaryletherketone (PAEK) within the carbon fiber bundle, thus achieving a higher PAEK loading capacity.

[0031] In some embodiments, the ultrasonic impregnation apparatus 5 includes a first vacuuming component 52 and a prepreg storage tank 53. The first vacuuming component 52 connects the impregnation tank and the prepreg storage tank 53. The first vacuuming component 52 recovers the volatile solvent into the prepreg storage tank 53. The prepreg storage tank 53 is connected to the impregnation tank. The recovered solvent can be used to prepare resin solutions. Organic solvents can be recovered and reused.

[0032] In some embodiments, the equipment for preparing amorphous polyaryletherketone carbon fiber prepreg by solution method further includes a microwave solvent removal device 6. The microwave solvent removal device 6 is located on one side of the ultrasonic impregnation device 5, and the resin-impregnated carbon fibers are drawn into the microwave solvent removal device 6. The microwave solvent removal device 6 includes a solvent removal chamber and multiple sets of scraper rollers 61 disposed within the solvent removal chamber. These include a first scraper roller 611 and a second scraper roller 612 located near the inlet of the microwave solvent removal device 6. The angle between the first scraper roller 611 and the second scraper roller 612 is 30-60°. The angle between the first scraper roller 611 and the second scraper roller 612 is the angle α formed by the carbon fibers passing through the first scraper roller 611 and the second scraper roller 612 and the horizontal plane. If the angle is too large, excess resin solution easily accumulates to the lower end under gravity, resulting in significant resin loss and affecting the actual content of the prepreg; if the angle is too small, excess resin cannot be effectively accumulated, affecting the scraping efficiency of the scraper rollers 61. An angle of 30-60° is suitable.

[0033] In some embodiments, the scraper roller 61 includes a scraper roller 613 disposed on one side of the scraper roller 612. The scraper roller 613 and the scraper roller 612 are located on the same horizontal line, which allows the solvent to evaporate further and the resin to adhere better to the fiber surface.

[0034] In some embodiments, the scraper roller 61 includes a scraper roller four 614 disposed on one side of scraper roller three 613. The angle α between scraper roller four 614 and scraper roller three 613 is 30-60°, which is beneficial for further enriching and removing excess resin in a small amount at once. At the same time, the pressure applied by the scraper roller 61 makes the resin solution more completely wetted with the fiber. The number of scraper rollers 61 can be increased or decreased according to the excess resin content of the prepreg.

[0035] In some embodiments, such as Figure 2 As shown, four sets of scraper rollers are configured. The angle α between scraper roller 1 (611) and scraper roller 2 (612) is 30°–60° (the height of scraper roller 2 (612) is lower than that of scraper roller 1 (611)). The angle α between scraper roller 2 (612) and scraper roller 3 (613) is 0° (i.e., the heights of scraper roller 2 (612) and scraper roller 3 (613) are the same). The angle α between scraper roller 3 (613) and scraper roller 4 (614) is 30°–60° (the height of scraper roller 4 (614) is lower than that of scraper roller 3 (613)). This relative positioning of the four sets of scraper rollers allows excess resin on the prepreg to flow and accumulate. Applying pressure through the scraper rollers removes the excess resin, making the resin content controllable and ensuring a tighter bond with the fibers, thus significantly improving the quality of the prepreg.

[0036] In some embodiments, a microwave generator 63 is provided above the scraper roller 61 to heat and evaporate the solvent. At the same time, the scraper roller 61 removes excess resin, making the fiber surface smooth. The excess resin is collected in a resin collector 62 at the bottom of the device. The resin collected in the resin collector 62 can still be used as a resin raw material for preparing resin solutions.

[0037] In some embodiments, the microwave solvent removal device 6 further includes a second vacuuming component 65, which is connected to the solvent removal chamber and the prepreg storage tank 53 via a solvent evaporation pipe 64. The second vacuuming component 65 recovers the solvent evaporated in the solvent removal chamber to the prepreg storage tank 53. The prepreg storage tank 53 is connected to the impregnation tank. The recovered solvent can be reused to prepare resin solutions, and the organic solvent can be recycled and reused.

[0038] By setting up the first and second vacuum components, the organic solvents are used in a closed environment. After use, the solvent is transported to the pre-impregnation liquid storage tank for recycling through condensation and reflux, which greatly saves costs, avoids solvent volatilization, produces no waste, is environmentally friendly, and meets the requirements of modern chemical technology for safe, efficient and controllable preparation processes.

[0039] The microwave solvent removal device 6 has a good solvent removal effect. By designing multiple sets of scraper rollers simultaneously, the residence time of the prepreg in the device can be controlled, allowing the solvent to fully evaporate. Furthermore, the relative position design of the scraper rollers allows excess resin on the prepreg to flow and accumulate. Then, a certain pressure is applied by the scraper rollers to remove the excess resin, making the resin content controllable and the resin bonded to the fiber more tightly, thus significantly improving the quality of the prepreg.

[0040] In some embodiments, a hot press roller 7, a cooling device 81, a cutting device 82, and a winding device 9 are sequentially arranged on one side of the microwave solvent removal device 6. The dried carbon fiber is drawn to the hot press roller 7 for shaping, then cooled by the cooling device 81, cut by the cutting device 82, and finally wound up by the winding device 9 to obtain carbon fiber prepreg.

[0041] The molding process for preparing phenolphthalein-based amorphous polyaryletherketone thermoplastic carbon fiber prepreg using the equipment of this invention includes the following steps:

[0042] (1) Preparation of prepreg solution: Phenolphthalein-based amorphous polyaryletherketone powder was dissolved in an organic solvent at room temperature to obtain a resin solution, which was then added to an ultrasonic impregnation device for later use;

[0043] (2) Carbon fiber surface treatment: After passing through the yarn spreading device, the carbon fiber is drawn and immersed in the hot solvent of the desizing device to remove the surface sizing agent, and then dried by the heating device;

[0044] (3) Prepreg coating: The surface-treated carbon fiber is pulled to the ultrasonic impregnation device, the ultrasonic generator is started, and the ultrasonic waves are used to form strong shock waves and micro jets, so that the resin is fully dissolved and dispersed in the solvent and fully contacted with the carbon fiber to better impregnate the carbon fiber. At the same time, the vacuum equipment is started to recover the volatile solvent.

[0045] (4) Solvent removal: The carbon fibers that are fully impregnated with resin are drawn to the microwave solvent removal device. The solvent is removed by microwave heating and evaporation. At the same time, excess resin is removed by the scraper roller to make the fiber surface smooth. The excess resin is collected in the resin collector at the bottom of the device.

[0046] (5) Prepreg winding: The dried carbon fiber is drawn to the hot press roller for shaping, and then cooled, cut and wound to obtain carbon fiber prepreg.

[0047] The above embodiments are only for illustrating the technical concept and features of this utility model. Their purpose is to enable those skilled in the art to understand the content of this utility model and implement it. They cannot be used to limit the protection scope of this utility model. All equivalent changes or modifications made in accordance with the spirit and essence of this utility model should be covered within the protection scope of this utility model.

[0048] Furthermore, various different embodiments of this utility model can be combined in any way, as long as they do not violate the spirit of this utility model, they should also be regarded as the content disclosed by this utility model.

Claims

1. A process apparatus for solution preparation of amorphous poly (arylene ether ketone) carbon fiber prepreg, characterized by, The microwave solvent removing device (6) comprises a desolventizing cavity and a plurality of groups of glue scraping rollers (61) arranged in the desolventizing cavity, the groups of glue scraping rollers (61) are arranged in sequence along the conveying direction of the carbon fibers in the desolventizing cavity, and the height of the glue scraping roller (61) near the inlet of the desolventizing cavity in the vertical direction is higher than or equal to the height of the glue scraping roller (61) near the outlet of the desolventizing cavity in the vertical direction.

2. The process apparatus for solution process preparation of amorphous poly (arylene ether ketone) carbon fiber prepreg according to claim 1, characterized in that, The included angle between the two adjacent groups of glue scraping rollers (61) is α, and α=0° or 30°-60°.

3. The process apparatus for solution process preparation of amorphous poly (arylene ether ketone) carbon fiber prepreg according to claim 2, characterized in that, The included angle α between the two groups of glue scraping rollers (61) near the inlet of the desolventizing cavity is 30°-60°.

4. The process plant for the solution process production of amorphous poly (arylene ether ketone) carbon fiber prepreg according to any one of claims 2-3, characterized in that, The two groups of glue scraping rollers (61) with an included angle α of 0° are arranged apart from the two groups of glue scraping rollers (61) with an included angle α of 30°-60°.

5. The process apparatus for solution processing of amorphous poly (arylene ether ketone) carbon fiber prepreg according to claim 1, wherein, A microwave generator (63) is arranged in the desolventizing cavity, and a resin collector (62) is arranged below the glue scraping roller (61).

6. The process apparatus for solution process preparation of amorphous poly (arylene ether ketone) carbon fiber prepreg according to claim 1, characterized in that, The microwave solvent removing device (6) further comprises a second vacuum pump (65) connected to the desolventizing cavity and a pre-impregnation liquid storage tank (53) through a solvent evaporation pipeline (64).

7. The process apparatus for solution preparation of amorphous poly (arylene ether ketone) carbon fiber prepreg according to any one of claims 1 to 3, characterized in that, The ultrasonic impregnation device (5) comprises an impregnation tank and an ultrasonic generator (51) arranged in the impregnation tank.

8. The process apparatus for solution process production of amorphous poly (arylene ether ketone) carbon fiber prepreg according to claim 7, characterized in that, The ultrasonic impregnation device (5) further comprises a pre-impregnation liquid storage tank (53) in communication with the impregnation tank.

9. The process apparatus for solution process preparation of amorphous poly (arylene ether ketone) carbon fiber prepreg according to claim 8, characterized in that, The ultrasonic impregnation device (5) further comprises a first vacuum pump (52) connected to the impregnation tank and the pre-impregnation liquid storage tank (53), and the first vacuum pump (52) is used to recycle the volatilized solvent in the impregnation tank into the pre-impregnation liquid storage tank (53).

10. The process plant for the solution process production of amorphous poly (arylene ether ketone) carbon fiber prepreg according to any one of claims 1 to 3, characterized in that The carbon fiber frame (1), the yarn spreading device (2), the desizing agent removing device (3) and the heating device (4) are arranged in sequence, and are used for surface treatment of the carbon fibers.

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