CN110815870A - 一种纤维增强塑料片材机专用的加压预浸渍模头 - Google Patents
一种纤维增强塑料片材机专用的加压预浸渍模头 Download PDFInfo
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Abstract
本发明涉及一种纤维增强塑料片材机专用的加压预浸渍模头,包括模头主体,所述模头本体的中部设有一纵向贯通设置的至少一组纤维通道,纤维通道内部输送纤维纱;模头本体包括相互连通的进料口和出料口,所述出料口位于纤维通道外侧并分别向纤维纱两侧铺设熔融状态的热塑性基料;本发明结构设计合理,在热塑性基料挤出的同时即可铺设在纤维纱两侧表面,设备整体生产工作效率高,能胜任大批量高效率的生产任务,复合材料片材及其制品的总体制备成本较低,纤维纱与热塑性基料分布均匀,结合效果好,适用于厚度较大的纤维纱。
Description
技术领域
本发明涉及复材材料设备技术领域,尤其涉及一种纤维增强塑料片材机专用的加压预浸渍模头。
背景技术
塑料纤维复合板是一种由熔融基料与增强纤维纱织物预浸渍和复合之后经压辊挤压成型的一种复合材料,塑料纤维板凭借其高强度高密度的优异性能在汽车零部件上获得了广泛的用。
塑料纤维增强板是一种由塑料纤维和熔融塑料层叠后在一定的温度下经压缩成型的一种复合材料增强的片材,片材厚度可以根据实际的要求进行调整,片材可制作加工成多种汽车零部件,可代替金属件,降低车重,对节能减排意义重大;
现有的塑料纤维增强制品件的生产过程一般是通过挤出机将长纤维丝用螺杆绞断与熔融塑料混合,然后放入模具挤压成型产品,过程中产品的变形难以控制,且因纤维长度较短,复合材料制品件的强度增强不明显,难以完成复材制品质量轻、强度高的使用要求,而现有的复合材料片材的生产是熔融塑料铺设到纤维纱上经压辊挤压成型的,成型过程中融胶需穿透预制的纤维布到另一侧,过程熔融效果不好,流动不够均匀,难以达到强度标准。
发明内容
为了解决现有技术中的不足,本发明的目的在于提供一种纤维增强塑料片材机专用的加压预浸渍模头,用于生产符合产品要求的复合材料片材。
本发明解决其技术问题所采用的技术方案是:
一种纤维增强塑料片材机专用的加压预浸渍模头,包括模头主体,其特征在于:
所述模头本体的中部设有一纵向贯通设置的至少一组纤维通道,纤维通道内部输送纤维纱;
模头本体包括相互连通的进料口和出料口,所述出料口位于纤维通道外侧并分别向纤维纱两侧铺设熔融状态的热塑性基料。
还包括了若干压辊,压辊分为两组并分别位于所述纤维通道下部两侧,纤维纱布及其两侧的热塑性基料经过两组压辊之间设置,并由压辊挤压所述纤维纱布及其两侧的热塑性基料。
所述纤维通道截面为细长状结构,且所述出料口分别位于所述纤维通道的两个长边侧内壁上。
所述模头本体内部设有用于热塑性基料输送使用的热流通道,热流通道一端与进料口连通,热流通道另一端则分别通过分流通道与所述出料口一一对应连通。
所述模头本体与挤出机的出料端连接,且模头本体的进料口与挤出机的出料端连通,挤出机将热塑性基料直接喂入所述模头本体的进料口。
所述出料口包括两组并分别位于所述纤维通道两侧;
同一组的所述出料口为一个开口;
或由两个及两个以上的开口依次排列构成,且多个开口分布在同一直线上或不同的直线上。
所述分流通道与所述热流通道连通的一端还设有一分流腔室,热流通道通过所述分流腔室分别与所述分流通道一一连通。
所述热流通道靠近进料口的一侧内部还包括一加压腔室,加压腔室内部设有一转动设置的加压螺杆,且所述加压螺杆一端伸出所述模头本体设置并与一驱动装置连接,驱动装置用于驱动所述加压螺杆转动并输送所述热塑性基料。
所述分流通道与所述出料口连通的一端为均料腔室,均料腔室一端与分流通道连通,均料腔室另一端与所述出料口连通。
所述出料口的开口为细长状结构,且与所述进料口连通的均料腔室为扁平状结构,均料腔室的两侧边为斜面,且均料腔室的厚度自分流通道至出料口之间逐渐减小设置。
本发明的有益效果是:结构设计合理,在热塑性基料挤出的同时即可铺设在纤维纱两侧表面,设备整体生产工作效率高,能胜任大批量高效率的生产任务,复合材料片材及其制品的总体制备成本较低,纤维纱与热塑性基料分布均匀,结合效果好,适用于厚度较大的纤维纱。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1为本发明的上部轴测结构示意图。
图2为本发明的下部轴测结构示意图。
图3为本发明的主视结构示意图。
图4为本发明的右视结构示意图。
图5为本发明的俯视结构示意图。
图6为模头主体的仰视结构示意图。
图7为模头主体中热流通道的透视结构示意图。
图8为热流通道的轴测结构示意图。
图9为热流通道的俯视结构示意图。
图中:1挤出机、2电动机、3减速机、4第一模块、5第二模块、6纤维通道、7第三模块、8第四模块、9压辊、10热流通道、11加压腔室、12分流腔室、13分流通道、14均料腔室、15出料口、16加压螺杆。
具体实施方式
以下由特定的具体实施例说明本发明的实施方式,熟悉此技术的人士可由本说明书所揭露的内容轻易地了解本发明的其他优点及功效。
如图1至图9所示:本实施例提供一种纤维增强塑料片材机专用的加压预浸渍模头,包括模头主体,模头主体安装在挤出机1的出料端,用于控制挤出机1内部热塑性基料的出料位置及形状,可以达到与纤维纱配合的两层结构,其中各视图中的挤出机1采用示意图形,挤出机1可以采用单螺杆挤出机或双螺杆挤出机,为了更好的对本实施例的结构原理进行说明,所述模头主体的具体实施结构如下所述。
所述模头本体的中部设有一纵向贯通设置的一组纤维通道6,纤维通道6截面为细长状结构,用于与纤维纱的片状截面形状匹配,纤维通道6内部用于输送纤维纱,且保持纤维纱两侧与纤维通道6内壁之间保持有一定的间隙,用于热塑性基料的铺设使用;
所述模头本体包括相互连通的进料口和出料口15,所述出料口15位于纤维通道6的两个长边侧内壁上,位于模头本体内部的熔融状态的热塑性基料由所述出料口15挤出,并将热塑性基料分别铺设在纤维纱两侧,使热塑性基料达到与纤维纱两侧表面同时浸渍,结合效果好,保障了复合材料片材的熔融效果及质量;
其中,位于纤维通道6两侧的所述出料口15均为一个细长状结构的开口,开口的长度方向直线分布,用于使热塑性基料在出料口15挤出时构成扁平状结构,可以直接铺设在纤维纱两侧表面;
进一步地,对于上述出料口15的实施方式还包括了:所述出料口15可以由多个开口构成并位于同一直线上,使得不同的开口的大小可以根据实际使用设计不同的尺寸,用于在纤维纱两侧不同的位置上铺设不同厚度的热塑性夹料;其中当开口位于不同的直线上时,则可以组合构成多个平行分布的出料口15,可以在纤维纱两侧铺设多层热塑性胶料,相对应的为了满足热塑性基料的输送效果,模头本体的内部的热流通道10中部的分流部分会设置对应的多组,而模头本体的体积也会增加,同时与模头本体匹配的挤出机1数量也会增加。
所述模头本体还包括了两组压辊9,每组压辊9分别设有一个,且两组压辊9分别位于所述纤维通道6下部两侧,纤维纱布及其两侧的热塑性基料经过两组压辊9之间设置,并由压辊9挤压所述纤维纱布及其两侧的热塑性基料;一般情况下压辊9之间的间隙应该略小于纤维纱布和热塑性基料所构成的复合材料片材的厚度,用于保持压辊9对复合材料片材的挤压效果,同时压辊9两侧应通过对应的支架进行安装固定,并保持压辊9的转动装配效果,同时利用驱动装置(例如减速电机)控制压辊9转动并向外侧同步输送复合材料片材,达到挤压以及牵引的效果,通过一定压力的挤压实现纤维纱与两层热塑性基料不同强度的浸渍效果,通过牵引保障复合材料片材的输送效果,同时应注意与热塑性基料的出料速度匹配,使该装置可以持续的完成复合材料片材的生产,其中对于上述结构中压辊9的安装及驱动效果属于现有技术中的常用结构,故本实施例中对于支架及驱动装置的具体结构及连接关系不再赘述。
进一步地,为了达到热塑性基料在所述模头本体稳定的输送效果,所述模头本体内部设有用于热塑性基料输送使用的热流通道10,热流通道10一端与进料口连通,热流通道10与两个所述出料口15一一对应连通,为了满足热塑性基料的正常输送,所述热流通道10自进料口至出料口15方形依次包括加压腔室11、分流腔室12、分流通道13和均料腔室14,其中:
所述加压腔室11纵向分布并靠近进料口设置,加压腔室11内部设有一转动设置的加压螺杆16,且所述加压螺杆16底端伸出所述模头本体设置并与一驱动装置连接,驱动装置包括电动机2和减速机3,电动机2的输出端与所述减速机3的输入端连接且两者之间相互连接固定构成一个整体,减速机3的输出端则与所述加压螺杆16连接固定,使得电动机2可以驱动所述加压螺杆16转动用于输送热塑性基料使用,减速机3的底部则安装固定在所述模头本体的顶部;上述结构中,热塑性基料自挤出机1通过进料口进入热流通道10后,便直接又进入了加压腔室11,由于加压腔室11纵向分布,热塑性基料依靠自身重力沉入加压腔室11的下部,在此过程中,加压螺杆16还会通过自身转动并将热塑性基料向下输送,其工作原理类似于单螺杆挤出机,从而实现了热塑性基料的加速、加压输送,保障出料口15处的热塑性基料供给效果稳定;
所述分流腔室12位于所述加压腔室11底端且两者相互连通,加压腔室11为扁平状结构,分流腔室12的两侧对称分布,加压腔室11位于分流腔室12中部,分流腔室12横向分布且其内部空间相对较大,可以对加压腔室11输送的热塑性基料进行短暂存储,同时加压腔室11的底面上还设有两个相对于加压腔室11对称分布的两个开口,且开口与所述分流通道13连通,该结构的设计可以保障向分流通道13输送的热塑性基料充足,且两个分流通道13内部的热塑性基料分配效果均匀;
所述均料腔室14位于分流通道13和出料口15之间,均料腔室14一端与分流通道13连通,均料腔室14另一端与所述出料口15连通,由于所述出料口15的开口长度要远远大于分流通道13的直径,故均料腔室14整体为三角形结构,分流通道13与三角形结构的一个顶角位置连通,而出料口15则占满了与分流通道13所在的顶角相对的一个侧边,热塑性基料进入分流通道13后逐步扩散并向出料口15移动;
所述均料腔室14为扁平状结构,均料腔室14的两侧边为斜面,且均料腔室14的厚度自分流通道13至出料口15之间逐渐减小设置,通过该结构设计,可以在热塑性基料进入均料腔室14后使其向整个均料腔室14截面内均匀输送,在输送过程中介于均料腔室14的厚度变化,也有助于物料向均料腔室14两侧的边缘分布扩散,最终保持热塑性基料在整个出料口15位置均匀输送出来。
同时,在本实施例中,介于上述结构中的热流通道10结构的加工,所述模头本体包括相互连接固定的第一模块4、第二模块5、第三模块7和第四模块8,其中第一模块4位于左侧上部,其内部设有加压腔室11和分流腔室12,第二模块5位于第一模块4底部及第三模块7顶部,第三模块7中部设有纤维通道6,第二模块5为U型结构,使其中部避开纤维通道6位置,而第二模块5和第三模块7内部分别设有所述分流通道13,第四模块8位于第三模块7底部,且两者之间设有所述均料腔室14;通过上述结构,使得热流通道10整体可以分区域在不同的模块上进行加工,并最终最配成一个满足使用要求的整体。
基于上述结构的纤维增强塑料片材机专用的加压预浸渍模头,其在实际生产时,其工艺如下:
长纤维纱布预热处理:将卷绕有纤维纱的纤维纱辊放在对应的支架并在纤维纱输送过程中通过加热辊等加热机构对纤维纱进行预热,预热温度220-240℃,预热能力应能保证片材制备效率;
热塑性基料熔融:同时,挤出机1采用单螺杆挤出机或双螺杆挤出机,将热塑性基料熔融并挤出至模头本体内部,热塑性基料可以采用聚乙烯、聚丙烯、聚氨酯、聚苯乙烯、聚氯乙烯、聚酰胺、环氧树脂、酚醛树脂、不饱和聚酯树脂中的任意一种或其对应的改性树脂;
热塑性基料与纤维纱的结合处理:纤维纱在纤维通道6内自上至下输送,同时模头本体的出料口15分别将熔融状态的热塑性基料铺设在纤维纱两侧,此时纤维纱和热塑性基料向下输送并同时喂入压辊9之间,在压辊9的挤压下使纤维布和热塑性基料进一步融合均匀,同时保持复合材料片材厚度均匀,完成第一遍预压;
最终将复合材料片材喂入链板式设备进行再次挤压,最终经剪裁后获得指定尺寸的复合材料片材,用于直接放进模压设备的模具内压制成制品。
以上所述仅为本发明的优先实施方式,只要以基本相同手段实现本发明的目的技术方案,都属于本发明的保护范围之内。
Claims (10)
1.一种纤维增强塑料片材机专用的加压预浸渍模头,包括模头主体,其特征在于:
所述模头本体的中部设有一纵向贯通设置的至少一组纤维通道,纤维通道内部输送纤维纱;
模头本体包括相互连通的进料口和出料口,所述出料口位于纤维通道外侧并分别向纤维纱两侧铺设熔融状态的热塑性基料。
2.根据权利要求1所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:还包括了若干压辊,压辊分为两组并分别位于所述纤维通道下部两侧,纤维纱布及其两侧的热塑性基料经过两组压辊之间设置,并由压辊挤压所述纤维纱布及其两侧的热塑性基料。
3.根据权利要求1所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述纤维通道截面为细长状结构,且所述出料口分别位于所述纤维通道的两个长边侧内壁上。
4.根据权利要求1所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述模头本体内部设有用于热塑性基料输送使用的热流通道,热流通道一端与进料口连通,热流通道另一端则分别通过分流通道与所述出料口一一对应连通。
5.根据权利要求1所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述模头本体与挤出机的出料端连接,且模头本体的进料口与挤出机的出料端连通,挤出机将热塑性基料直接喂入所述模头本体的进料口。
6.根据权利要求1所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述出料口包括两组并分别位于所述纤维通道两侧;
同一组的所述出料口为一个开口;
或由两个及两个以上的开口依次排列构成,且多个开口分布在同一直线上或不同的直线上。
7.根据权利要求4所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述分流通道与所述热流通道连通的一端还设有一分流腔室,热流通道通过所述分流腔室分别与所述分流通道一一连通。
8.根据权利要求4所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述热流通道靠近进料口的一侧内部还包括一加压腔室,加压腔室内部设有一转动设置的加压螺杆,且所述加压螺杆一端伸出所述模头本体设置并与一驱动装置连接,驱动装置用于驱动所述加压螺杆转动并输送所述热塑性基料。
9.根据权利要求4所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述分流通道与所述出料口连通的一端为均料腔室,均料腔室一端与分流通道连通,均料腔室另一端与所述出料口连通。
10.根据权利要求8所述的一种纤维增强塑料片材机专用的加压预浸渍模头,其特征在于:所述出料口的开口为细长状结构,且与所述进料口连通的均料腔室为扁平状结构,均料腔室的两侧边为斜面,且均料腔室的厚度自分流通道至出料口之间逐渐减小设置。
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