CN108973161B - Thermoplastic prepreg cloth for carbon fiber composite material artificial limb and preparation method of artificial limb component - Google Patents

Thermoplastic prepreg cloth for carbon fiber composite material artificial limb and preparation method of artificial limb component Download PDF

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Publication number
CN108973161B
CN108973161B CN201810654131.XA CN201810654131A CN108973161B CN 108973161 B CN108973161 B CN 108973161B CN 201810654131 A CN201810654131 A CN 201810654131A CN 108973161 B CN108973161 B CN 108973161B
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carbon fiber
artificial limb
thermoplastic
dimensional
component
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CN108973161A (en
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朱波
曹伟伟
乔琨
王永伟
张敏
高学平
赵圣尧
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping 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
    • B29C70/34Shaping 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 shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00Shaping characteristics in general
    • B29C2791/002Making articles of definite length, i.e. discrete articles

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Materials For Medical Uses (AREA)
  • Prostheses (AREA)

Abstract

The invention discloses thermoplastic prepreg cloth for a carbon fiber composite material artificial limb and a preparation method of an artificial limb component. The invention firstly adopts the fabrics with various structures mixed with carbon fiber and the thermoplastic membranous resin matrix to carry out hot melt compounding to prepare thermoplastic prepreg cloth, then the prepreg cloth is used for carrying out two-dimensional lamination melting or three-dimensional structure melting, the semi-finished artificial limb component is formed by cooling after the melting, and finally the artificial limb component with different shapes is obtained by softening and hot press molding in a closed die through mechanical cutting and trimming and cooling. The thermoplastic carbon fiber composite material artificial limb component has the characteristic of repeated softening and heating forming, can be adjusted in different physiological curvatures and appearance structures according to the specific requirements of users, and has good wearing adaptability.

Description

Thermoplastic prepreg cloth for carbon fiber composite material artificial limb and preparation method of artificial limb component
Technical Field
The invention relates to a composite material artificial limb protector, in particular to thermoplastic prepreg cloth for a carbon fiber composite material artificial limb and a preparation method of an artificial limb component.
Background
The artificial limb is an indispensable auxiliary tool in the rehabilitation process of the disabled, and the development of materials for the artificial limb is the earliest and fastest branch in the field of rehabilitation engineering. The complexity of the movement of the human body trunk organ necessarily brings about the complexity of the structural molding, which makes the technical content requirement in the preparation and molding of the artificial limb higher. At present, some ultra-light metal materials such as light aluminum alloy, titanium alloy and high-performance composite materials are adopted in the development of modern artificial limbs to improve the wearing flexibility and the movement comfort, but the self-weight requirement of artificial limb parts is lighter along with the continuous improvement of the movement requirement of disabled people, and meanwhile, the human body fusion in the wearing process is also a key requirement. The leg or arm structure of the human body is different from person to person, the shape and the physiological curvature are different, and the individual requirements of a plurality of users are often not met by adopting the structural design of the general shape, so that the artificial limb with the specific shape and the physiological curvature designed for different users becomes the key requirement of application. However, the molding process of the conventional metal material and the conventional thermosetting composite material is influenced by the characteristics of the materials, and the molding process can only be performed once and cannot be adapted to the micro adjustment of the shape and the curvature in the long-term use process, so that the research on the design, the material and the molding mode of the artificial limb fitting made of the novel composite material is very important.
Disclosure of Invention
In view of the above-mentioned deficiencies of the prior art, the inventors have conducted long-term technical and practical research and provide a method for preparing carbon fiber thermoplastic prepreg cloth, the thermoplastic prepreg cloth prepared by the method can be used for processing semi-finished carbon fiber composite artificial limb components, and meanwhile, the semi-finished carbon fiber composite artificial limbs with different shapes and physiological curvatures can be prepared by simple and efficient compression softening molding technology. Firstly, hot-melting and compounding various structural fabrics mixed with carbon fibers and a thermoplastic film-shaped resin matrix to prepare thermoplastic prepreg cloth, then carrying out two-dimensional lamination melting or three-dimensional structure melting by using the prepreg cloth, cooling to form a semi-finished artificial limb component after melting, finally sealing a die for softening and hot-pressing molding through mechanical cutting and trimming, and cooling to obtain artificial limb components with different shapes.
The invention aims to provide a preparation method of carbon fiber thermoplastic prepreg.
The invention also aims to provide a method for preparing the carbon fiber composite material artificial limb component based on the carbon fiber thermoplastic prepreg.
The invention also aims to provide the carbon fiber composite material artificial limb component.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect of the present invention, there is provided a method for preparing a carbon fiber thermoplastic prepreg, the method comprising: fixing and spreading the thermoplastic resin adhesive film according to the size matched with the width of the carbon fiber fabric, and rolling, dipping and compounding the carbon fiber fabric and the thermoplastic resin adhesive film.
Preferably, the carbon fiber fabric is prepared by weaving and molding high-strength carbon fibers/or high-modulus carbon fibers/or high-strength carbon fibers/or high-modulus carbon fibers and hybrid fibers;
the high-strength carbon fiber is any one of T300, T700, T800 and T1000;
the high modulus carbon fiber is any one of M40, M40J, M55, M55J, M60 and M60J;
the hybrid fiber can be selected from inorganic fibers including but not limited to alumina fiber, silicon carbide fiber, boron nitride fiber, silicon nitride fiber;
the carbon fiber can be in a one-way fiber or two-dimensional fabric structure form, and can also be in a three-dimensional weaving structure form; the two-dimensional fabric structure can be in a plain weave, twill weave or satin weave form, and the three-dimensional weaving structure can be any one of three-dimensional four-way, three-dimensional five-way, three-dimensional six-way and three-dimensional seven-way weaving structures;
preferably, the gram weight of the thermoplastic resin adhesive film is controlled to be 5-20g/m2The thermoplastic resin can be any one of polyethylene, acrylic acid-vinyl copolymer, ethylene-methacrylic acid copolymer, ethylene-methyl methacrylate copolymer, polypropylene, polyurethane, polyphenylene sulfide, polyether ether ketone and polyamide;
preferably, the rolling impregnation method comprises the following specific steps: continuously rolling, dipping and compounding the carbon fiber fabric and the adhesive film through a plurality of groups of hot rollers; further preferably rolling by four groups of hot rollers; the temperature of the roller bodies of the four groups of hot rollers can be automatically adjusted according to the hot melting temperature characteristic of the adhesive film so as to ensure the hot melting infiltration degree;
further preferably, the temperature of the four groups of hot roller bodies rises in a gradient manner, the temperature of the first group of hot roller bodies is 100-110 ℃, and the temperature of the fourth group of hot roller bodies is 120-150 ℃; after being pressurized and hot-melted by four groups of hot rollers, the glue film is melted and thoroughly permeates the carbon fiber fabric to form carbon fiber thermoplastic prepreg cloth; the total gel content of the carbon fiber thermoplastic prepreg is controlled within the range of 20-30%;
in a second aspect of the invention, there is provided a method of making a carbon fiber composite prosthetic component based on a carbon fiber thermoplastic prepreg, the method comprising:
s1, pressurizing and hot melting carbon fiber thermoplastic prepreg cloth in a closed die cavity, and cooling and forming to obtain a thermoplastic carbon fiber composite artificial limb semi-finished product component;
s2, performing mechanical secondary processing on the semi-finished product part of the thermoplastic carbon fiber composite artificial limb prepared in the step S1, then placing the semi-finished product part in a closed die cavity for softening and pressing, and cooling and molding to obtain the thermoplastic carbon fiber composite artificial limb part.
Preferably, the method further comprises the step of adjusting the micro-appearance and the curvature of the prosthetic component prepared in the step S2 by means of secondary heating and pressurizing softening molding;
preferably, the specific processing conditions of the pressure hot melting in the step S1 are as follows: the temperature is 120-;
preferably, in the step S2, the softening and pressing temperature is controlled to be 130-150 ℃, and the softening and pressing pressure is controlled to be 16-20 MPa;
in a third aspect of the invention, a prosthetic component is provided that is prepared by the above-described method.
The invention has the beneficial effects that:
the invention provides a carbon fiber thermoplastic prepreg cloth and a method for preparing a carbon fiber composite material artificial limb component based on the carbon fiber thermoplastic prepreg cloth, wherein the carbon fiber thermoplastic prepreg cloth is prepared by rolling, dipping and compounding a carbon fiber fabric and a thermoplastic resin adhesive film, and then the carbon fiber composite material artificial limb component is prepared, so that the finally prepared artificial limb component has the advantages of light weight, high strength, long service life and the like, and the prepared artificial limb component can flexibly adjust the requirements of appearance, curvature and special wearing body type according to the use requirement, thereby ensuring that a wearer can wear the artificial limb component more comfortably;
meanwhile, the preparation process of the invention does not need large-scale expensive devices and instruments, and is simple, thus the production is simple and the operation is convenient. Therefore, the invention has wide industrial application prospect and practical application value.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
In particular, in one embodiment of the present invention, a method for preparing a carbon fiber thermoplastic prepreg is provided, by which a semi-finished carbon fiber composite prosthetic component can be processed, and by which composite prosthetic limbs of different shapes and physiological curvatures can be prepared by a simple and efficient pressure softening molding technique. Firstly, hot-melting and compounding various structural fabrics mixed with carbon fibers and a thermoplastic film-shaped resin matrix to prepare thermoplastic prepreg cloth, then carrying out two-dimensional lamination melting or three-dimensional structure melting by using the prepreg cloth, cooling to form a semi-finished artificial limb component after melting, finally sealing a die for softening and hot-pressing molding through mechanical cutting and trimming, and cooling to obtain artificial limb components with different shapes.
In another embodiment of the present invention, the carbon fiber may be in a unidirectional fiber or two-dimensional fabric structure, and may also be in a three-dimensional woven structure. The two-dimensional fabric structure can be in a plain weave, twill weave or satin weave form, and the three-dimensional weaving structure can be any one of three-dimensional four-way, three-dimensional five-way, three-dimensional six-way and three-dimensional seven-way weaving structures.
In another embodiment of the present invention, the carbon fiber may be selected from high-strength carbon fiber and high-modulus carbon fiber for processing woven fabric preform, wherein the high-strength carbon fiber may be selected from any one of T300, T700, T800, and T1000, the high-modulus carbon fiber may be selected from any one of M40, M40J, M55, M55J, M60, and M60J, or the high-modulus or high-strength carbon fiber may be used as main fiber and mixed fiber for processing woven fabric.
In another embodiment of the present invention, the thermoplastic resin matrix can be selected from polyethylene, acrylic acid-vinyl copolymerThe thermoplastic resin matrix adopts a structural form of a resin adhesive film, wherein the gram weight of the adhesive film is 5-20g/m2Within the range.
In another embodiment of the present invention, the preparation of the thermoplastic carbon fiber prepreg includes first spreading the used carbon fiber fabric uniformly on a driving roller, then fixing and spreading an adhesive film according to a size matching with the width of the carbon fiber fabric, and continuously rolling, impregnating and compounding the carbon fiber fabric and the adhesive film through four sets of hot rollers, wherein the temperature of a roller body of the four-stage hot roller can be automatically adjusted according to the hot melting temperature characteristic of the adhesive film to ensure the hot melting infiltration degree. After four-stage pressurization and hot melting, the glue film is melted and thoroughly permeates the carbon fiber fabric to form a prepreg, and the total glue content of the prepreg is controlled within the range of 20-30%.
In another embodiment of the present invention, the thermoplastic carbon fiber composite material artificial limb semi-finished product may be prepared by using the prepreg, after two-dimensional fabric lamination or three-dimensional fabric lamination is selected, the prepreg fabric is placed in a closed mold, and pressurized by using a press, wherein the pressurized pressure is controlled within a range of 5 to 20MPa, the hot melting temperature is flexibly adjusted according to the melting temperature of the thermoplastic resin, the final pressurizing time is controlled within a range of 1 to 3 hours, and the artificial limb finished product component formed by composite molding is cooled to below 40 ℃ and then is opened to take out a sample.
In another embodiment of the present invention, the final product of the prosthetic component is manufactured by performing a secondary cutting process on the semi-finished product of the thermoplastic three-dimensional braided carbon fiber composite material prepared as described above to obtain a desired size, placing the cut semi-finished product into a final product forming mold, and performing a final forming process on the prosthetic component of the thermoplastic composite material by setting a certain forming pressure according to a specific softening temperature of the resin, wherein the micro-shape and curvature of the prosthetic component can be adjusted by performing a secondary heating and pressurizing softening forming process.
In order to make the technical solutions of the present invention more clearly understood by those skilled in the art, the technical solutions of the present invention will be described in detail below with reference to specific embodiments.
Example 1
Arranging unidirectional fibers of T300 carbon fibers into a continuous breadth with the width of 1 m, and adopting the grammage of 1 m as 5g/m2Fixing and spreading a fiber fabric and a hot melt adhesive film, continuously rolling and impregnating the fiber fabric and the adhesive film by four groups of hot rollers, wherein the temperatures of the four groups of hot rollers are sequentially set to be 100 ℃, 110 ℃, 120 ℃ and 130 ℃ from front to back, and the carbon fiber fabric and the adhesive film are subjected to pressurized melting by the four groups of hot rollers to form a prepreg with the total gel content controlled by 20%.
And arranging the unidirectional prepreg in a closed die, pressurizing by adopting pressure of 5MPa, controlling the hot melting temperature at 130 ℃ and the pressurizing time at 1 hour, cooling the finished product part of the composite molded artificial limb to below 40 ℃, opening the die and taking out a sample.
Placing the cut semi-finished product into a forming die, softening and pressing at a softening temperature of 140 ℃ under a pressure of 16.5MPa for forming for 1 hour, cooling the finally formed product to below 40 ℃, opening the die and sampling to prepare the final artificial limb component.
Example 2
The two-dimensional plain weave fabric adopting the T700 carbon fiber is arranged into a 2-meter width continuous breadth, and the gram weight of the 2-meter width is 20g/m2Fixing and spreading a fiber fabric and a hot melt adhesive film, continuously rolling and impregnating the fiber fabric and the adhesive film by four groups of hot rollers, wherein the temperatures of the four groups of hot rollers are sequentially set to be 110 ℃, 120 ℃, 130 ℃ and 150 ℃ from front to back, and the carbon fiber fabric and the adhesive film are subjected to pressurized melting by the four groups of hot rollers to form a prepreg with the total gel content of 30%.
And (3) placing the two-dimensional plain weave fabric prepreg cloth in a closed die, pressurizing by adopting the pressure of 20MPa, controlling the hot melting temperature at 150 ℃ and the pressurizing time at 2 hours, cooling the finished part of the composite molded artificial limb to below 40 ℃, opening the die and taking out a sample.
And placing the cut semi-finished product into a forming die, softening and pressing the semi-finished product at a softening temperature of 150 ℃ under a pressure of 20MPa for forming for 2 hours, cooling the finally formed product to below 40 ℃, opening the die and sampling to prepare the final artificial limb component.
Example 3
The two-dimensional twill fabric adopting the M40 carbon fibers is arranged into a continuous breadth with the width of 1M, and the gram weight of the width of 1M is 12g/M2And fixing and spreading the fiber fabric and the hot melt adhesive film, and continuously rolling, dipping and compounding the fiber fabric and the adhesive film by four groups of hot rollers, wherein the temperatures of the four groups of hot rollers are sequentially set to be 100 ℃, 110 ℃, 115 ℃ and 120 ℃ from front to back, and the prepreg with the total gel content controlled to be 20-30% is formed after the four groups of hot rollers are pressurized and melted.
Placing the two-dimensional twill fabric prepreg cloth in a closed die, pressurizing by adopting the pressure of 5-20MPa, controlling the hot melting temperature at 120 ℃, pressurizing for 2 hours, cooling the finished composite molded artificial limb part to below 40 ℃, and opening the die to take a sample.
Placing the cut semi-finished product into a forming die, softening and pressing the semi-finished product at a softening temperature of 130 ℃ under a pressure of 17.5MPa for forming for 2 hours, cooling the finally formed product to below 40 ℃, opening the die and sampling to prepare the final artificial limb component.
Example 4
The three-dimensional five-direction fabric adopting the M60 carbon fiber is arranged into a continuous breadth with the width of 1M, and the gram weight with the width of 1M is 18g/M2And the EMMA hot melt adhesive film fixes and spreads the fiber fabric and the hot melt adhesive film, and the fiber fabric and the adhesive film are continuously rolled, impregnated and compounded by four groups of hot rollers, wherein the temperature of the four groups of hot rollers is sequentially set to be 100 ℃, 105 ℃, 120 ℃ and 130 ℃ from front to back, and the prepreg with the total gel content controlled by 30% is formed after the four groups of hot rollers are pressurized and melted.
Placing the three-dimensional five-direction three-dimensional fabric prepreg cloth in a closed die, pressurizing by adopting the pressure of 20MPa, controlling the hot melting temperature at 128 ℃ and the pressurizing time at 3 hours, cooling the finished part of the composite molded artificial limb to below 40 ℃, opening the die and taking out a sample.
Placing the cut semi-finished product into a forming die, softening and pressing at the softening temperature of 130 ℃ under the pressure of 19.5MPa for forming for 1 hour, cooling the finally formed product to below 40 ℃, opening the die and sampling to prepare the final artificial limb component.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims (4)

1. A method of making a carbon fiber composite prosthetic component from a carbon fiber thermoplastic prepreg, the method comprising: fixing and spreading a thermoplastic resin adhesive film according to the size matched with the width of the carbon fiber fabric, and rolling, dipping and compounding the carbon fiber fabric and the thermoplastic resin adhesive film;
the rolling impregnation method comprises the following specific steps: continuously rolling, dipping and compounding the carbon fiber fabric and the adhesive film through four groups of hot rollers;
the temperature of the four groups of hot roller bodies rises in a gradient manner, the temperature of the first group of hot roller bodies is 100-110 ℃, and the temperature of the fourth group of hot roller bodies is 120-150 ℃;
pressurizing and hot-melting the carbon fiber thermoplastic prepreg cloth in a closed die cavity, and cooling and forming to obtain a thermoplastic carbon fiber composite artificial limb semi-finished product component;
performing mechanical secondary processing on the prepared thermoplastic carbon fiber composite artificial limb semi-finished product component, then placing the semi-finished product component in a closed die cavity for softening and pressing, and cooling and molding to obtain the thermoplastic carbon fiber composite artificial limb component;
the carbon fiber fabric is prepared by weaving and molding high-strength carbon fibers/or high-modulus carbon fibers/or high-strength carbon fibers/or high-modulus carbon fibers and hybrid fibers;
the high-strength carbon fiber is any one of T300, T700, T800 and T1000;
the high modulus carbon fiber is any one of M40, M40J, M55, M55J, M60 and M60J;
the hybrid fiber is inorganic fiber, and the inorganic fiber comprises alumina fiber, silicon carbide fiber, boron nitride fiber and silicon nitride fiber;
the carbon fiber is selected from a one-way fiber, a two-dimensional fabric structure form or a three-dimensional weaving structure form;
wherein the two-dimensional fabric structure is in a plain weave, twill or satin form;
the three-dimensional weaving structure is any one of three-dimensional four-direction, three-dimensional five-direction, three-dimensional six-direction and three-dimensional seven-direction weaving structures;
the method also comprises the step of adjusting the micro-appearance and the curvature of the prepared artificial limb component in a secondary heating, pressurizing, softening and molding mode;
the specific processing conditions of the pressurized hot melting are as follows: the temperature is 120-;
the softening and pressing temperature is controlled to be 130-150 ℃, and the softening and pressing pressure is controlled to be 16-20 MPa.
2. The method for preparing a carbon fiber composite material prosthetic component from the carbon fiber thermoplastic prepreg according to claim 1, wherein the gram weight of the thermoplastic resin adhesive film is controlled to be 5-20g/m2
The thermoplastic resin is selected from any one of polyethylene, acrylic acid-vinyl copolymer, ethylene-methacrylic acid copolymer, ethylene-methyl methacrylate copolymer, polypropylene, polyurethane, polyphenylene sulfide, polyether ether ketone and polyamide.
3. A method for forming a carbon fiber composite prosthetic component from a carbon fiber thermoplastic prepreg according to any one of claims 1-2 wherein the carbon fiber thermoplastic prepreg has an overall gel content within the range of 20-30%.
4. A prosthetic component made by the method of making a carbon fiber composite prosthetic component from a carbon fiber thermoplastic prepreg according to any one of claims 1-3.
CN201810654131.XA 2018-06-22 2018-06-22 Thermoplastic prepreg cloth for carbon fiber composite material artificial limb and preparation method of artificial limb component Active CN108973161B (en)

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CN111204086A (en) * 2020-03-10 2020-05-29 山东大学 Carbon fiber thermoplastic prepreg fabric with gradient structure
CN111452438A (en) * 2020-05-19 2020-07-28 山东大学 Thermoplastic composite film

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