CN110154421B

CN110154421B - Continuous production line and production method of glue injection box and fiber reinforced foam composite material

Info

Publication number: CN110154421B
Application number: CN201910431929.2A
Authority: CN
Inventors: 俞学良; 朱旭华; 许嘉浚
Original assignee: Huzhou Shouzhen New Material Technology Co ltd
Current assignee: Huzhou Shouzhen New Material Technology Co ltd
Priority date: 2019-05-22
Filing date: 2019-05-22
Publication date: 2023-12-22
Anticipated expiration: 2039-05-22
Also published as: CN110154421A

Abstract

The continuous production line for the fiber reinforced foamed composite material comprises a distribution frame, the glue injection box, a foaming device, a forming die and a traction device, wherein the distribution frame is used for enabling the fiber material to be spatially distributed according to design requirements; the glue injection box comprises a soaking channel, a glue injection channel and a discharging channel, wherein a plurality of soaking channels and glue injection channels are formed in the glue injection box, the foaming device is in a tunnel structure, one end of the foaming device is communicated with the glue injection box, the other end of the foaming device is communicated with the forming die, and the air supply device arranged on one side, close to the foaming device, of the glue injection box is provided with a heating device. The fiber material is infiltrated by the liquid matrix material injected into the infiltration channel through the glue injection channel to form a composite material precursor, and enters the foaming device after passing through the discharge channel to be pre-foamed, and then enters the forming die to be completely foamed and solidified or shaped.

Description

Continuous production line and production method of glue injection box and fiber reinforced foam composite material

Technical Field

The invention relates to the technical field of composite material pultrusion, in particular to a glue injection box, a continuous production line of a fiber reinforced foam composite material and a production method.

Background

Composite materials are materials with obvious phase separation characteristics formed by mixing two or more materials, the morphology and the performance of the composite materials are different from those of any single material, the main components of the composite materials are matrix materials and reinforcing materials, and fibers are the most commonly used reinforcing materials. In general, composite materials refer to materials in their final form after molding, while materials in their final form after mixing with reinforcing materials are referred to as composite precursors.

The continuous fiber reinforced foam composite material can fully exert the strength advantage of fibers, lighten the density of the composite material, is a low-density high-strength composite material, and has wide application prospect, such as sleeper, door and window frames, building floors, maintenance structures, trestle plates and the like instead of wood. Patent (application number 200610103934.3) discloses a glass fiber reinforced polyurethane composite sleeper and a manufacturing device and a manufacturing method thereof, however, the technology adopts a method that a liquid matrix material, namely polyurethane resin is sprayed on glass fibers to infiltrate the glass fibers to form a composite precursor, and then the composite precursor is solidified into a composite material along with a mold entering a drying tunnel; the continuous plate free foaming-like process of this method has several problems which cannot be solved: 1, as the distribution of the fibers in the composite material is realized by only freely foaming and filling the mold cavity in the forming mold by the composite material precursor, the fibers cannot be positioned according to the designed space position, the distribution position of the fibers cannot be designed according to the stress distribution, the reinforcing effect of the fibers can be exerted to the maximum extent, and the product with complex shape cannot be manufactured; 2. because the fiber is soaked by spraying the liquid matrix material on the fiber, the fiber is difficult to soak rapidly, so that the interface strength between the matrix material and the fiber material is affected, and the performance of the composite material is finally affected; meanwhile, the method is difficult to quickly soak a large amount of fibers at one time, so that large-size composite materials are difficult to manufacture; 3. the die is complex and the investment is large. Improvements are needed in the art.

Disclosure of Invention

In order to solve the technical problems, the invention provides a glue injection box and a continuous production line of fiber reinforced foaming composite materials, wherein the fiber materials are distributed in advance through a distribution frame, then the fiber materials sequentially pass through the glue injection box, a foaming device and a forming die, the glue injection box enables the liquid matrix materials to be soaked in the fiber materials rapidly and fully, the foaming device enables the liquid matrix materials to be foamed in advance and then enter the forming die to be foamed fully, and the fiber materials in the final formed composite materials are distributed according to designed positions and are stretched fully.

In order to achieve the above purpose, the technical scheme of the invention is as follows:

as shown in fig. 3 to 7, a glue injection box is used for impregnating a fiber material with a liquid matrix material to form a composite material precursor, and comprises 2 or more impregnating channels 21 used for impregnating the fiber material and glue injection channels 22 used for allowing the liquid matrix material to enter the impregnating channels 21, wherein the impregnating channels 21 comprise a feed port 211 used for allowing the fiber material to enter and a discharge port 212 used for allowing the composite material precursor formed by impregnating the fiber material with the liquid matrix material to pass through, and the area of the feed port 211 is larger than or equal to that of the discharge port 212. The injecting glue box sets up a plurality of infiltration channels, and the cross section of every infiltration channel can compare the cross section of prior art's single channel and reduce greatly, improves fibrous material's infiltration effect and efficiency, the area of feed inlet 211 is greater than or equal to the area of discharge gate 212 has further improved the pressure of liquid matrix material in infiltration channel inside again, further promotes fibrous material's infiltration effect and efficiency. In addition, two or more infiltration channels can facilitate different liquid matrix materials to be injected into different infiltration channels according to the requirements, and/or different fiber materials to be introduced into different infiltration channels, so that different parts of the produced composite material have different functions.

Further, the infiltration channel 21 is a continuous channel, and the area of the inlet 211 is larger than the area of the outlet 212; or the infiltration channel 21 is a continuous channel, and the cross section of the infiltration channel is gradually reduced or stepwise reduced from the feeding hole 211 to the discharging hole 212; or the cross section of the part of the infiltration channel near the discharge hole is gradually reduced. In general, the cross section of each infiltration channel decreases linearly or nonlinearly from the inlet end to the outlet end, and the cross section of each infiltration channel can be generally rectangular (or can be in other shapes, such as circular, W-shaped or similar to the cross section of the final product, if needed), and the change of the cross section can be the change of the height dimension of the rectangle, the change of the wide dimension of the rectangle, or the change of both the height and the width directions; the technical effect is that in the process that the fiber material advances in the infiltration channel and is infiltrated into the composite material precursor by the liquid matrix material, as the cross-sectional area is smaller and smaller, the internal pressure in the composite material precursor is higher and higher, the liquid matrix material can rapidly infiltrate between the fiber materials, and air bubbles among the fibers are extruded, so that a rapid and full infiltration effect is achieved; meanwhile, when the cross section of the infiltration channel is linearly reduced, the fiber materials can be closely distributed on the inner wall of the infiltration channel through the distribution frame, so that the liquid matrix materials attached to the inner wall of the infiltration channel can be continuously taken away while the fibers pass through, the liquid matrix materials are not deposited on the inner wall of the infiltration channel, and the more the accumulation is, the more the infiltration channel is finally blocked, so that the production shutdown or the quality problem is caused, and the method is particularly necessary for the liquid matrix materials such as polyurethane resin which are rapidly solidified.

Further, the height of the outlet 212 is 20mm or less. The method is used for controlling the thickness of the composite material from a single infiltration channel, ensuring that the precursor of the composite material is easy to heat and is heated uniformly, and ensuring the efficiency of subsequent foaming; this is particularly important in the case where the liquid matrix material is a poor conductor of polyurethane, phenolic resin, etc., because if the composite precursor is too thick, a long heating time is required, affecting the production efficiency or increasing the cost of the production apparatus.

Further, the inner wall of the infiltration channel 21 is further provided with a diversion trench 221, the diversion trench 221 is circumferentially arranged along the cross section of the inner wall of the infiltration channel 21, and the diversion trench 221 is communicated with the glue injection channel 22; the technical effect is that the diversion trenches can be used for rapidly distributing the injected liquid matrix material in the circumferential direction of the infiltration channel, so that the liquid matrix material can infiltrate the fibers entering the infiltration channel as simultaneously as possible, and simultaneously, air clamped between the fibers is discharged, thereby preventing the defects of void and the like of the composite material caused by the phenomena of air inclusion or air inclusion.

Further, the glue injection channel 22 is a vertical channel 222, and the vertical channel 222 is disposed between the feeding port 211 and the discharging port 212 and is communicated with the infiltration channel 21.

Further, the number of the glue injection channels 22 is at least one, and all the infiltration channels 21 are communicated with all the glue injection channels 22; alternatively, the number of the glue injection channels 22 is at least two, and each infiltration channel 21 is communicated with one, two or more of the glue injection channels 22; or, the number of the glue injection channels 22 is equal to or greater than the number of the infiltration channels 21, and each glue injection channel 22 is correspondingly communicated with only one infiltration channel 21; alternatively, one or more of the infiltration channels are not communicated with other infiltration channels, but are communicated with one or more of the glue injection channels only, so that the technical effect is that a fiber infiltration method capable of being flexibly designed is provided.

The invention also provides a continuous production line of the fiber reinforced foam composite material, which comprises the following steps:

the distribution frame 1 is used for enabling the fiber materials passing through the distribution frame 1 to enter the glue injection box according to a distribution state;

the glue injection box 2 is provided with a soaking channel 21 for fiber material soaking and a glue injection channel 22 for liquid matrix material entering the soaking channel 21, wherein the soaking channel 21 comprises a feed port 211 for fiber material entering and a discharge port 212 for passing through a composite material precursor formed by impregnating the fiber material with the liquid matrix material, and the area of the feed port 211 is larger than or equal to that of the discharge port 212;

One end of the forming die 4 is a feeding end and is correspondingly arranged or connected with the discharging hole, and the other end of the forming die 4 is a discharging end and is correspondingly arranged with the traction device and is used for curing or shaping the composite material precursor in the forming die 4;

and a traction device 8, wherein the composite material is pulled out of the forming die 4 by the traction device 8 after being solidified or shaped in the forming die 4.

By adopting the technical scheme, before the fiber materials are infiltrated by the liquid matrix materials, the fiber materials are distributed and arranged in space through the distribution frame to form the required fiber space arrangement shape and space distribution position, the fiber materials enter the infiltration channel, the liquid matrix materials are injected into the infiltration channel through the glue injection channel, the fiber materials are infiltrated by the liquid matrix materials through the infiltration channel to form composite material precursors, then enter the foaming device to be prefoamed, then enter the forming die to be completely foamed and solidified or shaped, the area of the feed inlet of the infiltration channel is larger than or equal to the area of the discharge outlet, the internal pressure of the liquid matrix materials in the infiltration channel is increased, the fiber materials of the finally formed composite materials are fully infiltrated with the liquid matrix materials, and the fiber materials in the finally formed composite materials are distributed and fully stretched according to the design.

Further, the distribution frame 1 includes a distribution plate 12, the distribution plate 12 is provided with distribution holes 13 penetrating through the distribution plate 12 and used for passing through the fiber material, the distribution holes 13 are in a hole shape or a slit shape, and the fiber material simultaneously passes through all or part of the distribution holes 13 to complete the distribution of the fiber material in space.

By adopting the technical scheme of the distribution frame, an operator can adjust the distribution of the fiber materials in the composite material by adjusting the distribution holes penetrated by the fiber materials, so that the distribution of the fiber materials in the composite material is ensured not to change. When the distribution holes are in a hole shape, the fiber yarn material is suitable for being penetrated, when the distribution holes are in a strip slit shape, the fiber yarn material is suitable for the fiber fabric to pass, and the fiber fabric can be changed from a plane shape to an arc surface shape or a fold line shape by changing the shape of the strip slit, such as an arc shape and a fold line shape, so that the structure of the fiber fabric in the composite material can be further adjusted, and the structure and the performance index of the composite material can be adjusted. Meanwhile, the distribution of the fiber materials in the cross section of the composite material is changed through the distribution of the distribution holes, the fiber materials can be uniformly distributed, can be distributed according to different shapes, can be distributed at different positions and can be further adjusted in terms of the structure and performance index of the composite material.

Further, the glue injection box 2 has the structure as any one of the glue injection boxes.

Further, the continuous production line of the fiber reinforced foam composite material further comprises a foaming device 3, wherein the foaming device 3 is provided with a continuous through foaming cavity; one end of the foaming device 3 is correspondingly arranged or connected with the discharge hole 212 of the glue injection box 2, the other end of the foaming device is correspondingly arranged or connected with the forming die 4, the composite material precursor enters the foaming device 3 through the discharge hole 212 and is pre-foamed in the foaming device 3, the length L of the foaming device 3 is less than or equal to s x t, s is the advancing speed of the composite material precursor, and t is the time from starting foaming expansion to stopping expansion of the composite material precursor in the foaming device 3. The composite material precursor enters a foaming device to carry out incomplete foaming reaction, the reaction time is T, and the T is larger than zero but is smaller than the time T when the composite material precursor just completes foaming in the foaming device 3 and stops expanding. Generally, the value of L needs to be set so that the time of the composite precursor in the foaming device 3 is less than the value of T, so that the composite precursor enters the forming die in a state of not being fully foamed, and the final foaming expansion is continued to be completed, and the shaping and curing are completed. In one particular case, when T is equal to T, the composite precursor enters the forming die in the state after expansion has been completed, and as it is no longer expanded, the final forming quality is adversely affected, with less effect than T < T.

Further, the forming die 4 is provided with a cavity which is continuously communicated, and is divided into a pre-foaming section and a forming die section, the part close to one side of the glue injection box is the pre-foaming section, the part close to one side of the traction device is the forming die section, and the composite material precursor enters the pre-foaming section from the glue injection box to be pre-foamed and then enters the forming die section to be solidified or shaped.

Further, the foaming device 3 further comprises a heating device 6 for foaming the liquid matrix material, and the heating device 6 comprises one or a combination of more of a hot air circulation device, a microwave heating device, an electromagnetic heating device and an infrared heating device.

Further, an air supply device 5 is arranged at one side close to the discharge port of the glue injection box 2, and the air supply device 5 supplies air to the composite material precursor discharged from the discharge port.

Further, the air supply device 5 includes a fan 52 and an air supply pipe 54 connected to the fan 52, where the air supply pipe 54 is far away from the discharge hole 212, and one or more second air supply holes 542 are formed at an included angle of 10 ° to 90 ° with the advancing direction of the composite material from the discharge hole 212, and are used for supplying air toward the composite material precursor.

Further, when the number of the infiltration channels 21 in the glue injection box 2 is two or more, the air supply pipes 54 are disposed between two adjacent discharge ports 212, the air supply pipes 54 are disposed at one side close to the discharge ports 212, and the air supply pipes 54 are provided with first air supply openings 541 toward one side far away from the discharge ports 212, for supplying air between the composite precursors coming out from the two adjacent discharge ports 212.

Further, the continuous production line of the fiber reinforced foam composite material is further provided with a waste heat recovery device, which comprises a hot air recovery cover arranged between the foaming device and the forming die and used for recovering hot air exhausted from the outlet section of the foaming device, and further comprises an air inlet pipe 53 communicated with the hot air recovery cover and a fan 52 used for enabling the air inlet pipe 53 to generate negative pressure near one end of the forming die 4, wherein the other end of the air inlet pipe 53 is communicated with the air supply device 5, and air in the forming die 4 enters the air supply device 5 after being recovered through the air inlet pipe 53 and is finally exhausted through the air supply device 5.

Further, a film covering assembly 7 is arranged between the foaming device 3 and the forming die 4, and is used for attaching a strip-shaped film 72 on the surface of the composite material precursor and entering the forming die 4 along with the composite material precursor; and/or attaching a fabric to the surface of the composite precursor as the composite precursor enters the forming die 4; the composite material has the advantages that the film with one or more of the functions of decoration, weather resistance, wear resistance, flame retardance and demolding can be conveniently compounded on the surface of the composite material, so that the working requirements of the composite material are met; meanwhile, a plurality of film-covering components can be used for compounding a plurality of or a plurality of films on the surface of the composite material; further, the fabric can be compounded on the surface of the composite material by a film coating component singly or between the composite material precursor and the film, and the function of the composite material is supplemented or the strength of the composite material perpendicular to the existing direction, namely the transverse strength, is reinforced.

Further, the film covering assembly 7 includes one or more roller bodies 71 rotatably disposed, and the roller bodies 71 are wound with a band-shaped film or fabric or are provided with a rolled band-shaped film or fabric.

The present invention also provides a continuous production method of a fiber-reinforced foamed composite material, manufactured by the continuous production line for a fiber-reinforced foamed composite material according to any one of claims 10 or 11, comprising the steps of:

s1, fiber materials are distributed and positioned according to design through the distribution frame 1 and then enter the infiltration channel 21 of the glue injection box 2;

s2, a liquid matrix material enters the glue injection box 2 through the glue injection channel 22, and a fiber material is impregnated by the liquid matrix material to form a composite material precursor while passing through the infiltration channel 21, and then enters the foaming device 3, a gap between the forming die 4 and the glue injection box 2 or a pre-foaming section arranged on the forming die 4 through the discharge hole 212;

s3, the composite material precursor is pre-foamed in a gap or a pre-foaming section between the foaming device 3, the forming die 4 and the glue injection box 2, and the liquid matrix material expands and enters the forming die 4 or a forming die section arranged on the forming die 4 when or before foaming is stopped;

S4, the composite material is fully foamed and cured or shaped in the forming die 4 or the forming die section;

s5, the formed composite material is pulled out of the forming die 4 by the pulling device 8, and in the process, fiber materials from one side of the feed port 211 of the glue injection box 2 through the distribution frame 1 continuously enter the glue injection box 2.

Further, the step S5 further includes: the ribbon film 72 or fibrous web is compounded on the surface of the composite precursor as it enters the forming die 4.

Further, there are at least 2 infiltration channels 21 in the glue injection box 2, and the glue injection channels 22 are respectively communicated with the corresponding infiltration channels 21; in S2, different types of liquid matrix materials are injected into different infiltration channels 21 through different glue injection channels 22, or different fibers enter different infiltration channels 21 through different feed inlets, so as to form different composite precursors.

Further, in the step S3, the foaming process of the composite material is accelerated by using one or more of the first air supply opening 541 and the second air supply opening 542 provided in the air supply pipe 54.

The invention also provides a fibre reinforced foamed composite material manufactured by a continuous production line for fibre reinforced foamed composite material as described in any of the above, or by a method as described in any of the above, comprising a composite material formed from a fibre material and a liquid matrix material.

The invention also provides an application of the fiber reinforced foam composite material as claimed in claim 23, which is applied to railway sleeper, floor, trestle plate, house maintenance structure, highway crash barrier, door and window curtain wall frame section bar, ship deck, maintenance plate and floating bridge plate.

Further, the fiber material comprises one or more of inorganic fibers, organic polymer fibers, metal fibers and natural fibers, and the inorganic fibers comprise one or more of glass fibers, basalt fibers and carbon fibers; the organic polymer fiber comprises one or a combination of more of polyester fiber, kevlar fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyvinyl alcohol fiber, polyvinyl chloride fiber and polypropylene cyanide fiber; the metal fibers comprise one or more of steel fibers, aluminum fibers and copper fibers; the natural fiber comprises one or more of flax fiber, ramie fiber, sisal fiber, jute fiber, bamboo fiber and cotton fiber.

Further, the liquid matrix comprises one, two or more of organic polymer resin and inorganic cementing material, or one, two or more of inorganic cementing material and metal material; wherein the inorganic cementing material comprises one or more of cement, magnesia, gypsum; the metallic material comprises one or more of aluminum and its alloys, magnesium and its alloys; the organic polymer resin comprises a thermosetting resin and a thermoplastic resin; the thermosetting resin comprises one or more of polyurethane resin, epoxy resin, phenolic resin, unsaturated polyester resin, vinyl resin and cyanate resin.

Further, the weight ratio of the liquid matrix in the composite material is 15% -65%.

Further, the liquid matrix may further contain a lubricant or an internal mold release agent.

Further, the composite material also comprises a fiber fabric, wherein the fiber fabric comprises one or a combination of a plurality of fiber cloth, a chopped strand mat, a continuous mat, a knitted mat, a stitch-bonded mat and a needled mat.

Further, the surface of the composite material also comprises a film layer or a fiber fabric layer with a decorative function or a protective function.

Further, the outer layer of the composite material is made of a fibrous material and a weather-resistant resin, and the weather-resistant resin comprises one or a combination of a plurality of aliphatic polyurethane resins, acrylic resins and fluorocarbon resins.

Through adopting above-mentioned technical scheme, the fan is through being responsible for supplying with many blast pipes, has simplified the air supply structure of blast pipe, is convenient for implement, can supply air respectively to multilayer combined material precursor simultaneously, has improved heating efficiency for foaming, just also improved production efficiency.

Through adopting above-mentioned technical scheme who sets up first supply-air outlet, the blast pipe setting is between two adjacent discharging channel and implement the air supply through first supply-air outlet, and the air current that first supply-air outlet blown out forms the hot air current between two adjacent laminar composite precursors, makes laminar composite precursors foam fast, avoids because the monolayer composite precursor is too thick, and heat transfer is too slow to lead to foaming too slow, problem that production efficiency is lower.

By adopting the technical scheme of arranging the second air supply openings, the two oppositely arranged second air supply openings supply air along the vertical direction or towards the composite material precursor, on one hand, the composite material precursor pulled out from the discharge hole is supported and separated through hot air flow, so that the premature bonding of the composite material precursor after the composite material precursor exits from the discharge hole is avoided, the heating efficiency is influenced, on the other hand, the hot air flow is directly contacted with the composite material precursor, the heating efficiency is improved, and when all fibers contained in the composite material precursor are yarn bundles, the hot air flow can even penetrate the composite material precursor to enable the composite material precursor to be heated more fully, thus promoting the foaming reaction of the liquid matrix material, reducing the time required by pre-foaming and improving the production efficiency; finally, the technical scheme of the second air supply outlet can also prevent the liquid matrix material in the composite material precursor pulled out from the discharge outlet from sagging at the discharge outlet and accumulating, and finally blocking the discharge outlet.

Through adopting above-mentioned technical scheme, can also be by the air-supply line of settling on the hot-blast collection fan housing of moulded die entry hot-blast that blows out of blast pipe in with the foaming device through axial fan take out and carry the blast pipe for, improve the foaming device and produce thermal utilization ratio, reduce the production energy consumption of equipment.

By adopting the technical scheme, the film with one or more of the decorative function, the weather-proof function, the wear-resistant function, the flame-retardant function and the demolding function can be conveniently compounded on the surface of the composite material, so that the working requirement of the composite material is met; meanwhile, a plurality of film-covering components can be used for compounding a plurality of or a plurality of films on the surface of the composite material; further, the fabric can be compounded on the surface of the composite material by a film coating component singly or between the composite material precursor and the film, and the function of the composite material is supplemented or the strength of the composite material perpendicular to the fiber direction, namely the transverse strength, is reinforced.

By adopting the technical scheme, the continuous production of the composite material is realized.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly described below.

FIG. 1 is a schematic diagram of the overall structure of a fiber reinforced foam composite continuous production line;

FIG. 2 is a schematic diagram of a distribution frame;

FIG. 3 is a schematic structural view of the glue injection box;

FIG. 4 is a schematic view of the internal structure of the glue injection box;

FIG. 5 is a schematic view of the internal structure of the glue injection box, mainly for showing the structure of the glue injection channel;

FIG. 6 is an enlarged partial view of the position of the glue injection box A, which is mainly used for embodying the cross-sectional structure of the glue injection hole;

FIG. 7 is an enlarged view of a portion of the injection molding box B, which is mainly used for showing the cross-sectional structure of the air supply pipe;

FIG. 8 is a flow chart of the production of a composite material;

FIG. 9 is a front view of one example of a glue cassette;

FIG. 10 is a top view of one example of a glue cassette;

FIG. 11 is a left side view of one example of a glue cassette;

FIG. 12 is a right side view of one example of a glue cassette;

FIG. 13 is a B-B cross-sectional view of one example of a glue cassette;

FIG. 14 is a cross-sectional view A-A of one example of a glue cassette;

fig. 15 is an enlarged view of a portion of an example of a section A-A of the cartridge.

In the figure: 1. a distribution frame; 11. a frame body; 12. a distribution plate; 13. distributing holes; 2. a glue injection box; 21. a soaking channel; 211. a feed inlet; 212. a discharge port; 22. a glue injection channel; 221. a vertical channel; 222. a diversion trench; 3. a foaming device; 4. forming a mold; 5. an air supply device; 51. a main pipe; 52. a blower; 53. an air inlet pipe; 54. an air supply pipe; 541. a first air supply port; 542. a second air supply port; 6. a heating device; 7. a film covering component; 71. a roller body; 72. a band-shaped film; 8. a traction device.

Detailed Description

The invention is described in further detail below with reference to the accompanying drawings.

In order to achieve the object of the invention, the following technical solutions can be adopted,

as shown in fig. 3-7, a glue injection box is used for impregnating a fiber material with a liquid matrix material to form a composite material precursor, and comprises 2 or more impregnating channels 21 used for impregnating the fiber material and glue injection channels 22 used for allowing the liquid matrix material to enter the impregnating channels 21, wherein the impregnating channels 21 comprise a feed port 211 used for allowing the fiber material to enter and a discharge port 212 used for allowing the composite material precursor formed by impregnating the fiber material with the liquid matrix material to pass through, and the area of the feed port 211 is larger than or equal to that of the discharge port 212. The injecting glue box sets up a plurality of infiltration channels, and the cross section of every infiltration channel can compare the cross section of prior art's single channel and reduce greatly, improves fibrous material's infiltration effect and efficiency, the area of feed inlet 211 is greater than or equal to the area of discharge gate 212 has further improved the pressure of liquid matrix material in infiltration channel inside again, further promotes fibrous material's infiltration effect and efficiency. In addition, two or more infiltration channels can conveniently inject different liquid matrix materials into different infiltration channels according to the needs, and or different fiber materials are introduced into different infiltration channels, so that more complex composite materials with different functions can be produced.

In practical applications, the infiltration channel 21 is a continuous channel and the area of the inlet 211 is larger than the area of the outlet 212; or the infiltration channel 21 is a continuous channel, and the cross section of the infiltration channel is gradually reduced or stepwise reduced from the feeding hole 211 to the discharging hole 212; or the cross section of the part of the infiltration channel near the discharge hole is gradually reduced. In general, the cross-section of each infiltration channel decreases linearly or nonlinearly from the end of the feed inlet 211 to the end of the discharge outlet 212, preferably linearly, more preferably, with a taper of 0.2 ° to 5 °, and most preferably, with a taper of 0.2 ° to 2 °. The cross section of the infiltration channel 21 may be generally rectangular (or other shapes if desired), and the cross section may be varied by either changing the height or the width of the rectangle or both the height and width.

By adopting the technical scheme, the gradually reduced cross-sectional area of the infiltration channel 21 increases the internal pressure of the liquid matrix in the infiltration channel 21, so that the infiltration efficiency is improved, and the infiltration is ensured to be sufficient.

In a preferred embodiment, the height of the outlet 212 is 20mm or less, preferably 10mm or less, more preferably 5mm or less. The method is used for controlling the thickness of the composite material from a single infiltration channel, ensuring that the composite material is easy to heat and is heated uniformly, and ensuring the efficiency of subsequent foaming.

In some preferred embodiments, the inner wall of the infiltration channel 21 is further provided with a diversion trench 221, and the diversion trench 221 is circumferentially disposed along the cross section of the inner wall of the infiltration channel 21, preferably, the diversion trench 221 is disposed in a closed loop on the cross section of the inner wall of the infiltration channel 21; the diversion trench 221 is communicated with the glue injection channel 22. When the liquid matrix material enters the infiltration channel 21 from the glue injection channel 22, the cross section corresponding to the diversion trench 221 can be quickly distributed along the diversion trench 221, so that the liquid matrix material can annularly wrap the fiber material in the infiltration channel 21, and the fiber material is impregnated almost simultaneously, thereby improving the infiltration efficiency and quality.

In some embodiments, the glue injection channel 22 is a vertical channel 222, and the vertical channel 222 is disposed between the feed inlet 211 and the discharge outlet 212 and is in communication with the infiltration channels 21, preferably, the vertical channel 222 is in communication with the diversion trenches 221 of all the infiltration channels 21, so that the injected liquid matrix material can be rapidly distributed in each infiltration channel.

In some embodiments, the number of the glue injection channels 22 is at least one, and all the infiltration channels 21 are in communication with all the glue injection channels 22, so that the liquid matrix material can be more rapidly distributed in each infiltration channel by using a plurality of glue injection channels; in this case, the glue cassette is generally used for simultaneously injecting the same liquid matrix material into all the infiltration channels 21.

Alternatively, in other embodiments, the glue injection channels 22 are at least two, each of the infiltration channels 21 being in communication with one, two or more of the glue injection channels 22; the glue injection channels are two or more, when all the glue injection channels are communicated with all the infiltration channels, the glue injection channels are arranged at different positions on the ring where the same cross section of the glue injection box is positioned (the two or more glue injection channels can be arranged at other positions of the glue injection box according to the requirement, so that the injection flow of the liquid matrix material can be increased and the speed of the liquid matrix material entering into different infiltration channels can be accelerated.

Or, the number of the glue injection channels 22 is equal to or greater than the number of the infiltration channels 21, and each glue injection channel 22 is correspondingly communicated with only one infiltration channel 21; alternatively, one or more of the infiltration channels may not be in communication with other infiltration channels, but only with one or more of the glue injection channels. The method is equivalent to grouping the infiltration channels, not only can the same liquid matrix material be injected into all the infiltration channels, but also different liquid matrix materials can be injected into different infiltration channels through different glue injection channels, so that more requirements on products are met.

Fig. 9-15 are schematic views of another embodiment of a glue cassette, fig. 9 being a front view of the glue cassette (the rear view being consistent therewith and not being shown again); FIG. 10 is a top view of the glue cassette (bottom view consistent with it and not shown); FIG. 11 is a left side view of the glue cassette; FIG. 12 is a right side view of the glue cassette; FIG. 13 is a B-B cross-sectional view of the cartridge; FIG. 14 is a cross-sectional view of the cartridge A-A; fig. 15 is an enlarged view of a portion of the section A-A of the cartridge. In this example, the number of the infiltration channels is reduced to 5, namely, one upper infiltration channel 21A, 3 middle infiltration channels 21B, and 1 lower infiltration channel 21C, so as to more clearly illustrate the structure and the working principle of the glue injection box, and the other embodiments described above are also applicable to the following technical schemes. That is, in the implementation, the two or more upper-layer impregnating channels 21A (the upper-layer impregnating channels in fig. 9-15 are only one impregnating channel, but may also be plural, for example, the uppermost 1-2 or more impregnating channels in the glue-injection boxes in fig. 3-7 are used as the upper-layer impregnating channels, they are communicated with one or more glue-injection channels, which are equivalent to that the upper-layer impregnating channels are communicated with each other, the same liquid matrix material can be injected), the middle-layer impregnating channel 21B (the middle-layer impregnating channels in fig. 9-15 are composed of 3 impregnating channels, but may also be plural, for example, the middle-layer impregnating channels in the glue-injection boxes in fig. 3-7 are used as the middle-layer impregnating channels, which are equivalent to that the middle-layer impregnating channels are all communicated with each other, the lower-layer impregnating channels 21C (the lower-layer impregnating channels in fig. 9-15 are only one impregnating channel, but also may be plural, for example, the middle-layer impregnating channels in the 3-layer impregnating boxes in the 3-layer impregnating channels are not all communicated with each other, the lower-layer impregnating channels in the layer impregnating boxes in fig. 3-7 are not all communicated with each other, the upper-layer impregnating channels in the same liquid matrix material can be introduced into the two or more than one layer impregnating channels 21A) may be used as the middle-layer impregnating channels in the layer impregnating channels, and the two or the upper-layer impregnating channels 21B are different from each other, and the upper-layer impregnating channels 21B can be different from each other layer impregnating channels and the upper-layer impregnating channels 21B and different from each other material can be introduced into the layer material into the upper-layer impregnating channels and different material can be different material into the layer material and different layer material and the upper-layer material can be different from the upper-layer impregnating channels 21B layer material can be different. This allows for the production of more complex products, resulting in products of different characteristics as desired. In fig. 9-15, the 3 infiltration channels of the middle infiltration channel share two horizontally arranged glue injection channels 221B (front, rear, left, right, upper, lower, etc. directions are defined by front and rear views), and after the glue injection channels 221B enter the glue injection box as shown in fig. 13-15, all the 3 infiltration channels of the middle infiltration channel 21B and the diversion trenches 222B of the 3 infiltration channels are communicated through one vertical diversion pipeline 2210, so that the liquid matrix material can be injected into the 3 infiltration channels of the middle infiltration channel 21B and the diversion trenches 222B of the 3 infiltration channels simultaneously through the front and rear glue injection channels 221B. In fig. 13 and 14, the upper injection passage 221A communicates with the upper infiltration passage 21A and the diversion trench 222A thereof, and injects the liquid base material thereto; the lower glue injection channel 221C communicates with the lower infiltration channel 21C and the diversion trench 222C, and injects a liquid matrix material into the lower glue injection channel. In this example, the upper layer infiltration channel 21A, the middle layer infiltration channel 21B, and the lower layer infiltration channel 21C may be all filled with the same liquid matrix material or may be filled with different liquid matrix materials. After the diversion pipeline 2210 surrounds the glue injection box for one circle, the upper layer infiltration channel 21A, the middle layer infiltration channel 21B, the lower layer infiltration channel 21C and the corresponding diversion trenches thereof are all communicated, so that a liquid matrix material can be injected at the same time. Or different liquid matrix materials are injected at different times so that the composite material has different materials and characteristics in the longitudinal section of the composite material. The glue injection box can be used for conveniently producing fiber materials with the same or different layer structures and various materials and composite materials with different arrangements. In the example of fig. 13, the upper fibrous material 911 enters through the inlet 2111 of the upper infiltration channel 21A and the infiltrated fibrous material 912 is pulled out through its outlet 2121; the middle layer fibrous material 921 enters through the inlet 2112 of the middle layer infiltration channel 21B, and the infiltrated fibrous material 922 is pulled out through the outlet 2122 thereof; the lower fiber material 931 enters through the inlet 2113 of the lower infiltration channel 21C and the infiltrated fiber material 932 is pulled out through the outlet 2123 thereof.

a distribution frame 1, configured to enter the fiber material passing through the distribution frame 1 into the glue injection box (the structure and the working principle thereof as described above) according to a distribution state;

the glue injection box 2 (the structure and the working principle thereof as described above) is provided with a soaking channel 21 for fiber material to soak and a glue injection channel 22 for liquid matrix material to enter the soaking channel 21, wherein the soaking channel 21 comprises a feed port 211 for fiber material to enter and a discharge port 212 for a composite material precursor formed by impregnating the fiber material with the liquid matrix material to pass through, and the area of the feed port 211 is larger than or equal to that of the discharge port 212;

Through adopting above-mentioned technical scheme, fibre material distributes in the space through the distribution frame and arranges, forms required fibre density, fibre material gets into in the infiltration passageway, liquid matrix material is through injecting glue passageway injection infiltration passageway in, liquid matrix material infiltration fibre material, fibre material mixed liquid matrix material gets into in the clearance between injecting glue box and the moulded die after passing the infiltration passageway, perhaps after carrying out the prefoaming in the foaming device who sets up in addition, reentrant moulded die carries out complete foaming and solidification or shaping, the area of the feed inlet of infiltration passageway is greater than or equal to the area of discharge gate for the internal pressure of liquid matrix material increases in the infiltration passageway, fully infiltrates between the final fashioned combined material fibre material and the liquid matrix material, guarantee the fibre material evenly distributed and fully stretches in the final fashioned combined material.

In some embodiments, the distribution frame 1 includes a distribution plate 12, the distribution plate 12 is provided with distribution holes 13 penetrating through the distribution plate 12 and used for passing through fiber materials, the distribution holes 13 are in a hole shape or a slit shape, the fiber materials simultaneously complete the distribution of the fiber materials in space through all or part of the distribution holes 13, preferably, the fiber materials in the form of fabric are distributed through the slit-shaped distribution holes 13, and the fiber materials in the form of yarn bundles are distributed through the slit-shaped distribution holes 13; more preferably, a portion of the fibrous material is distributed against the inner wall of the infiltration channel 21. The spatial arrangement mode of the distribution holes determines the arrangement position of the fiber materials in the composite material, so that the distribution condition of the fiber materials in the composite material can be conveniently controlled through the design of the distribution holes.

By adopting the technical scheme of the distribution frame, an operator can adjust the distribution of the fiber materials in the composite material by adjusting the distribution holes penetrated by the fiber materials, so as to realize the design of the distribution of the fiber materials in the composite material. When the distribution holes are in a hole shape, the fiber yarn material is suitable for being penetrated, when the distribution holes are in a strip slit shape, the fiber yarn material is suitable for the fiber fabric to pass, and the fiber fabric can be changed from a plane shape to an arc surface shape or a fold line shape by changing the shape of the strip slit, for example, the arc shape and the fold line shape, the structure of the fiber fabric in the composite material can be further adjusted, and the structure and the performance index of the composite material can be adjusted. Meanwhile, the distribution of the fiber materials in the cross section of the composite material is changed through the distribution of the distribution holes, the fiber materials can be uniformly distributed, can be distributed according to different shapes, can be distributed at different positions and can be further adjusted in terms of the structure and performance index of the composite material.

In some embodiments, the continuous production line of fiber-reinforced foamed composite material further comprises a foaming device 3, the foaming device 3 being provided with a continuous through foaming cavity; one end of the foaming device 3 is correspondingly arranged or connected with the discharge hole 212 of the glue injection box 2, the other end of the foaming device is correspondingly arranged or connected with the forming die 4, the composite material precursor enters the foaming device 3 through the discharge hole 212 and is pre-foamed in the foaming device 3, the length L of the foaming device 3 is less than or equal to s x t, s is the advancing speed of the composite material, and t is the time from starting foaming expansion to stopping expansion of the composite material precursor in the foaming device 3.

Or, the forming die 4 is provided with a cavity which is continuously communicated and is divided into a pre-foaming section and a forming die section, the part close to one side of the glue injection box is the pre-foaming section, the part close to one side of the traction device is the forming die section, and the composite material precursor enters the pre-foaming section from the glue injection box to be pre-foamed and then enters the forming die section to be solidified or shaped.

In some embodiments, the foaming device 3 further comprises a heating device 6 for foaming the liquid matrix material, the heating device 6 comprises one or more of a hot air circulation device, a microwave heating device, an electromagnetic heating device and an infrared heating device, and preferably, the heating device 6 further comprises a hot air collecting device arranged at the inlet of the forming die 4. To heat and recover pre-heat the composite precursor in the foaming device.

In some embodiments, a blowing device 5 is disposed near a discharge port of the glue injection box 2, and the blowing device 5 blows air to the composite precursor coming out of the discharge port.

In some embodiments, the air supply device 5 includes a fan 52 and an air supply pipe 54 that is communicated with the fan 52, where the air supply pipe 54 forms an included angle of 10 ° to 90 ° with the advancing direction of the composite material from the outlet 212 towards the side far away from the outlet 212, and one or more second air supply openings 542 are formed, preferably, one or more second air supply openings 542 are formed at an included angle of 60 ° to 90 °, and more preferably, an upper and a lower second air supply openings 542 are formed for supplying air towards the composite material precursor; on one hand, the composite material precursors pulled out from the discharge hole are supported and separated by the hot air flow, so that the premature adhesion of the composite material precursors after the composite material precursors exit the discharge hole is avoided, and the heating efficiency is influenced; finally, the second air supply port 542 may also prevent the liquid matrix material in the composite precursor pulled out of the discharge port from sagging and piling up at the discharge port, eventually blocking the discharge port.

In some embodiments, when the number of the infiltration channels 21 in the glue injection box 2 is two or more, the air supply pipes 54 are disposed between two adjacent discharge ports 212, the air supply pipes 54 are disposed on one side close to the discharge ports 212, and the air supply pipes 54 are provided with first air supply openings 541 toward the side far from the discharge ports 212, for supplying air between the composite precursors coming out from the two adjacent discharge ports 212; the airflow blown out by the first air supply opening 541 forms a hot airflow between two adjacent layered composite material precursors, so that the layered composite material precursors are foamed rapidly, and the problems of too slow foaming and low production efficiency caused by too thick single-layer composite material precursors and too slow heat transfer are avoided.

Through adopting above-mentioned technical scheme, the fan can be through being responsible for supplying with many blast pipes, has simplified the air feed structure of blast pipe, is convenient for implement.

Through adopting above-mentioned technical scheme, can also be by the air-supply line of settling on the hot-blast collection fan housing of moulded die entry hot-blast that blows out of blast pipe in the foaming device is taken out and is carried the blast pipe through axial fan, improves the heat efficiency that foaming device produced.

In some embodiments, the continuous production line of fiber reinforced foamed composite material is further provided with a waste heat recovery device, which comprises a hot air recovery cover arranged between the foaming device and the forming die, an air inlet pipe 53 communicated with the hot air recovery cover, and a fan 52 for making the air inlet pipe 53 close to one end of the forming die 4 generate negative pressure, wherein the other end of the air inlet pipe 53 is communicated with the air supply device 5, and the air in the foaming section 3 enters the air supply device 5 after being recovered by the air inlet pipe 53 and finally is discharged by the air supply device 5. This saves energy.

In some embodiments, a film-covering assembly 7 is disposed between the foaming device 3 and the forming die 4, for attaching a strip film 72 on the surface of the composite precursor and entering the forming die 4 along with the composite precursor; and/or attaching the fabric to the surface of the composite precursor as the composite precursor enters the forming die 4. The surface layer structure required on the surface of the final composite material product can be compounded, and the effect of the surface layer structure is that a film with one or more of a decorative function, a weather-proof function, a wear-resistant function, a flame-retardant function and a demolding function can be compounded on the surface of the composite material very conveniently, so that the working requirement of the composite material product is met; meanwhile, a plurality of film-covering components can be used for compounding a plurality of or a plurality of films on the surface of the composite material; further, the fabric can be compounded on the surface of the composite material by a film coating component singly or between the composite material precursor and the film, and the function of the composite material is supplemented or the strength of the composite material perpendicular to the existing direction, namely the transverse strength, is reinforced.

In some embodiments, the film covering assembly 7 includes one or more roller bodies 71 rotatably disposed, and the roller bodies 71 are wound with a band-shaped film or fabric or are provided with a rolled band-shaped film or fabric.

Through the technical scheme, the fiber materials are distributed and arranged in space according to the distribution holes of the distribution frame 1 to form the required fiber density and distribution pattern, then the fiber materials enter the infiltration channel 21, the liquid matrix materials are injected into the infiltration channel through the glue injection channel 22, the fiber materials are infiltrated into the fiber materials, the fiber materials are mixed with the liquid matrix materials, after passing through the infiltration channel 21, enter the foaming device 3 to be prefoamed, enter the forming die 4 to be completely foamed and cured or shaped, the area of the feed port 211 of the infiltration channel 21 is larger than or equal to the area of the discharge port 212, so that the internal pressure of the liquid matrix materials in the infiltration channel 21 is increased, the fiber materials are infiltrated rapidly and fully, the fiber materials in the final formed composite material are ensured to be distributed and fully stretched according to the design intention, the reinforcing effect of the fiber materials is exerted to the maximum extent, and the continuous production of the composite material after the shaping or curing is realized through the continuous traction of the traction device 8. The invention creatively distributes the fiber materials before being infiltrated according to the requirement, then the fiber materials enter a glue injection box and a liquid matrix material to be fully infiltrated and mixed into a composite material precursor, and then the composite material precursor enters a foaming device to carry out incomplete foaming reaction, wherein the reaction time is T, and the T is greater than zero but is equal to or less than the time T when the composite material just completes foaming in the foaming device 3 and stops expanding. Generally, the value of L needs to be set so that the time of the composite material in the foaming device 3 is smaller than the value of T, so that the composite material enters the forming die in a state of not being fully foamed, and the final foaming expansion is continuously completed, and the shaping and curing are completed. In one particular case, when T is equal to T, the composite material is put into the forming die after it has been completely expanded, and since it is no longer expanded, it has an adverse effect on the final forming quality, less effective than T < T, so T < T is preferably set. In a specific implementation, the distribution frame 1 may be set according to the following scheme, and as shown in fig. 2, the distribution frame 1 includes a frame body 11 and a distribution plate 12 disposed on the frame body 11, where a plurality of distribution holes 13 for fiber materials to pass through are uniformly disposed on the distribution plate 12, or the distribution holes 13 may be unevenly disposed, and the distribution form of the distribution holes 13 determines the spatial distribution state of each fiber material after passing through all or part of the distribution holes 13, so as to determine the distribution situation of the final fiber material in the composite material. Simultaneously, the fiber material continuously enters the glue injection box 2 through the traction device 8 at a controllable traction speed, so that the whole production line realizes continuous production.

As shown in fig. 3, the glue injection box 2 includes a box body, in which a plurality of infiltration channels 21 for fibrous materials to enter, glue injection channels 22 for liquid matrix materials to enter, and discharge channels 23 for controlling the thickness of composite materials are provided, in the embodiment shown in fig. 4, the infiltration channels 21 are uniformly distributed from top to bottom, the discharge channels 23 are arranged in a one-to-one correspondence with the infiltration channels 21, the glue injection channels 22 are arranged between the feed inlet 211 and the discharge outlet 212 and penetrate through all the infiltration channels 21, the liquid matrix materials enter all the infiltration channels 21 in the glue injection box 2 through the glue injection channels 22, and the fibrous materials enter different infiltration channels 21 in a layered manner after being distributed by the distribution plate 12; in an example shown in fig. 5, the cross section of the glue injection channel 22 along the vertical direction is in a necking configuration, in this embodiment, the cross section of the glue injection channel 22 is in an oval structure, and may also be in a circular structure, and the fiber material in the infiltration channel 21 is infiltrated with a liquid matrix material that is continuously injected according to the amount required for infiltrating the fiber material and drives the liquid matrix material to move, so as to ensure continuous infiltration of the fiber material.

The fiber material passing through the crossing position of the infiltration channel 21 and the glue injection channel 22 is infiltrated by the liquid matrix material to form a composite material precursor, and is pulled out through the discharge hole 212 under the traction action of the traction device 8, and the thickness is limited by the height of the discharge hole 212.

In some embodiments, the portion of the channel near the discharge port 212 after the intersection of the infiltration channel 21 and the glue injection channel 22 may be defined as a discharge channel, where the discharge channel is arranged in a necking manner (with a gradually decreasing cross section) toward the discharge port 212, and the gradually decreasing discharge channel increases the internal pressure of the liquid matrix material, accelerates the infiltration of the fiber material by the liquid matrix material, and simultaneously makes the thickness of the composite material reach a specified thickness. Of course, the structural design of the discharge hole 212 with smaller height and size than the feed hole 211 can increase the internal pressure of the liquid matrix material, accelerate the impregnation of the fiber material by the liquid matrix material, and simultaneously lead the thickness of the composite material to reach the specified thickness

With reference to the examples shown in fig. 1 and 4, the foaming device 3 has a tunnel structure, one end of the foaming device 3 is communicated with the glue injection box 2, the other end of the foaming device is communicated with the forming die 4, the foaming device 3 is communicated with all the discharge holes 212, and the layered composite material precursors are separated from the discharge holes 212 and then enter the foaming device 3, and the layered composite material precursors are in a sheet shape with one end separated from each other in the foaming device 3; in order to accelerate the foaming of the composite material precursor, the glue injection box 2 is further provided with an air supply device 5, the air supply device 5 comprises a fan 52 and a main pipe 51 connected with the fan 52, the main pipe 51 is provided with a plurality of air supply pipes 54, the air supply pipes 54 are arranged between two adjacent discharge holes 212 and close to one side of the glue injection box 2, the air supply pipes 54 are horizontally provided with a first air supply hole 541 arranged towards one side of the foaming device 3 as shown in fig. 6, air flows blown by the first air supply hole 541 form hot air flows between two adjacent layered composite materials and are used for separating the composite material precursor, so that the composite material precursor is prevented from being heated prematurely, the air supply pipes 54 are also provided with two second air supply holes 542 in the vertical direction, and the two second air supply holes 542 are arranged vertically for supplying air; in addition, the technical scheme of the second air supply port can prevent the liquid matrix material in the composite material precursor pulled out from the discharge port from sagging and accumulating at the discharge port, and finally blocking the discharge port, and finally, the first air supply port 541 and the second air supply port 542 are arranged at one side of the glue injection box to blow the relatively high-temperature hot air to the composite material precursor just coming out from the glue injection box 2, so as to accelerate the foaming of the composite material precursor; the time required by pre-foaming is reduced, and the production efficiency is improved.

In the example shown in fig. 1, the forming die 4 is provided with a heating device 6, and the heating device 6 includes a heating plate provided on the forming die 4, and the heating plate maintains the temperature in the forming die 4 within a certain range to complete sufficient foaming and curing or shaping of the composite material precursor. Finally, the fully foamed and cured or set composite material is continuously pulled out by the pulling device 8 and can be cut into the required products according to the required length by a subsequent cutting device.

In some embodiments, the distribution frame comprises a distribution plate, wherein the distribution plate is provided with distribution holes penetrating through the distribution plate and used for the fiber material to pass through, the distribution holes are in a hole shape or a slit shape, and the fiber material simultaneously passes through all or part of the distribution holes to complete the distribution of the fiber material in space.

By adopting the technical scheme, an operator can adjust the distribution of the fiber materials in the composite material by adjusting the distribution holes penetrated by the fiber materials, so that the distribution of the fiber materials in the composite material is ensured not to change. When the distribution holes are in a hole shape, the fiber yarn material is suitable for being penetrated, when the distribution holes are in a strip slit shape, the fiber yarn material is suitable for the fiber fabric to pass, and the fiber fabric can be changed from a plane shape to an arc surface shape or a fold line shape by changing the shape of the strip slit, such as an arc shape and a fold line shape, so that the structure of the fiber fabric in the composite material can be further adjusted, and the structure and the performance index of the composite material can be adjusted. Meanwhile, the distribution of the fiber materials in the cross section of the composite material is changed through the distribution of the distribution holes, the fiber materials can be uniformly distributed, can be distributed according to different shapes, can be distributed at different positions and can be further adjusted in terms of the structure and performance index of the composite material.

Preferably, the infiltration channel is a continuous channel, and the area of the inlet 211 is larger than the area of the outlet 212. By adopting the technical scheme, the internal pressure of the liquid matrix material is increased, and the impregnation is ensured to be full. In a specific implementation, the following scheme may be further selected, where the infiltration channel 21 is a continuous channel and the cross section of the infiltration channel gradually decreases linearly or stepwise from the feed inlet 211 to the discharge outlet 212; or the cross section of the part of the infiltration channel near the discharge hole is gradually reduced. As long as the internal pressure provided by the infiltration channel 21 is reached in the infiltration channel 21, the gradually decreasing internal space can gradually increase the internal pressure, so that the infiltration effect and efficiency of the liquid matrix material on the fiber material are higher, the sufficient infiltration is ensured, and the product quality is improved.

The height of the discharge hole is less than or equal to 20mm. The method is used for controlling the thickness of the composite material from a single infiltration channel, ensuring that the composite material is easy to heat and is heated uniformly, and ensuring the efficiency of subsequent foaming.

In a preferred embodiment, the inner wall of the infiltration channel 21 is further provided with a diversion trench 221, and the diversion trench 221 is circumferentially arranged along the cross section of the inner wall of the infiltration channel 21. The glue injection channel 22 is a vertical channel 222, the vertical channel 222 is disposed between the feed inlet 211 and the discharge outlet 212 and penetrates through the infiltration channel 21, and the diversion trench 221 is communicated with the vertical channel 222. The infiltration channel 21 is located at the diversion trench 221, and has a larger volume, and can be used as a pressure buffer area for stabilizing the glue injection pressure and uniformly distributing the liquid matrix material.

In a preferred embodiment, there are at least 2 infiltration channels 21 in the glue injection box 2, and all infiltration channels 21 are in communication with the glue injection channel 22; alternatively, the number of the glue injecting channels 22 is identical to the number of the impregnating channels, and the glue injecting channels are respectively communicated with the corresponding impregnating channels 21. In this way, when processing a composite material with a large thickness, if the composite material is a single infiltration channel 21, the infiltration efficiency becomes low, and the foaming efficiency and quality are difficult to control due to slow heat transfer. Because of the adoption of 2, 3 and more infiltration channels for layered infiltration of fiber materials, besides the advantages, liquid matrix materials with different materials or different formulations can enter different infiltration channels in the glue injection box 2 through the glue injection channel 22, so that a composite material with more complex materials can be constructed, products meeting different performance requirements can be obtained, and a single infiltration channel in the prior art cannot achieve the aim.

In practical application, the foaming device 3 further comprises a heating device 6 for foaming the liquid matrix material, and the heating device 6 comprises one or more combinations of a hot air circulation device, a microwave heating device, an electromagnetic heating device and an infrared heating device.

In practical application, an air supply device 5 is disposed on one side of the glue injection box 2 near the foaming device 3, the air supply device 5 includes a fan 52 and an air supply pipe 54 communicated with the fan 52, and the air supply pipe 54 supplies air into the foaming device 3.

In practical application, when the number of the infiltration channels 21 in the glue injection box 2 is two or more, the air supply pipes 54 are disposed between two adjacent discharge ports 212, the air supply pipes 54 are disposed on one side close to the discharge ports 212, and the air supply pipes 54 are provided with first air supply openings 541 toward one side far away from the discharge ports 212, for supplying air between the composite materials coming out from the two adjacent discharge ports 212.

In practical application, the air supply pipe 54 is provided with one or more second air supply openings 542 at an angle of 10 ° to 90 ° with respect to the advancing direction of the composite material from the outlet 212, and is configured to supply air toward the composite material.

In some embodiments, the continuous production line of fiber reinforced foamed composite material is further provided with a waste heat recovery device, which comprises an air inlet pipe 53 with one end communicated with the forming die 4 and a fan 52 for making the air inlet pipe 53 close to one end of the forming die 4 generate negative pressure, the other end of the air inlet pipe 53 is communicated with the air supply device 5, and the air in the foaming section 3 enters the air supply device 5 after being recovered by the air inlet pipe 53 and finally is discharged by the air supply pipe 54. In practical application, the following settings can be set: in order to improve the full utilization of the heat in the foaming section 3, the forming die 4 is connected with an air inlet pipe 53, the fan 52 is an axial flow fan 52 arranged on the air inlet pipe 53, the axial flow fan 52 flows the hot air in the forming die 4 into the foaming device 3, so that the high-temperature air exhausted by the air inlet pipe 54 can accelerate the foaming reaction of the composite material in the foaming device 3, and the production efficiency of the composite material is further improved. Through adopting above-mentioned technical scheme, the fan is through being responsible for supplying with many blast pipes, has simplified the air feed structure of blast pipe, is convenient for implement.

In some embodiments, in order to reduce the production efficiency of the composite material with surface coating, a coating assembly 7 is arranged between the foaming device 3 and the forming die 4, and is used for attaching the strip-shaped film 72 on the surface of the composite material and entering the forming die 4 along with the composite material; and/or attaching the fabric to the surface of the composite material as the composite material enters the forming die 4. In practical application, the film covering assembly 7 includes one or more roller bodies 71 rotatably disposed, and a strip film or fabric is wound on the roller bodies 71. For example, the film covering assembly includes a roller 71 rotatably disposed, and a strip film 72 is wound on the roller 71, where the strip film 72 is attached to the surface of the composite material, and is attached to the surface of the composite material as the composite material enters the forming mold 4 and is cured by the composite material, and the strip film 72 may be a decorative fabric or a weather-proof fabric with UV protection function, or a fiber felt or a cloth for increasing the transverse strength of the composite material, or may be a release cloth for facilitating the release of the composite material in the forming mold 4. The composite material has the advantages that the film with one or more of the functions of decoration, weather resistance, wear resistance, flame retardance and demolding can be conveniently compounded on the surface of the composite material, so that the working requirements of the composite material are met; meanwhile, a plurality of film-covering components can be used for compounding a plurality of or a plurality of films on the surface of the composite material; further, the fabric can be compounded on the surface of the composite material by a film coating component singly or between the composite material precursor and the film, and the function of the composite material is supplemented or the strength of the composite material perpendicular to the existing direction, namely the transverse strength, is reinforced.

The fiber material is one or more of organic fiber, inorganic nonmetallic fiber, plant fiber and metal fiber, preferably one or more of polymer fiber, plant fiber, glass fiber, carbon fiber and basalt fiber, more preferably one or more of polymer fiber and glass fiber; the liquid matrix material is a polymer, a metal or a nonmetal, preferably a thermosetting resin or a thermoplastic resin or an aluminum alloy or a magnesium alloy or glass or cement or gypsum, more preferably one or a combination of more of polyurethane, phenolic resin, fluorocarbon resin, acrylic resin and silicone resin.

The traction device 8 for traction of the composite material is further arranged in the scheme, the traction device 8 comprises a driving roller for clamping the composite material, the motion of the composite material is realized through the rotation of the driving roller, and as fibers in the composite material are continuous, the fiber material can be pulled to move on a continuous production line through traction of the composite material. By adopting the technical scheme, the continuous production of the composite material is realized.

As shown in fig. 7, the present invention also provides a continuous production method of a fiber-reinforced foamed composite material, which is manufactured by using any one of the continuous production lines for fiber-reinforced foamed composite materials, and includes the following steps:

In some embodiments, the S5 further includes: the ribbon film 72 or fibrous web is compounded on the surface of the composite precursor as it enters the forming die 4.

In some embodiments, there are at least 2 infiltration channels 21 in the glue injection box 2, and the glue injection channels 22 are respectively communicated with the corresponding infiltration channels 21; in S2, different types of liquid matrix materials are injected into different infiltration channels 21 through different glue injection channels 22, or different fibers enter different infiltration channels 21 through different feed inlets to form different composite material precursors, preferably, weather-resistant aliphatic polyurethane or fluorocarbon resin or acrylic resin is injected into the outer infiltration channels, and reinforced aromatic polyurethane or epoxy comfort or vinyl resin or unsaturated resin is injected into the inner infiltration channels.

In some embodiments, in S3, the blowing process is accelerated by using one or more of the first air supply opening 541 and the second air supply opening 542 provided on the air supply duct 54 to supply hot air to the composite material.

In some embodiments, the fibrous material comprises one or more combinations of inorganic fibers, organic polymer fibers, metal fibers, natural fibers, including one or more combinations of glass fibers, basalt fibers, carbon fibers; the organic polymer fiber comprises one or a combination of more of polyester fiber, kevlar fiber, ultra-high molecular weight polyethylene fiber, polyamide fiber, polyvinyl alcohol fiber, polyvinyl chloride fiber and polypropylene cyanide fiber; the metal fibers comprise one or more of steel fibers, aluminum fibers and copper fibers; the natural fiber comprises one or more of flax fiber, ramie fiber, sisal fiber, jute fiber, bamboo fiber and cotton fiber.

In some embodiments, the liquid matrix comprises one, two, or more combinations of organic polymer resins, inorganic gelling materials, or one, two, or more combinations of inorganic gelling materials, metallic materials; wherein the inorganic cementing material comprises one or more of cement, magnesia, gypsum; the metallic material comprises one or more of aluminum and its alloys, magnesium and its alloys; the organic polymer resin comprises a thermosetting resin and a thermoplastic resin; the thermosetting resin comprises one or more of polyurethane resin, epoxy resin, phenolic resin, unsaturated polyester resin, vinyl resin and cyanate resin.

In some embodiments, the liquid matrix is 15% to 65% by weight of the composite material.

In some embodiments, the liquid matrix further comprises a lubricant or an internal mold release agent.

In some embodiments, the composite material further comprises a fibrous fabric comprising one or more combinations of fibrous cloth, chopped strand mat, continuous mat, knitted mat, stitch-bonded mat, needled mat.

In some embodiments, the surface of the composite material further comprises a film layer or a fiber fabric layer having a decorative or protective function.

In some embodiments, the outer layer of the composite is made of a fibrous material and a weatherable resin comprising a combination of one or more of an aliphatic polyurethane resin, an acrylic resin, a fluorocarbon resin.

The selection of the above materials and the selection of the mixture ratio are discussed in the prior art, and will not be repeated.

In practical application, the surface of the composite material also comprises a film layer or a fiber fabric layer with a decorative function or a protective function.

In practical applications, the outer layer of the composite material is made of a fibrous material and a weather-resistant resin, wherein the weather-resistant resin comprises one or a combination of a plurality of aliphatic polyurethane resins, acrylic resins and fluorocarbon resins.

The invention also provides application of the fiber reinforced foam composite material to railway sleeper, floor, trestle plate, house maintenance structure, highway crash barrier, door and window curtain wall frame section bar, ship deck, maintenance plate and floating bridge plate.

In summary, the present invention can obtain the following effects:

1. the distribution frame can enable the fiber materials in the composite material to be distributed, fully soaked and fully straightened according to the design intention, and the reinforcing effect of the fiber materials is improved;

2. the glue injection box can quickly soak a large amount of fiber materials at one time, so that the glue injection box can be used for producing extremely thick composite materials;

3. the foaming device can uniformly heat the precursor of the composite material, foam the precursor rapidly, and improve the production efficiency of the foamed composite material;

4. the forming die can be used for preparing products with complex shapes through a special die cavity at one time, and the thickness and the shape of the prepared composite material are not limited as long as the conditions of the forming die permit;

5. the design of multiple channels can enable different parts of the prepared composite material to have different functions, so that different requirements are met.

It should be noted that modifications and improvements can be made by those skilled in the art without departing from the inventive concept, and these are all within the scope of the present invention.

Claims

1. A continuous production line for fiber-reinforced foamed composite material, comprising:

the distribution frame (1) is used for enabling the fiber materials passing through the distribution frame (1) to enter the glue injection box according to a distribution state;

the glue injection box (2) is provided with a soaking channel (21) used for soaking fiber materials and a glue injection channel (22) used for allowing liquid matrix materials to enter the soaking channel (21), wherein the soaking channel (21) comprises a feeding hole (211) used for allowing the fiber materials to enter and a discharging hole (212) used for allowing composite material precursors formed by soaking the fiber materials into the liquid matrix materials to pass through, and the area of the feeding hole (211) is larger than or equal to that of the discharging hole (212);

one end of the forming die (4) is a feeding end and is correspondingly arranged or connected with the discharging hole, and the other end of the forming die is a discharging end and is correspondingly arranged with the traction device and is used for curing or shaping the composite material precursor in the forming die (4);

a traction device (8), wherein the composite material is pulled out of the forming die (4) by the traction device (8) after being solidified or shaped in the forming die (4);

the continuous production line of the fiber reinforced foam composite material further comprises a foaming device (3), wherein the foaming device (3) is provided with a continuous through foaming cavity; one end of the foaming device (3) is correspondingly arranged or connected with a discharge hole (212) of the glue injection box (2), the other end of the foaming device is correspondingly arranged or connected with a forming die (4), a composite material precursor enters the foaming device (3) through the discharge hole (212) and is pre-foamed in the foaming device (3), the length L of the foaming device (3) is less than or equal to s x t, s is the advancing speed of the composite material precursor, and t is the time from the starting of foaming expansion to the stopping of the expansion of the composite material precursor in the foaming device (3);

A film covering component (7) is arranged between the foaming device (3) and the forming die (4) and is used for attaching a strip-shaped film (72) on the surface of the composite material precursor and entering the forming die (4) along with the composite material precursor; and/or attaching a fabric to the surface of the composite precursor into the forming mould (4) with the composite precursor;

the film covering component (7) comprises one or more roller bodies (71) which are rotatably arranged, wherein a strip-shaped film or fabric is wound on the roller bodies (71) or a coiled strip-shaped film or fabric is arranged on the roller bodies; an air supply device (5) is arranged at one side close to the discharge port of the glue injection box (2);

the continuous production line of the fiber reinforced foam composite material is also provided with a waste heat recovery device, and the waste heat recovery device is used for recovering hot air exhausted from an outlet section of the foaming device, and the hot air enters an air supply device (5) after being recovered and is finally exhausted through the air supply device (5).

2. Continuous production line of fiber-reinforced foamed composite material according to claim 1, characterized in that the distribution frame (1) comprises a distribution plate (12), wherein the distribution plate (12) is provided with distribution holes (13) penetrating the distribution plate (12) and used for the fiber material to pass through, the distribution holes (13) are in a hole shape or a slit shape, and the fiber material simultaneously passes through all or part of the distribution holes (13) to finish the distribution of the fiber material in space.

3. Continuous production line of fiber-reinforced foamed composite material according to claim 2, characterized in that the forming mould (4) is provided with a continuous through cavity, which is divided into a prefoaming section and a forming mould section, the part near the side of the glue injection box is the prefoaming section, the part near the traction device is the forming mould section, the composite material precursor enters the prefoaming section from the glue injection box for prefoaming, and then enters the forming mould section for curing or shaping.

4. A continuous production line for fibre reinforced foamed composite material according to claim 3, characterized in that the foaming device (3) further comprises a heating device (6) for foaming the liquid matrix material, the heating device (6) comprising one or a combination of more of a heated air circulation device, a microwave heating device, an electromagnetic heating device and an infrared heating device.

5. A continuous production line for fibre reinforced foamed composite material according to claim 4, characterized in that the blowing device (5) blows air towards the composite material precursor coming out of the outlet.

6. The continuous production line of fiber reinforced foamed composite material according to claim 5, wherein the air supply device (5) comprises a fan (52) and an air supply pipe (54) communicated with the fan (52), and one or more second air supply openings (542) are formed at an included angle of 10-90 degrees with the advancing direction of the composite material from the discharge opening (212) towards one side far away from the discharge opening (212) of the air supply pipe (54) and are used for supplying air towards the composite material precursor.

7. The continuous production line of fiber reinforced foamed composite material according to claim 6, wherein when the number of infiltration channels (21) in the glue injection box (2) is two or more, the air supply pipe (54) is arranged between two adjacent discharge ports (212), the air supply pipe (54) is arranged at one side close to the discharge ports (212), and a first air supply port (541) is arranged at one side of the air supply pipe (54) far away from the discharge ports (212) and is used for supplying air between composite material precursors coming out from the two adjacent discharge ports (212).

8. The continuous production line of fiber reinforced foamed composite materials according to claim 7, wherein the waste heat recovery device comprises a hot air recovery cover arranged between the foaming device and the forming die, and further comprises an air inlet pipe (53) communicated with the hot air recovery cover and a fan (52) for enabling the air inlet pipe (53) to be close to one end of the forming die (4) to generate negative pressure, the other end of the air inlet pipe (53) is communicated with the air supply device (5), and hot air in the foaming device (3) close to one end of the forming die (4) enters the air supply device (5) after being recovered through the air inlet pipe (53) and is finally discharged through the air supply device (5).

9. The continuous production line of fiber-reinforced foamed composite material according to claim 7, wherein the glue injection box (2) comprises 2 or more infiltration channels (21) for infiltration of fiber material and glue injection channels (22) for entry of liquid matrix material into the infiltration channels (21), the infiltration channels (21) comprise a feed port (211) for entry of fiber material and a discharge port (212) for passage of composite material precursor formed by impregnation of fiber material by liquid matrix material, and the area of the feed port (211) is greater than or equal to the area of the discharge port (212); the glue injection channel (22) is a vertical channel (222), and the vertical channel (222) is arranged between the feeding hole (211) and the discharging hole (212) and is communicated with the infiltration channel (21).

10. The continuous production line of fiber-reinforced foamed composite material according to claim 9, wherein the glue injection channels (22) are at least two, each impregnation channel (21) being in communication with one, two or more of the glue injection channels (22); or the number of the glue injection channels (22) is equal to that of the infiltration channels (21), and each glue injection channel (22) is correspondingly communicated with only one infiltration channel (21); alternatively, one or more of the infiltration channels may not be in communication with other infiltration channels, but only with one or more of the glue injection channels.

11. The continuous production line of fiber-reinforced foamed composite material according to claim 10, characterized in that the infiltration channel (21) is a continuous channel and the area of the feed opening (211) is larger than the area of the discharge opening (212); or the infiltration channel (21) is a continuous channel, and the cross section of the infiltration channel is gradually reduced or stepwise reduced from the feeding hole (211) to the discharging hole (212); or the cross section of the part of the infiltration channel near the discharge hole is gradually reduced.

12. The continuous production line of fiber-reinforced foamed composite material according to claim 11, wherein the height of the discharge opening (212) is 20mm or less.

13. The continuous production line of fiber reinforced foamed composite materials according to claim 11, wherein the inner wall of the infiltration channel (21) is further provided with a diversion trench (221), the diversion trench (221) is circumferentially arranged along the cross section of the inner wall of the infiltration channel (21), and the diversion trench (221) is communicated with the glue injection channel (22).

14. A continuous production method of a fiber-reinforced foamed composite material, characterized in that a continuous production line for the fiber-reinforced foamed composite material according to any one of claims 1 to 13 is used for preparing the fiber-reinforced foamed composite material, and comprises the following steps:

s1, fiber materials enter an infiltration channel (21) of the glue injection box (2) after being distributed and positioned according to design through the distribution frame (1);

s2, a liquid matrix material enters the glue injection box (2) through the glue injection channel (22), and a fiber material is infiltrated by the liquid matrix material to form a composite material precursor while passing through the infiltration channel (21) and then enters a foaming device (3), a gap between the forming die (4) and the glue injection box (2) or a pre-foaming section arranged on the forming die (4) through a discharge hole (212);

s3, the composite material precursor is pre-foamed in a gap or a pre-foaming section between the foaming device (3) or the forming die (4) and the glue injection box (2), and the liquid matrix material is foamed and expanded and enters the forming die (4) or a forming die section arranged on the forming die (4) when or before foaming is stopped;

S4, the composite material is fully foamed and cured or shaped in the forming die (4) or the forming die section;

s5, the formed composite material is pulled away from the forming die (4) through the traction device (8), and in the process, fiber materials from one side of a feed inlet (211) of the glue injection box (2) through the distribution frame (1) continuously enter the glue injection box (2).

15. The continuous production method of a fiber-reinforced foamed composite according to claim 14, wherein S5 further comprises: a strip-like film (72) or a fiber web is compounded on the surface of the composite material precursor, and enters the forming die (4) along with the composite material precursor.

16. A continuous production method of a fiber-reinforced foamed composite material according to claim 15, wherein at least 2 infiltration channels (21) are provided in the glue injection box (2), and the glue injection channels (22) are respectively communicated with the corresponding infiltration channels (21); in S2, different types of liquid matrix materials are injected into different infiltration channels (21) through different glue injection channels (22), or different fibers enter different infiltration channels (21) through different feed inlets, so as to form different composite material precursors.

17. A method for continuously producing a fiber reinforced foam composite according to claim 16, wherein in S3, the blowing process is accelerated by supplying hot air to the composite using one or a combination of a first air supply port (541) and a second air supply port (542) provided in the air supply duct (54).

18. A fibre reinforced foamed composite material, characterized in that the composite material is manufactured by a continuous production line for fibre reinforced foamed composite material according to any one of claims 1-13 or by a method according to any one of claims 14 to 17, comprising a composite material formed from a fibre material and a liquid matrix material.

19. Use of a fibre reinforced foam composite according to claim 18 for railway sleepers, floors, trestle plates, house maintenance structures, highway crash barriers, door and window curtain wall frame profiles, ship decks, maintenance boards, floating bridge boards.