CN111844521B - Melt impregnation device and preparation method of continuous fiber reinforced thermoplastic prepreg tape - Google Patents
Melt impregnation device and preparation method of continuous fiber reinforced thermoplastic prepreg tape Download PDFInfo
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- CN111844521B CN111844521B CN202010567773.3A CN202010567773A CN111844521B CN 111844521 B CN111844521 B CN 111844521B CN 202010567773 A CN202010567773 A CN 202010567773A CN 111844521 B CN111844521 B CN 111844521B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/14—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length of filaments or wires
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
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Abstract
本发明提供了一种连续纤维增强热塑性预浸带的熔融浸渍装置与制备方法，装置包括依次设置的纱架、分丝系统、加热系统、浸渍系统、若干均化辊、上光辊和牵拉系统，加热系统包括升温通道和若干电热吹风机，浸渍系统包括浸渍辊、挤出多孔口模和挤出机，挤出多孔口模设置在浸渍辊的下方，挤出多孔口模包括弧形多孔口模一和弧形多孔口模二，弧形多孔口模一与浸渍辊的凹槽之间配合形成浅腔，挤出机与弧形多孔口模二连通；牵拉系统牵拉进入分丝系统后的纤维带自浸渍辊上方绕过，绕过浸渍辊的纤维带经过多个均化辊后进入动力对辊之间成型预浸带。本发明实现高粘度聚醚醚酮类树脂熔体对连续纤维束的浸渍，同时保证浸渍带的纤维浸渍程度与制备的连续性。
The invention provides a melt impregnation device and a preparation method for a continuous fiber reinforced thermoplastic prepreg tape. The device includes a creel, a yarn splitting system, a heating system, an impregnation system, a plurality of homogenizing rollers, a glazing roller and a drawing roller arranged in sequence. The heating system includes a heating channel and several electric heating blowers. The impregnation system includes a dipping roller, an extrusion porous die and an extruder. The extrusion porous die is arranged below the dipping roller, and the extrusion porous die includes an arc-shaped porous mouth. Die 1 and arc-shaped porous die 2, the arc-shaped porous die 1 cooperates with the groove of the dipping roll to form a shallow cavity, and the extruder is communicated with the arc-shaped porous die 2; the drawing system is drawn into the wire separating system The final fiber tape bypasses the impregnating roll, and the fiber tape bypassing the impregnating roll passes through a plurality of homogenizing rolls and then enters between the power rollers to form a prepreg. The invention realizes the impregnation of the continuous fiber bundles by the high-viscosity polyetheretherketone resin melt, and at the same time ensures the degree of fiber impregnation of the impregnating tape and the continuity of preparation.
Description
Technical Field
The invention belongs to the field of continuous fiber reinforced thermoplastic composite materials, and particularly relates to a melting impregnation device and a preparation method of a continuous fiber reinforced thermoplastic prepreg tape.
Background
The continuous carbon fiber reinforced thermoplastic composite material has obvious advantages in the aspects of preparation process and forming rate, such as direct fusion welding, high forming rate (more than 10 times of that of a thermosetting composite material), excellent fracture toughness, high mechanical property, recyclability, difficult combustion, low smoke rate and toxicity, long-term storage at room temperature and the like, and is rapidly applied and developed in the industries of aerospace, automobiles and the like. In recent years, a new turning point has emerged for the application of thermoplastic composites in the field of commercial aircraft, i.e. thermoplastic composites have been used for the preparation of large-sized aircraft parts (such as nacelles), which will play an important role in promoting the development of commercial aircraft.
The thermoplastic carbon fiber composite material for aerospace is mainly a continuous carbon fiber reinforced polyether ether ketone high-performance resin (such as polyether ether ketone, polyether ketone and the like) composite material or a continuous carbon fiber reinforced polyphenylene sulfide high-performance resin composite material, and the thermoplastic resin system is different from general resin, has high melting temperature and high melt viscosity, is extremely difficult to melt and impregnate fibers, and restricts the preparation of corresponding prepreg tapes. The existing thermoplastic prepreg tape (material) impregnation device and preparation method mainly impregnate a fiber bundle through a glue groove, and impregnated or non-impregnated fibers directly generate relative motion on the surface of a metal roller or an impregnation die to realize the preparation of the prepreg tape, but the fibers can not completely take away resin in the glue groove, and the residual resin is degraded at a continuous high temperature, so that the performance of the material is reduced, and the impregnation of the fibers is also influenced by the degraded resin (such as carbonization); the relative movement between the fiber and the surface of the metal roller or the mold can cause the fiber and the resin melt to generate larger shearing force and possibly cause the problems of fiber damage, fiber breakage and the like due to the high viscosity of the polyether ether ketone resin melt or the polyphenylene sulfide resin melt.
Therefore, it is necessary to design a new type of impregnation device, and develop a method for preparing a continuous fiber prepreg tape for high temperature and high melt viscosity thermoplastic resin melt based on the device to avoid impregnating fiber bundles with glue baths and to avoid relative movement of the impregnated or non-impregnated fiber directly on the surface of a metal roller or an impregnation mold.
Disclosure of Invention
In view of the above, the present invention provides a melt impregnation device and a preparation method for a continuous fiber reinforced thermoplastic prepreg tape, which aims to solve the problems of high melt viscosity and difficulty in fiber impregnation of polyether ether ketone or polyphenylene sulfide thermoplastic resins, and the prepreg tape is prepared by controlling uniform coating of resin on an impregnation roller, realizing fiber impregnation of resin melt under the action of fiber tension, improving fiber and resin distribution by a homogenizing roller, and curing and molding by a glazing roller.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a melting and dipping device of a continuous fiber reinforced thermoplastic prepreg tape comprises a creel, a yarn dividing system, a heating system, a dipping system, a plurality of homogenizing rollers, a polishing roller and a drawing system which are arranged in sequence,
the heating system comprises a heating channel and a plurality of electric heating blowers, the plurality of electric heating blowers are uniformly distributed above and below the heating channel, a thermocouple is arranged in the heating channel corresponding to each electric heating blower, and the thermocouple detects the air temperature in the heating channel;
the impregnation system comprises an impregnation roller, an extrusion porous mouth mold and an extruder connected with the extrusion porous mouth mold, wherein the extrusion porous mouth mold is arranged below the impregnation roller, a groove is formed in the surface of the impregnation roller, the impregnation roller is connected with a motor through a transmission shaft, the extrusion porous mouth mold comprises a first arc porous mouth mold and a second arc porous mouth mold which are integrally formed and arranged up and down, a shallow cavity is formed between the first arc porous mouth mold and the groove of the impregnation roller, and the extruder is communicated with the second arc porous mouth mold through an extruder connecting pipe;
the device comprises a plurality of homogenizing rollers, an upper polishing roller, a lower polishing roller and a lower polishing roller, wherein the homogenizing rollers are arranged in parallel, the homogenizing rollers are arranged below the center of an impregnation roller, the upper polishing roller is a power pair roller and comprises a concave roller and a convex roller which are arranged up and down and used in a matched mode, a groove for accommodating a prepreg tape is formed in the concave roller, the groove of the concave roller is matched with the bulge of the convex roller, and the two ends of the power pair roller provide pressure between the rollers through springs;
the fiber belt drawn by the drawing system and drawn by the creel to the yarn separating system bypasses above the impregnation roller after passing through the temperature rising channel, and enters a space between the power pair rollers to form the prepreg belt after passing through the plurality of homogenizing rollers.
Furthermore, the second arc-shaped porous mouth mold and the first arc-shaped porous mouth mold are separated by a porous steel plate, and the upper surface of the first arc-shaped porous mouth mold is also provided with the porous steel plate.
Furthermore, the dipping roller and all the homogenizing rollers are power rollers capable of regulating speed and controlling temperature.
Further, a heat insulation system for reducing heat dissipation of the impregnation roller and the homogenizing roller is arranged on the peripheries of the impregnation roller and the homogenizing roller, and the heat insulation system is a heat insulation box made of a ceramic fiber blanket.
Furthermore, a pretensioning device for providing pretension for the fiber bundles is arranged at the front end of the creel.
Further, the surface of the homogenizing roller is subjected to mirror surface polishing and chromium plating, and the polishing roller is provided with a cooling structure.
Furthermore, a heating sleeve is wrapped at the bottom of the arc-shaped porous mouth mold.
A method for preparing a continuous fiber reinforced thermoplastic prepreg tape by using the melt impregnation device specifically comprises the following steps:
step one, a plurality of fiber bundles are withdrawn from a creel under certain pretension and enter a fiber dividing system, and the fiber dividing system divides the fiber bundles into fiber belts with uniform thickness and constant width;
step two, the fiber belt enters a heating system, the temperature of the fiber belt is raised to the impregnation temperature, and the fiber belt is pulled by a pulling system to enter the impregnation system;
extruding the resin melt into an arc-shaped porous opening die II by using an extruder, wherein the resin melt in the arc-shaped porous opening die II enters a first arc-shaped porous opening die through holes along with the increase of the amount of the extruded resin melt, the resin melt in the first arc-shaped porous opening die enters a shallow cavity of an impregnation roller through the holes, and the resin melt is uniformly coated on the surface of a groove of the impregnation roller along with the rotation of the impregnation roller; the fiber belt with certain pretension after being heated in the second step passes through the impregnation roller at a certain wrap angle, and under the pretension action of the fiber bundle, the resin melt on the surface of the groove of the impregnation roller is extruded into the fiber belt to form a preformed prepreg belt;
step four, the preformed prepreg tape is continuously pulled by a system to pass through a plurality of homogenizing rollers at a certain wrap angle, so that the fiber bundles and the resin melt are uniformly distributed; the preformed prepreg tape after passing through the plurality of homogenizing rollers is further pulled to pass through a polishing roller, and the prepreg tape is formed; and (3) drawing and rolling the continuous fiber reinforced thermoplastic prepreg tape by a drawing system.
Further, in the first step, the width of the fiber band dispersed by the yarn separating system is consistent with the width of the groove of the impregnation roller, the thickness of the fiber band after yarn separation is controlled to be 0.02mm-1mm, and the pretension of a single fiber bundle is 0.1N-50N.
Further, in the second step, the fiber band is heated to 360-450 ℃ by the heating system and then enters the impregnation system.
Compared with the prior art, the melt impregnation device for the continuous fiber reinforced thermoplastic prepreg tape has the following advantages:
1) the high viscosity polyether ether ketone resin melt or polyphenylene sulfide resin melt is uniformly coated on the surface of a power impregnation roller, a fiber bundle with certain pre-tension is wound on the power impregnation roller at a certain wrap angle and passes through the impregnation roller along with the rotation of the impregnation roller, and the impregnation force of the fiber by the resin melt comes from the pressure formed between a fiber belt and the impregnation roller. The invention avoids the high relative shearing force of the fiber bundle and the high-viscosity resin melt in the drawing direction, avoids the damage of the fiber and the discontinuity of the impregnation process caused by the damage.
2) The high-viscosity resin melt film on the surface of the impregnation roller is completely impregnated into the fiber band, and the thickness of the high-viscosity resin melt film can be accurately controlled through the drawing speed and the extrusion speed, so that the fiber content of the prepreg band is accurately controlled, the waste of resin is avoided, and the problem that the quality of the prepreg band and the continuity of the impregnation process are influenced due to the degradation of the non-impregnated fiber resin at high temperature is avoided.
3) The method realizes the impregnation of the high-viscosity polyether ether ketone resin melt or polyphenylene sulfide resin melt on the continuous fiber bundle, and simultaneously ensures the fiber impregnation degree of the impregnation belt and the preparation continuity.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic diagram of a melt impregnation apparatus for a continuous fiber reinforced thermoplastic prepreg tape according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a melt impregnation apparatus for a continuous fiber reinforced thermoplastic prepreg tape according to an embodiment of the present invention;
fig. 3 is a schematic structural view of a hair dryer heating system of the present invention;
FIG. 4 is a schematic view of the construction of the impregnation system of the present invention;
FIG. 5 is a sectional view taken along line A-A of FIG. 4;
FIG. 6 is a schematic view of the glazing roller of the present invention.
Description of reference numerals:
1-creel, 2-devillicating system, 3-heating system, 31-electric heating blower, 32-temperature-raising channel, 33-thermocouple, 4-dipping system, 41-dipping roller, 411-transmission shaft, 42-extrusion porous die, 421-arc porous die I, 422-arc porous die II, 423-heating sleeve, 43-extruder, 44-shallow cavity, 5-homogenizing roller, 6-glazing roller, 61-concave roller, 62-convex roller, 63-spring, 7-drawing system, 8-heat preservation system, 9-prepreg tape and 10-resin melt.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
As shown in fig. 1-6, a melting and dipping device for a continuous fiber reinforced thermoplastic prepreg tape comprises a creel 1, a yarn dividing system 2, a heating system 3, a dipping system 4, a plurality of homogenizing rollers 5, a glazing roller 6 and a drawing system 7 which are arranged in sequence, wherein a pre-tension device for providing pre-tension for a fiber bundle is arranged at the front end of the creel 1, and the tension after the fiber bundle is drawn can be controlled; the silk dividing system 2 can uniformly disperse a plurality of bundles of fibers into fiber belts with uniform thickness by using a silk dividing roller or blowing method and the like, and the thickness of the fiber belts after silk dividing can be controlled to be 0.02-1 mm;
the heating system 3 comprises a heating channel 32 and a plurality of electric heating blowers 31, the plurality of electric heating blowers 31 are uniformly distributed above and below the heating channel 32, a thermocouple 33 is arranged in the heating channel 32 corresponding to each electric heating blower 31, and the thermocouple 33 detects the air temperature in the heating channel 32; heating the upper surface and the lower surface of the dispersed continuous fiber band in a heating channel 32 by using an electric heating blower 31, testing the wind temperature by using a thermocouple 33, regulating and controlling the heating temperature of the fiber bundle by adjusting the wind speed, heating the passing fiber band to 360-450 ℃, and controlling the temperature precision to be +/-1 ℃;
the impregnation system 4 comprises an impregnation roller 41, an extrusion porous die 42 and an extruder 43 connected with the extrusion porous die, wherein the extrusion porous die 42 is arranged below the impregnation roller 41, a groove is formed in the surface of the impregnation roller 41, the impregnation roller 41 is connected with a motor through a transmission shaft 411, the extrusion porous die 42 comprises an arc porous die I421 and an arc porous die II 422 which are integrally formed and arranged up and down, a shallow cavity 44 is formed between the arc porous die I421 and the groove of the impregnation roller 41, the depth of the shallow cavity 44 is 0.05mm to 1mm, the depth of the shallow cavity is adjusted by adjusting the height of the extrusion porous die 42, namely the thickness of a resin melt coated on the surface of the impregnation roller is controlled, and the extruder 43 is communicated with the arc porous die II 422 through an extruder connecting pipe; the bottom of the arc-shaped porous mouth mold 2 is wrapped with a heating sleeve 423;
the homogenizing rollers 5 are arranged in parallel at equal heights, the homogenizing rollers 5 are arranged lower than the center of the dipping roller 41, the polishing rollers 6 are power roller pairs and comprise concave rollers 61 and convex rollers 62 which are arranged up and down and matched with each other, grooves for accommodating prepreg tapes are formed in the concave rollers 61, the grooves of the concave rollers 61 are matched with the protrusions of the convex rollers 62, and the two ends of each power roller pair provide pressure between the rollers through springs 63;
the fiber band drawn by the drawing system 7 and fed into the yarn separating system 2 after being drawn from the creel 1 passes through the temperature rising channel 32 and then bypasses above the soaking roller 41, and the fiber band bypassing the soaking roller 41 passes through the two homogenizing rollers 5 in an S-shaped winding mode and then extends into the space between the power roller pairs to form the prepreg tape 9.
The arc-shaped porous mouth mold two 422 and the arc-shaped porous mouth mold one 421 are separated by a porous steel plate, the upper surface of the arc-shaped porous mouth mold one 421 is also provided with the porous steel plate, the pore diameter of the arc-shaped porous mouth mold is 0.01mm-1mm, and the density is 1-100/mm2The two arc-shaped porous dies ensure that the extruded polyether ether ketone resin melt or polyphenylene sulfide resin melt is uniformly extruded along the surface of the impregnation roller and coated on the surface of the groove of the impregnation roller, and the thickness of the resin coating on the surface of the groove of the impregnation roller is regulated and controlled to be 0.02-1mm by regulating the extrusion rate and the rotating speed of the impregnation roller. The extrusion multi-hole die 42 is formed by three arc-shaped steel plates arranged from top to bottom in a surrounding mode, the side edges of the three arc-shaped steel plates are connected and sealed through a horizontal connecting plate, and a plurality of holes are uniformly formed in the first arc-shaped steel plate and the second arc-shaped steel plate from top to bottom and used for extruding resin melt.
The dipping rollers 41 and all the homogenizing rollers 5 are power rollers capable of regulating speed and controlling temperature, and the dipping rollers 41 and the homogenizing rollers 5 are heated in an electric heating mode; the speed of the dipping roller 41 is controlled to be 0.2 to 20 revolutions per minute; meanwhile, the surface temperature of the dipping roller 41 is controlled to be 360-450 ℃, and the temperature change is less than 1 ℃; two or more homogenizing rollers 5 are arranged, the surface of the homogenizing roller 5 is subjected to mirror surface treatment of polishing and chrome plating, and the surface hardness after treatment is between 800 and 1200 HV; the rotating speed of the homogenizing roller 5 is controlled to be 0.2-20 r/min, the temperature is controlled to be 360-450 ℃, and the control precision is +/-1 ℃; the wrap angle of the prepreg tape to the impregnation roller 41 and the homogenizing roller 5 is changed by adjusting the longitudinal position of the homogenizing roller 5.
The periphery of the impregnation roller 41 and the homogenization roller 5 is provided with a heat insulation system 8, the heat insulation system 8 is a heat insulation box made of a ceramic fiber blanket, the impregnation roller 4 and the homogenization roller 5 are integrally sealed, the heat dissipation of the high-temperature impregnation roller 4 and the homogenization roller 5 is reduced, and the temperature of the outer layer heat insulation material is lower than 50 ℃.
The surface of the polishing roller 6 is subjected to electroplating hardening and mirror surface treatment, and the surface hardness after treatment is between 800 and 1200 HV; the pressure between the pair of rollers is controlled by the tension of springs at two ends, and the tension is 10N-1000N; the rotating speed of the homogenizing roller is controlled to be 0.2-20 rpm, and the polishing roller 6 is provided with a water cooling structure which specifically comprises the following components: the power roller pair is cooled by water, and the temperature is controlled to be less than 100 ℃.
The drawing system 7 draws out the formed prepreg tape stably at a speed of 0.1-5 m/min.
A method for preparing a continuous fiber reinforced thermoplastic prepreg tape by using the melt impregnation device specifically comprises the following steps:
step one, a plurality of fiber bundles are withdrawn from a creel 1 under certain pretension and then enter a fiber dividing system 2, and the fiber bundles are divided into fiber belts with uniform thickness and constant width by the fiber dividing system 2; the width of the fiber band dispersed by the yarn separating system 2 is consistent with the width of the groove of the impregnation roller 41, the thickness of the fiber band after yarn separation is controlled to be 0.02mm-1mm, and the pretension of a single fiber bundle is 0.1N-50N;
step two, the fiber belt enters a heating system 3, and the fiber belt is pulled by a pulling system 7 to enter an impregnation system 4 after the temperature of the fiber belt is raised to 360-450 ℃ through the heating system 3;
extruding the polyether ether ketone resin melt into an arc-shaped porous opening die II 422 by an extruder 43, wherein along with the increase of the amount of the polyether ether ketone resin melt extruded, the resin melt in the arc-shaped porous opening die II 422 enters an arc-shaped porous opening die I421 through holes, the resin melt in the arc-shaped porous opening die I421 enters an impregnation roller shallow cavity 44 through holes, and along with the rotation of an impregnation roller 41, the resin melt 10 is uniformly coated on the surface of a groove of the impregnation roller 41; the fiber belt with certain pretension after being heated in the step two passes through an impregnation roller 41 at a certain wrap angle, radial pressure perpendicular to the fiber bundle is formed between the fiber belt with certain tension and the impregnation roller coated with polyether ether ketone resin film with certain thickness on the surface, and under the action of the radial pressure, the resin melt 10 on the surface of the groove of the impregnation roller 41 is extruded into the fiber belt to form a preformed prepreg belt;
step four, the preformed prepreg tape is continuously pulled by a system to pass through a plurality of homogenizing rollers 5 at a certain wrap angle, so that the uniform distribution of the fiber bundles and the resin melt 10 is realized; the pre-formed prepreg tape passing through the plurality of homogenizing rollers 5 is further pulled to pass through two reverse low-temperature press rollers, and the prepreg tape is formed; and (3) drawing and rolling the continuous fiber reinforced thermoplastic prepreg tape by a drawing system 7.
Extruding the high-viscosity polyether ether ketone melt through a specially designed extrusion die to uniformly coat the high-viscosity polyether ether ketone melt on the surface of the power high-temperature impregnation roller; drawing the preheated continuous fiber bundle with certain prestress and certain thickness through a high-temperature impregnation roller with the surface coated with the resin melt film at a certain wrap angle which is higher than or equal to the surface linear speed of the impregnation roller; in the process, the fiber bundle with certain pre-tension forms radial force on the surface of the impregnation roller, and the radial force extrudes the resin on the surface of the impregnation roller into the fiber bundle to realize impregnation of the fiber bundle; the fiber bundles subjected to primary resin impregnation continuously pass through a plurality of high-temperature homogenizing rollers at a certain wrap angle, so that the distribution uniformity of the fibers and the resin in the prepreg tape is further improved; the prepreg tape is then drawn through two opposing low temperature nip rolls to form a continuous fiber reinforced polyether ether ketone thermoplastic prepreg tape having a smooth surface.
In the invention, the fiber bundle, the high-viscosity resin melt and the impregnation roller do not generate obvious relative movement in the traction direction, thereby avoiding the problems of damage and fracture of the fiber under the action of high shear force, discontinuous production caused by excessive traction force and the like; meanwhile, the method can ensure that the resin melt extruded by the extruder is completely impregnated with the fibers, thereby avoiding resin waste, and simultaneously avoiding the problems that the resin at certain parts in the glue tank technology cannot be taken out by the fibers to be degraded, the quality of the prepreg tape is influenced, the prepreg tape cannot be continuously produced and the like.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (8)
1. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape, characterized by: comprises a creel (1), a yarn dividing system (2), a heating system (3), an impregnation system (4), a plurality of homogenizing rollers (5), a glazing roller (6) and a traction system (7) which are arranged in sequence,
the heating system (3) comprises a heating channel (32) and a plurality of electric heating blowers (31), the electric heating blowers (31) are uniformly distributed above and below the heating channel (32), a thermocouple (33) is arranged in the heating channel (32) corresponding to each electric heating blower (31), and the thermocouple (33) detects the wind temperature in the heating channel (32);
the dipping system (4) comprises a dipping roller (41), an extrusion porous mouth mold (42) and an extruder (43) connected with the extrusion porous mouth mold, the extrusion porous mouth mold (42) is arranged below the dipping roller (41), a groove is formed in the surface of the dipping roller (41), the dipping roller (41) is connected with a motor through a transmission shaft (411), the extrusion porous mouth mold (42) comprises a first arc-shaped porous mouth mold (421) and a second arc-shaped porous mouth mold (422) which are integrally formed and arranged up and down, a shallow cavity (44) is formed by matching the first arc-shaped porous mouth mold (421) and the groove of the dipping roller (41), and the extruder (43) is communicated with the second arc-shaped porous mouth mold (422) through an extruder connecting pipe; the two arc-shaped porous dies ensure that the extruded polyether ether ketone resin melt or polyphenylene sulfide resin melt is uniformly extruded along the surface of the impregnation roller and coated on the surface of the groove of the impregnation roller; the second arc-shaped porous mouth die (422) and the first arc-shaped porous mouth die (421) consist ofThe porous steel plates are separated, and the upper surface of the first arc-shaped porous die (421) is also provided with the porous steel plates; the diameter of the pores of the arc-shaped porous mouth mold is 0.01mm-1mm, and the density is 1 to 100 per mm2The two arc-shaped porous dies ensure that the extruded polyether ether ketone resin melt or polyphenylene sulfide resin melt is uniformly extruded along the surface of the impregnation roller and coated on the surface of the groove of the impregnation roller, and the thickness of the resin coating on the surface of the groove of the impregnation roller is regulated and controlled to be 0.02-1mm by regulating the extrusion rate and the rotating speed of the impregnation roller;
the device comprises a plurality of homogenizing rollers (5), wherein the homogenizing rollers (5) are arranged in parallel, the homogenizing rollers (5) are lower than the center of a soaking roller (41), the polishing rollers (6) are power roller pairs and comprise concave rollers (61) and convex rollers (62) which are arranged up and down and used in a matched mode, grooves for containing prepreg tapes are formed in the concave rollers (61), the grooves of the concave rollers (61) are matched with the protrusions of the convex rollers (62), and pressure between the rollers is provided at two ends of each power roller pair through springs (63);
the fiber belt drawn by the drawing system (7) and returned from the creel (1) into the yarn separating system (2) bypasses from the upper part of the impregnation roller (41) after passing through the temperature rising channel (32), and enters the space between the power roller pairs to form a prepreg belt (9) after passing through the plurality of homogenizing rollers (5) after bypassing the impregnation roller (41);
extruding the high-viscosity polyether ether ketone melt through an extrusion die and uniformly coating the high-viscosity polyether ether ketone melt on the surface of the power high-temperature impregnation roller; drawing the preheated continuous fiber bundle with certain prestress and certain thickness through a high-temperature impregnation roller with the surface coated with the resin melt film at a certain wrap angle which is higher than or equal to the surface linear speed of the impregnation roller; in the process, the fiber bundle with certain pre-tension forms radial force on the surface of the impregnation roller, and the radial force extrudes the resin on the surface of the impregnation roller into the fiber bundle to realize impregnation of the fiber bundle; the fiber bundles subjected to primary resin impregnation continuously pass through a plurality of high-temperature homogenizing rollers at a certain wrap angle, so that the distribution uniformity of the fibers and the resin in the prepreg tape is further improved; then, the prepreg tape is drawn through two reverse low-temperature press rollers to form a continuous fiber reinforced polyether ether ketone thermoplastic prepreg tape with a smooth surface;
and a heat insulation system (8) for reducing the heat dissipation of the impregnation roller and the homogenization roller is arranged at the periphery of the impregnation roller (41) and the homogenization roller (5), and the heat insulation system (8) is a heat insulation box made of a ceramic fiber blanket.
2. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the dipping roller (41) and all the homogenizing rollers (5) are power rollers capable of regulating speed and controlling temperature.
3. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the front end of the creel (1) is provided with a pre-tension device for providing pre-tension for the fiber bundle.
4. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the surface of the homogenizing roller (5) is subjected to mirror surface polishing and chromium plating, and the polishing roller (6) is provided with a cooling structure.
5. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: and a heating sleeve (423) is wrapped at the bottom of the arc-shaped porous die II (422).
6. A method of making a continuous fiber reinforced thermoplastic prepreg tape using the melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape according to any one of claims 1 to 5, characterized by: the method specifically comprises the following steps:
step one, a plurality of fiber bundles are withdrawn from a creel (1) under certain pretension and then enter a fiber dividing system (2), and the fiber bundles are divided into fiber belts with uniform thickness and constant width by the fiber dividing system (2);
step two, the fiber belt enters a heating system (3), the temperature of the fiber belt is raised to the impregnation temperature, and the fiber belt is pulled by a pulling system (7) to enter an impregnation system (4);
extruding the resin melt (10) into an arc-shaped porous opening die II (422) by an extruder (43), wherein the resin melt in the arc-shaped porous opening die II (422) enters an arc-shaped porous opening die I (421) through holes along with the increase of the amount of the extruded resin melt (10), the resin melt in the arc-shaped porous opening die I (421) enters a shallow cavity (44) of the impregnation roller through the holes, and the resin melt (10) is uniformly coated on the surface of the groove of the impregnation roller (41) along with the rotation of the impregnation roller (41); the fiber belt with certain pretension after being heated in the second step passes through an impregnation roller (41) at a certain wrap angle, and under the pretension action of a fiber bundle, the resin melt (10) on the surface of the groove of the impregnation roller (41) is extruded into the fiber belt to form a preformed prepreg belt;
step four, continuously drawing the preformed prepreg tape by a drawing system to pass through a plurality of homogenizing rollers (5) at a certain wrap angle, so that the fiber bundles and the resin melt (10) are uniformly distributed; the preformed prepreg tape passing through the plurality of homogenizing rollers (5) is further pulled to pass through a polishing roller (6) to be formed; and (3) drawing and rolling the continuous fiber reinforced thermoplastic prepreg tape by a drawing system (7).
7. The method of making a continuous fiber reinforced thermoplastic prepreg tape according to claim 6, characterized in that: in the first step, the width of the fiber band dispersed by the yarn separating system (2) is consistent with the width of the groove of the impregnation roller (41), the thickness of the fiber band after yarn separation is controlled to be 0.02mm-1mm, and the pretension of a single fiber bundle is 0.1N-50N.
8. The method of making a continuous fiber reinforced thermoplastic prepreg tape according to claim 7, characterized in that: in the second step, the fiber band is heated to 360-450 ℃ through the heating system (3) and then enters the impregnation system (4).
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