Thermoplastic composite mold pressing equipment and production line

Abstract

According to the thermoplastic composite molding equipment and the production line provided by the utility model, electrode conduction type heating and composite self-resistance heating are organically combined, and a mode of independently using a mold temperature controller or self-resistance heating in the prior art is replaced, so that the problem that the heating efficiency and the temperature uniformity are difficult to consider at the same time is fundamentally solved; and the accuracy of temperature control over materials such as carbon fibers in the mold pressing process can be remarkably improved. On the basis, welding and hot stamping procedures before and after die pressing are further designed and integrated, a corresponding production line is designed, efficient and accurate machining of thermoplastic composite products can be achieved, and the device and production cost is low.

Description

Technical Field

[0001] This utility model belongs to the field of thermoplastic fiber reinforced composite material molding technology, specifically relating to a thermoplastic composite molding equipment and production line. Background Technology

[0002] Currently, the manufacturing processes for carbon fiber components such as aircraft air intakes and high-performance automotive parts can be broadly categorized into thermoplastic molding and thermosetting molding. Among these, thermoplastic composite molding offers greater flexibility in temperature and pressure control and boasts higher production efficiency. However, there is still a lack of suitable supporting equipment for thermoplastic molding in this field. Some existing technologies, such as CN112277340A, JP6598477B2, US20130193606A1, and US20130049266A1, provide various forms of thermoplastic and thermosetting composite molding equipment. However, these technologies generally lack effective optimization and integration of the entire process, including material handling before and after molding, transitions between processes, and operating temperature and pressure parameters. In particular, the heating efficiency and uniformity of existing technologies using mold temperature controllers and self-resistance heating methods during molding remain significantly deficient. These problems have led to high production costs and low efficiency of existing equipment, making it unable to adequately meet the requirements for large-scale production of thermoplastic composite products. Summary of the Invention

[0003] In view of the above, and in response to the technical problems existing in this field, this utility model provides a thermoplastic composite molding equipment, specifically comprising:

[0004] Mobile worktable, equipment frame, slider, molding module and driver;

[0005] The mobile worktable is fixed to the molding station by the equipment frame and can be replaced according to different composite blank shapes and sizes; the driver is fixed above the equipment frame and its lower end is connected to the slider; the molding module is fixed on the mobile worktable and includes the upper mold and the lower mold.

[0006] The driver includes multiple clamping cylinders and locking cylinders for applying clamping force to the molding module via a slider;

[0007] Both the upper and lower molds are equipped with heating electrodes electrically connected to an external power source. These electrodes generate heat through conduction via heat-conducting plates in direct contact with the thermoplastic composite material. Simultaneously, the heating electrodes, along with the thermoplastic composite material and the external power source, form a heating circuit to achieve self-resistive heating of the thermoplastic composite material. Both the upper and lower molds have cooling pipes to regulate temperature conditions during molding and to cool the heating electrodes and thermoplastic composite material. The lower mold has vents connected to an external air source to provide nitrogen or inert gas to the mold cavity after mold closing, preventing oxidation of the resin material in the composite. Sealing spring pads are installed at the vents. The outer periphery of both the upper and lower molds has mating dynamic sealing components. The dynamic sealing component of the lower mold has a vacuum pipe connected to an external vacuum pump to provide a negative pressure environment within the mold after mold closing.

[0008] Furthermore, the equipment adopts a flat mold. The upper mold plate has a stepped upper ceramic plate in the center, and the upper mold heating electrode is set on the stepped recessed edge. The lower mold plate has a flat lower ceramic plate, and the lower mold heating electrode is set at its end. A ceramic pad and a damping module are set below the lower mold heating electrode to connect the lower mold plate. The damping module is used to keep the mold pressed tightly when the composite material thickness changes during the molding process. The upper mold heat-conducting plate and the lower mold heat-conducting plate are respectively set on the corresponding ceramic plates. The edge of the heat-conducting plate is equipped with a pressure-bearing insulating pad, which can be replaced and the distance between the upper and lower molds can be adjusted according to the composite material thickness. Cooling pipes extend inside the upper and lower mold ceramic plates and the heat-conducting plates respectively.

[0009] Furthermore, the upper mold and the lower mold's dynamic sealing components are kept sealed by a sealing ring, and the two can achieve venting through a certain stroke of relative movement.

[0010] Furthermore, the equipment frame is specifically composed of an upper beam, columns, and a lower beam. The movable worktable is fixedly installed on the lower beam, and the drive unit is installed on the upper beam.

[0011] Furthermore, the mobile worktable is also equipped with a connected loading and unloading conveyor belt for transferring thermoplastic composites between molding and other processes.

[0012] Accordingly, this utility model also provides a thermoplastic composite production line including the above-mentioned molding equipment, which includes, in sequence: a feeding station, a molding station, a heating station, a hot stamping station and a unloading station;

[0013] Conveyor belts are installed between different workstations to transfer composite materials to be processed;

[0014] The loading station receives single-layer or multi-layer composite blanks formed after welding and conveys them to the molding station equipped with the aforementioned thermoplastic molding equipment. The molding station performs molding on single-layer or multi-layer composite blanks. The heating method used in the molding process is a hybrid heating method that includes both electrode conduction heating and self-resistance heating. The heating station receives the composite material after molding and cooling and demolding, and heats it to the temperature required for hot stamping. The hot stamping station performs hot stamping on the composite material heated to the specified temperature. The unloading station receives the hot-stamped composite material and performs necessary work such as cutting, grinding, and quality inspection to output the final thermoplastic composite product.

[0015] The thermoplastic composite molding equipment and production line provided by this utility model organically combines electrode conductive heating and composite self-resistance heating, replacing the existing technology of using a mold temperature controller or self-resistance heating alone. This fundamentally solves the problem of difficulty in simultaneously achieving heating efficiency and temperature uniformity, and significantly improves the accuracy of temperature control for materials such as carbon fiber during the molding process. Furthermore, this utility model also designs and integrates welding and hot stamping processes before and after molding, and designs corresponding production lines, enabling efficient and precise processing of thermoplastic composite products with lower equipment and production costs. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the thermoplastic composite molding equipment provided by this utility model;

[0017] Figure 2 A schematic diagram of an optional flat-plate molding module for thermoplastic composite molding equipment;

[0018] Figure 3 This is a schematic diagram of the thermoplastic composite production line provided by this utility model.

[0019] Explanation of reference numerals in the attached drawings: 1. Moving worktable; 2. Molding module; 2-1. Upper mold plate; 2-2. Upper mold ceramic plate; 2-3. Upper mold heating electrode; 2-4. Pressure-bearing insulating pad; 2-5. Dynamic sealing assembly; 2-6. Vacuum pipe; 2-7. Lower mold heating electrode; 2-8. Ceramic pad; 2-9. Damping module; 2-10. Lower mold plate; 2-11. Lower mold ceramic plate; 2-12. Blank; 2-13. Lower mold heat-conducting plate; 2-14. Upper mold heat-conducting plate; 3. Slider; 4. Driver; 5. Upper beam; 6. Column platform; 7. Lower beam; 8. Loading station; 9. Thermoplastic composite flat plate molding station; 10. Heating station; 11. Hot stamping station; 12. Unloading station. Detailed Implementation

[0020] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0021] In the description of this utility model, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0022] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0023] The thermoplastic composite molding equipment provided by this utility model, such as Figure 1 , 2 As shown, it specifically includes:

[0024] 1. Mobile worktable, 2. Equipment frame, 3. Slider, 4. Molding module, and 5. Driver;

[0025] The mobile worktable 1 is fixed to the molding station by the equipment frame and can be replaced according to the shape and size of different composite blanks 2-12; the driver 4 is fixed above the equipment frame and its lower end is connected to the slider 3; the molding module 2 is fixed on the mobile worktable 1 and includes an upper mold and a lower mold.

[0026] The driver 4 includes multiple mold-closing cylinders and mold-locking cylinders, which are used to apply mold-closing force to the molding module 2 via the slider 3;

[0027] The upper and lower molds are respectively equipped with upper mold heating electrodes 2-3 and lower mold heating electrodes 2-7, which are electrically connected to an external power source. These electrodes generate heat through electrical conduction via upper and lower mold heat-conducting plates 2-14 and 2-13, which are in direct contact with the blank 2-12. Simultaneously, the upper and lower mold heating electrodes 2-3 and 2-7, together with the thermoplastic composite and the external power source, form a heating circuit to achieve self-resistance heating of the thermoplastic composite. Both the upper and lower molds are equipped with cooling pipes for regulating molding pressure through the circulation of cooling liquid or gas. The process includes temperature conditions and cooling of the heating electrodes and thermoplastic composite blanks; the lower mold is equipped with an air hole connected to an external air source to provide nitrogen or inert gas to the mold cavity after mold closing to protect the environment and prevent oxidation of the resin material in the composite; a sealing spring pad is provided at the air hole; the outer periphery of the upper mold and the lower mold is equipped with a mutually cooperating dynamic sealing component 2-5; the dynamic sealing component 2-5 of the lower mold is equipped with a vacuum pipe 2-6 connected to an external vacuum pump to provide a negative pressure environment inside the mold after mold closing.

[0028] In a preferred embodiment of this utility model, the device employs as follows: Figure 2 The flat mold shown has a stepped upper mold ceramic plate 2-2 in the center of the upper mold template 2-1, and an upper mold heating electrode 2-3 on the stepped recessed edge. The lower mold template 2-10 has a flat lower mold ceramic plate 2-11 with a lower mold heating electrode 2-7 at its end. A ceramic pad 2-8 and a damping module 2-9 are provided below the lower mold heating electrode 2-7 to connect to the lower mold template. The damping module 2-9 is used to keep the mold pressed tightly when the thickness of the composite material changes during the molding process. The upper mold heat-conducting plate 2-14 and the lower mold heat-conducting plate 2-13 are respectively set on the corresponding ceramic plates. The edge of the heat-conducting plate is provided with a pressure-bearing insulating pad 2-4, which can be replaced and the distance between the upper and lower molds can be adjusted according to the thickness of the composite material. Cooling pipes extend inside the upper and lower mold ceramic plates and the heat-conducting plates, respectively.

[0029] In a preferred embodiment of this utility model, the upper mold and the lower mold dynamic sealing components 2-5 are kept sealed by a sealing ring, and the two can achieve venting through a certain stroke of relative movement.

[0030] In a preferred embodiment of this utility model, the equipment frame is specifically composed of an upper beam 5, a column 6 and a lower beam 7, the movable workbench 1 is fixedly installed on the lower beam 7, and the driver 4 is installed on the upper beam 7.

[0031] In a preferred embodiment of this utility model, the movable worktable is further provided with a loading and unloading conveyor belt connected thereto, for transferring the thermoplastic composite material between molding and other processes.

[0032] Accordingly, this utility model also provides a thermoplastic composite production line including the above-mentioned molding equipment, such as... Figure 3As shown, it includes, in sequence: loading station 8, molding station 9, heating station 10, hot stamping station 11, and unloading station 12;

[0033] Conveyor belts are installed between different workstations to transfer composite materials to be processed;

[0034] The loading station 8 is used to receive single-layer or multi-layer composite blanks 2-12 formed after welding, and convey them to the molding station 9 with the above-mentioned thermoplastic molding equipment; the molding station 9 is used to perform molding on single-layer or multi-layer composite blanks, and the molding process adopts a hybrid heating method including electrode conduction heating and self-resistance heating; the heating station 10 is used to receive the composite after molding and cooling and demolding, and heat it to the temperature required for hot stamping; the hot stamping station 11 is used to perform hot stamping on the composite heated to the specified temperature; the unloading station 12 is used to receive the composite after hot stamping, and perform the necessary work such as cutting, grinding, and quality inspection, and output the final thermoplastic composite finished product.

[0035] It should be understood that the sequence number of each step in the embodiments of this utility model does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this utility model.

[0036] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A thermoplastic composite molding equipment, characterized in that: Specifically, it includes: Mobile worktable, equipment frame, slider, molding module and driver; The mobile worktable is fixed to the molding station by the equipment frame and can be replaced according to different composite blank shapes and sizes; the driver is fixed above the equipment frame and its lower end is connected to the slider; the molding module is fixed on the mobile worktable and includes the upper mold and the lower mold. The driver includes multiple clamping cylinders and locking cylinders for applying clamping force to the molding module via a slider; Both the upper and lower molds are equipped with heating electrodes electrically connected to an external power source. These electrodes generate heat through conduction via heat-conducting plates in direct contact with the thermoplastic composite material. Simultaneously, the heating electrodes, along with the thermoplastic composite material and the external power source, form a heating circuit to achieve self-resistive heating of the thermoplastic composite material. Both the upper and lower molds have cooling pipes to regulate temperature conditions during molding and to cool the heating electrodes and thermoplastic composite material. The lower mold has vents connected to an external air source to provide nitrogen or inert gas to the mold cavity after mold closing, preventing oxidation of the resin material in the composite. Sealing spring pads are installed at the vents. The outer periphery of both the upper and lower molds has mating dynamic sealing components. The dynamic sealing component of the lower mold has a vacuum pipe connected to an external vacuum pump to provide a negative pressure environment within the mold after mold closing.

2. The thermoplastic composite molding equipment as described in claim 1, characterized in that: The equipment uses a flat mold. The upper mold plate has a stepped upper ceramic plate in the center, and the upper mold heating electrode is located on the stepped recessed edge. The lower mold plate has a flat lower ceramic plate, and the lower mold heating electrode is located at its end. A ceramic pad and a damping module are located below the lower mold heating electrode to connect to the lower mold plate. The damping module is used to keep the mold pressed tightly when the composite material thickness changes during the molding process. The upper mold heat-conducting plate and the lower mold heat-conducting plate are respectively set on the corresponding ceramic plates. The edge of the heat-conducting plate is equipped with a pressure-bearing insulating pad, which can be replaced and the distance between the upper and lower molds can be adjusted according to the composite material thickness. Cooling pipes extend inside the upper and lower mold ceramic plates and the heat-conducting plates respectively.

3. The thermoplastic composite molding equipment as described in claim 1, characterized in that: The upper mold and the lower mold are sealed by a sealing ring, and the two can exhaust air through a certain stroke of relative movement.

4. The thermoplastic composite molding equipment as described in claim 1, characterized in that: The equipment frame consists of an upper beam, columns, and a lower beam. The movable worktable is fixed to the lower beam, and the drive unit is installed on the upper beam.

5. The thermoplastic composite molding equipment as described in claim 2, characterized in that: The mobile worktable is also equipped with a connected loading and unloading conveyor belt for transferring thermoplastic composites between molding and other processes.

6. A thermoplastic composite production line comprising the thermoplastic composite molding equipment as described in any one of claims 1-5, comprising, in sequence: Loading station, molding station, heating station, hot stamping station and unloading station; Conveyor belts are installed between different workstations to transfer composite materials to be processed; The loading station receives single-layer or multi-layer composite blanks formed after welding and conveys them to the molding station equipped with the aforementioned thermoplastic molding equipment. The molding station performs molding on single-layer or multi-layer composite blanks. The heating method used in the molding process is a hybrid heating method that includes both electrode conduction heating and self-resistance heating. The heating station receives the composite material after molding and cooling and demolding, and heats it to the temperature required for hot stamping. The hot stamping station performs hot stamping on the composite material heated to the specified temperature. The unloading station receives the hot-stamped composite material and performs necessary work including at least cutting, grinding, and quality inspection, and outputs the final thermoplastic composite finished product.

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