CN112848389A - Method for rapidly forming hybrid fiber reinforced thermoplastic composite structure - Google Patents
Method for rapidly forming hybrid fiber reinforced thermoplastic composite structure Download PDFInfo
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- CN112848389A CN112848389A CN202011519358.7A CN202011519358A CN112848389A CN 112848389 A CN112848389 A CN 112848389A CN 202011519358 A CN202011519358 A CN 202011519358A CN 112848389 A CN112848389 A CN 112848389A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- Injection Moulding Of Plastics Or The Like (AREA)
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Abstract
The invention provides a method for quickly forming a hybrid fiber reinforced thermoplastic composite structure. The method adopts an injection molding-compression molding process and a rapid variable mold temperature technology, fixes fiber woven cloth in a cavity of an injection mold through primary mold closing of the mold, and forms a reserved impregnation gap; and opening the rapid variable mold temperature system, heating the fiber woven cloth in the cavity to a temperature higher than the melting temperature of the thermoplastic resin, injecting short fiber reinforced thermoplastic resin melt to a reserved impregnation gap, carrying out secondary mold closing to complete the full impregnation of the molten resin in the thickness direction of the fiber woven cloth and the injection molding of the surface characteristic structure of the fiber woven cloth, and then maintaining the pressure and cooling to obtain the composite structure. The invention has one-step molding and simultaneously has a continuous fiber and short fiber reinforced thermoplastic composite structure, thereby greatly shortening the molding period and adding production procedures and improving the production efficiency. The method has wide application prospect in the fields of aerospace, rail transit, automobile industry and the like.
Description
Technical Field
The invention relates to an integrated molding method of a complex structural part made of a composite material, in particular to a method for quickly molding a hybrid fiber reinforced thermoplastic composite structure.
Background
Energy conservation and environmental protection are common problems in current industrial development, and less energy consumption and emission reduction become problems which are urgently needed to be solved in the development of manufacturing industry, particularly in the fields of aerospace, rail transit, automobile industry and the like. Taking an automobile as an example, the mass is reduced by 10%, the fuel consumption can be reduced by 7-8%, the emission of carbon dioxide can be reduced by 6-7%, and the emission of other harmful gases can be reduced by 3-4%. The development of light weight has become a trend of global manufacturing development.
The fiber reinforced thermoplastic composite material has the advantages of light weight, high specific strength, easy processing, recoverability and the like, and is increasingly applied to bearing structural members in the fields of automobiles, aerospace and the like. Because the light-weight structural member has different service working conditions and different structural shapes, a single composite material cannot meet the requirements of various aspects of design to the greatest extent. In order to realize the light weight to the maximum extent and simultaneously consider the cost and the structural performance, a hybrid fiber reinforced thermoplastic composite material composite structure is produced, a thin-wall high-strength part reinforced by continuous fibers in the structure is used as a main bearing part, and a short fiber strong characteristic structure is used as a secondary bearing part to play roles of connection and energy absorption. Currently, the manufacture of hybrid fiber reinforced thermoplastic composite structures requires two processes: (1) preparation of a sheet (prepreg). The method mainly adopts the processes of a hot pressing process, a double-steel belt press continuous dipping method, a powder dipping method, a film laminating method, a fiber mixing method and the like to prepare the continuous fiber reinforced thermoplastic composite material plate, and (2) the molding of a composite structure. The thermoplastic composite material composite structure is manufactured by post-processing methods such as injection-hot press molding process or welding. The existing manufacturing process has the problems of complicated working procedures, long forming period, high additional energy consumption and the like.
Therefore, it is necessary to invent a novel hybrid fiber reinforced thermoplastic composite structure forming method to reduce the production processes, improve the processing efficiency and quality, reduce the production energy consumption, and realize mass automatic production.
Disclosure of Invention
In view of the above-mentioned drawbacks and needs of improvement in the prior art, the present invention provides a method for rapidly forming a hybrid fiber-reinforced thermoplastic composite structure, which simultaneously forms a continuous fiber-reinforced thermoplastic composite member and its surface structure features by using a rapid mold temperature varying system and an injection-compression molding process, thereby achieving the integrated manufacturing of the hybrid fiber-reinforced thermoplastic composite structure.
In order to achieve the above object, an embodiment of the present invention provides a method for rapidly forming a hybrid fiber reinforced thermoplastic composite structure, comprising the steps of:
step (a), placing fiber cloth:
cutting, drying and dedusting fiber cloth, and then placing the fiber cloth on a parting surface of an injection mold;
step (b), intermittent dipping stage:
carrying out primary die assembly on the injection mold, fixing the fiber cloth in a cavity of the injection mold by using a die locking force, and forming a reserved impregnation gap; opening the rapid variable mold temperature system, setting the heating temperature and the heating rate according to the melting point of the thermoplastic material, and injecting the short fiber reinforced thermoplastic resin melt into the reserved gap between the mold cavity and the fiber cloth after the temperature of the fiber cloth in the mold cavity is raised to the set temperature
Step (c), the composite structure forming stage:
carrying out secondary die assembly on the injection mould, realizing impregnation of the fiber cloth in the thickness direction by using an injection-compression molding process, and simultaneously molding the surface structure characteristic;
and (d) pressure maintaining and cooling:
closing the heating system, opening the cooling system, cooling the injection mold according to the set cooling rate and the demolding temperature, and maintaining the pressure;
step (e), opening the die to take out the part:
and opening the injection mold, taking down the composite structure and preparing for the next processing cycle procedure.
Preferably, in the step (b), the heating temperature is 1.1 to 1.3 times of the melting temperature of the injection molding material. The temperature rise rate is 20-1000 ℃/min.
Preferably, in the step (b), the temperature rise rate is 60-300 ℃/min.
Preferably, in the step (b-c), the injection pressure is 50-200 MPa.
Preferably, in the step (b-c), the injection pressure is 80-120 MPa.
Preferably, in the step (d), the cooling rate is 10-500 ℃/min, the injection mold is cooled to 40-80 ℃, and the pressure maintaining pressure is 20-100 MPa and is lower than the injection pressure in the step (b-c).
Preferably, in the step (d), the cooling rate is 50-200 ℃/min, and the pressure maintaining pressure is 40-60 MPa.
Preferably, the composite structure comprises a continuous fiber reinforced thermoplastic composite structure and a short fiber reinforced thermoplastic resin molded surface feature.
Preferably, the surface features comprise one or more of ribs, bosses or the like.
The embodiment of the invention also provides a rapid variable mold temperature system, which comprises the following structures: the temperature sensor, the heating device and the cooling channel are arranged on the injection mold; two ends of the heating device are respectively connected with the temperature controller and the relay to form a loop; two ends of the cooling channel are sequentially connected with the electric valve and the cooling device to form a cooling circulation loop; the electric valve is connected with the temperature sensor through the variable frequency controller; and the PLC controls the relay and the variable frequency controller according to signals of the temperature controller and the temperature sensor so as to control the heating rate and the cooling rate.
Preferably, a pump is arranged on the cooling device. For controlling the flow of the cooling medium.
Preferably, the pump is connected to the electrically operated valve via a filter.
The scheme of the invention has the following beneficial effects:
the invention adopts a rapid variable mold temperature system to heat the fiber woven cloth in the cavity, combines the injection pressure and the molten resin provided by the injection molding platform, and has a continuous fiber and short fiber reinforced thermoplastic composite structure at the same time by one-step molding, thereby greatly shortening the molding period and additional production procedures and improving the production efficiency of high-performance thermoplastic composite material members.
The rapid forming method provided by the invention can reduce the working procedures and improve the processing efficiency and the processing quality, can realize large-scale automatic production by adopting the advanced and efficient injection forming process, and simultaneously designs and develops the rapid variable mold temperature system to solve the problem that the thermoplastic resin cannot be directly used for producing the continuous fiber reinforced composite material structure by adopting the injection forming process due to high viscosity.
The invention is suitable for the integrated manufacture of thermoplastic composite material members with light weight, high strength and complex structure, and has wide application prospect in the fields of aerospace, rail transit, automobile industry and the like.
Drawings
FIG. 1 is a process flow of the present invention.
FIG. 2 is a schematic view of a composite structure formed in accordance with an embodiment of the present invention.
Fig. 3 is a rapid temperature change control system of the present invention.
[ description of reference ]
1-injection molding; 111-fiber cloth; 112-a clamping device; 113-a spring device; 114-a compression structure; 115-locating pins; 116-a composite structure; 116 a-a continuous fiber reinforced thermoplastic composite structure; 116 b-surface features; 2-an injection molding machine; 3-a cooling device; 4-a pump; 5-a filter; 6, electrically operated valve; 7-a variable frequency controller; 8-a temperature sensor; 9-a heating device; 10-a cooling channel; 11-a temperature controller; 12-PLC; 13-relay.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
Example 1
As shown in fig. 1 and 2, an embodiment of the present invention provides a method for rapid prototyping a hybrid fiber reinforced thermoplastic composite structure, comprising the steps of:
(a) placing fiber cloth: the fiber cloth 111 is woven by glass fiber, cut into 240mm × 150mm × 1mm, dried and dedusted, and placed at the parting surface of the injection mold through a clamping device 112;
(b) a gap impregnation stage: the injection mold 1 is subjected to primary mold closing, the positioning pin 115 is matched with the pressing structure 114 to close the mold cavity, and meanwhile, under the action of the spring device 113, the fiber cloth is fixed in the mold cavity by the mold male mold; opening a rapid mold temperature changing system, setting the heating temperature of the mold to be 200 ℃, the heating rate to be 100 ℃/min, and starting heat preservation after the mold is heated to the specified temperature; injecting short fiber reinforced molten polypropylene into a gap area between a male die of a die and fiber cloth, wherein the injection pressure is 80MPa, and the injection time is 20 s;
(c) and (3) forming a composite structure: after the gap impregnation stage is finished, carrying out secondary die assembly on the injection mould, pushing the molten polymer in the gap area to finish impregnation in the thickness direction of the fiber cloth, forming a continuous fiber reinforced thermoplastic composite material structure 116a, and simultaneously injecting short fiber reinforced resin reinforcing ribs on the surface of the continuous fiber reinforced thermoplastic composite material structure, so as to form a surface structure characteristic 116b, and finishing bonding of the continuous fiber reinforced composite material structure and the short fiber reinforced resin reinforcing rib structure;
(d) pressure maintaining and cooling processes: closing the heating system, opening the cooling system to cool the injection molded structural part to the demolding temperature of 80 ℃, wherein the cooling rate is 50 ℃/min, and the pressure of a mold cavity is kept to be 40MPa during cooling;
(e) opening the mold and taking out the parts: the injection mold 1 is opened and the structural part 116 is removed and ready for the next processing cycle.
Example 2
As shown in fig. 1 and 2, an embodiment of the present invention provides a method for rapid prototyping a hybrid fiber reinforced thermoplastic composite structure, comprising the steps of:
(a) placing fiber cloth: the fiber cloth 111 is woven carbon fiber cloth, cut into 240mm × 150mm × 1mm, dried and dedusted, and then placed at the parting surface of the injection mold through a clamping device 112;
(b) a gap impregnation stage: the injection mold 1 is subjected to primary mold closing, the positioning pin 115 is matched with the pressing structure 114 to close the mold cavity, and meanwhile, under the action of the spring device 113, the fiber cloth is fixed in the mold cavity by the mold male mold; opening a rapid mold temperature changing system, setting the heating temperature of the mold to be 290 ℃, the heating rate to be 100 ℃/min, and starting to cool when the mold is heated to a specified temperature; injecting short fiber reinforced molten polyamide 66(PA66) into a gap area between a male die of the die and the fiber cloth, wherein the injection pressure is 80MPa, and the injection time is 20 s;
(c) and (3) forming a composite structure: after the gap impregnation stage is finished, the injection mold is subjected to secondary mold closing, the molten PA66 in the gap area is pushed to finish the impregnation in the thickness direction of the fiber cloth, a continuous fiber reinforced thermoplastic composite material structure 116a is formed, meanwhile, short fiber reinforced PA66 is injected on the surface of the continuous fiber reinforced thermoplastic composite material structure to form a PA66 reinforcing rib, namely, a surface structure feature 116b is formed, and the bonding of the continuous fiber reinforced PA66 composite material and the short fiber reinforced PA66 reinforcing rib is finished.
(d) Pressure maintaining and cooling processes: closing the heating system, opening the cooling system to cool the injection molded composite structure to the demolding temperature of 100 ℃, wherein the cooling rate is 50 ℃/min, and the pressure of a mold cavity is kept to be 40MPa during cooling;
(e) opening the mold and taking out the parts: the injection mold 1 is opened and the composite structural member 116 is removed in preparation for the next processing cycle.
Example 3
As shown in fig. 3, an embodiment of the present invention provides a rapid mold temperature changing system, which includes the following structure:
the injection molding machine comprises an injection molding die 1 arranged on an injection molding machine 2, wherein a temperature sensor 8, a heating device 9 and a cooling channel 10 are arranged on the injection molding die 1; two ends of the heating device 9 are respectively connected with the temperature controller 11 and the relay 13 to form a loop; one end of the cooling channel 10 is sequentially connected with the electric valve 6, the filter 5, the pump 4 and the cooling device 3, and the cooling device 3 is connected with the other end of the cooling channel 10 to form a cooling circulation loop; the electric valve 6 is connected with a temperature sensor 8 through a variable frequency controller 7; the PLC12 controls the relay 13 and the variable frequency controller 7 according to signals of the temperature controller 11 and the temperature sensor 8 to control the heating rate and the cooling rate.
During heating, a target temperature is set through the temperature controller 11, and the PLC12 sends out a control signal according to the temperature rising rate requirement and a signal of the temperature sensor 8 to control the working mode of the relay 13, so that the heating time is controlled to adjust different temperature rising rates. During cooling, the pump 4 is opened, cooling medium enters the die cooling channel 10 from the cooling device 3 through the filter 5 and the electric valve 6, the PLC12 sends out a control signal to control the variable frequency controller 7 according to the set target cooling temperature and the set cooling rate requirement, and finally the cooling rate requirement is controlled by adjusting the flow rate and the flow rate of the cooling medium.
The invention improves the processing efficiency, reduces the production cost, prepares the high-performance hybrid fiber reinforced thermoplastic composite material composite structural member, and adopts the advanced and efficient injection molding process to realize the automatic mass production, designs and develops the rapid variable mold temperature system and the injection-compression molding process, and simultaneously molds the continuous fiber reinforced thermoplastic composite material and the surface short fiber reinforced resin characteristic structure thereof, thereby realizing the integrated manufacturing of the hybrid fiber reinforced thermoplastic composite material composite structure
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (10)
1. A method for rapidly forming a hybrid fiber reinforced thermoplastic composite structure is characterized by comprising the following steps:
step (a), placing fiber cloth:
placing the fiber cloth at the parting surface of the injection mold,
step (b), intermittent dipping stage:
carrying out primary die assembly on the injection mold, fixing the fiber cloth in a cavity of the injection mold, simultaneously opening a rapid die temperature changing system, and setting a heating temperature and a heating rate according to the melting point of the thermoplastic resin; after the temperature of the fiber cloth in the cavity is raised to a set temperature, injecting short fiber reinforced thermoplastic resin melt into a reserved gap between the cavity of the mold and the fiber cloth,
step (c), the composite structure forming stage:
carrying out secondary die assembly on the injection mold, realizing impregnation of the fiber cloth in the thickness direction by using an injection-compression molding process, and simultaneously molding a surface characteristic structure of the fiber cloth;
pressure maintaining and cooling processes in the step (d):
closing the heating system, opening the cooling system, cooling the injection mold according to the set cooling rate and the demolding temperature, and maintaining the pressure;
step (e), opening the die to take out the part:
after cooling, the injection mold is opened and the composite structure is removed.
2. The method for rapid prototyping of hybrid fiber reinforced thermoplastic composite structure as described in claim 1 wherein in step (b-c) the heating temperature is 1.1 to 1.3 times the melting temperature of the injection molding material. The heating rate is 20-1000 ℃/min; the injection pressure is 50-200 MPa.
3. The method for rapid prototyping of the hybrid fiber reinforced thermoplastic composite structure of claim 2 wherein in step (b-c) the temperature rise rate is 60-300 ℃/min; the injection pressure is 80-120 MPa.
4. The method for rapid prototyping of hybrid fiber reinforced thermoplastic composite structure as described in claim 3, wherein in the step (d), the cooling rate is 10-500 ℃/min, the injection mold is cooled to 40-80 ℃ below the crystallization temperature of the thermoplastic resin, and the pressure holding pressure is 20-100 MPa, which is lower than the injection pressure in the step (b-c).
5. The method for rapid prototyping of the hybrid fiber reinforced thermoplastic composite structure of claim 4 wherein in step (d) the cooling rate is 50-200 ℃/min and the dwell pressure is 40-60 MPa.
6. The method of rapid prototyping a hybrid fiber reinforced thermoplastic composite structure as described in claim 5 wherein the composite structure comprises a continuous fiber reinforced thermoplastic composite structure and a surface feature formed of a short fiber reinforced thermoplastic resin.
7. The method of rapid prototyping as in claim 6 wherein the surface features comprise one or more of ribs and bosses.
8. The utility model provides a quick variable mould temperature system which characterized in that includes following structure: the temperature sensor, the heating device and the cooling channel are arranged on the injection mold; two ends of the heating device are respectively connected with the temperature controller and the relay to form a loop; two ends of the cooling channel are sequentially connected with the electric valve and the cooling device to form a cooling circulation loop; the electric valve is connected with the temperature sensor through the variable frequency controller; and the PLC controls the relay and the variable frequency controller according to signals of the temperature controller and the temperature sensor so as to control the heating rate and the cooling rate.
9. The rapid temperature change system according to claim 8, wherein the cooling device is provided with a pump for controlling the flow of the cooling medium.
10. The system of claim 9, wherein said pump is connected to said electrically operated valve through a filter.
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