CN111438967B - Forming device and process of long fiber reinforced thermoplastic resin composite material - Google Patents
Forming device and process of long fiber reinforced thermoplastic resin composite material Download PDFInfo
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- CN111438967B CN111438967B CN202010297124.6A CN202010297124A CN111438967B CN 111438967 B CN111438967 B CN 111438967B CN 202010297124 A CN202010297124 A CN 202010297124A CN 111438967 B CN111438967 B CN 111438967B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
- B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
Abstract
The invention discloses a forming device and a forming process of a long fiber reinforced thermoplastic resin composite material, belongs to the field of long fiber reinforced thermoplastic resin composite materials, and solves the problems of poor wettability, high fracture rate and poor reliability of long fiber reinforced thermoplastic resin composite materials in the prior art. The forming device of the long fiber reinforced thermoplastic resin composite material comprises an airflow fiber opening device, a mechanical unfolding roller and a fiber infiltration forming device which are sequentially arranged, wherein the fiber infiltration forming device comprises a molten resin impregnation die, and a counter pressure roller and a tension roller which are sequentially arranged are arranged in the molten resin impregnation die. The device can improve the wettability of the long fiber reinforced thermoplastic resin composite material, reduce the fracture rate and improve the reliability.
Description
Technical Field
The invention relates to the technical field of long fiber reinforced thermoplastic resin composite materials, in particular to a forming device and a forming process of a long fiber reinforced thermoplastic resin composite material.
Background
Long fiber-reinforced thermoplastic resin composite (LFT-G) is a long fiber-reinforced thermoplastic matrix composite that is marketed as a long-pellet prepreg. The fiber is generally manufactured by adopting the processes of fiber premixing, staple fiber mixing extrusion, continuous fiber extrusion coating and the like. The semi-finished prepreg material is subjected to secondary processing by adopting molding processes such as heating, pressing, injection molding and the like to form a thermoplastic composite material part. Compared with chopped fiber reinforced composite materials, the composite material has the advantages of high modulus, high strength and high toughness, can replace a part of metal parts in the automobile industry, household appliances and equipment facilities, and can effectively improve the practical performance of products and reduce the cost and weight of the products.
However, in some related patents disclosed so far and the actual situation of obtaining long fiber reinforced thermoplastic resin composites on the market, the method has a serious defect of poor wettability of resin to fibers, and particularly when a tool is used to destroy the obtained long fiber reinforced thermoplastic resin composites on the market, it is found that fibers wrapped by resin can be stripped out of fiber bundles which are not wetted by resin, and only fibers on the surface layer wrap the resin. In addition, according to the analysis of the production process of the prior art, the production efficiency of the long fiber-reinforced thermoplastic resin composite material is low, and the long fiber-reinforced thermoplastic resin composite material having high wettability cannot be stably provided.
The production device of the long fiber reinforced thermoplastic resin which is widely used at present comprises a melt impregnation chamber, wherein a resin melt for impregnating the fiber bundles is contained in the impregnation chamber, a fiber bundle inlet is arranged on one side wall of the melt impregnation chamber, a fiber bundle outlet is arranged on the side wall of the melt impregnation chamber, which is opposite to the side wall provided with the fiber bundle inlet, and the number of the fiber bundle outlets is smaller than that of the fiber bundle inlets. Although the device can improve the fiber content in the composite material, the fibers are not internally infiltrated under the process condition, the running speed of the fibers is low when two bundles of fibers are combined into one bundle, and the breakage of the fibers is caused by the improvement of the running speed.
At present, a forming device and a forming method for long fiber reinforced thermoplastic resin are provided, wherein the fiber needs to pass through a plurality of small grooves with arc shapes or concave polygons with 2-6 concave characteristics when being soaked with the resin, and actually, when the fiber passes through the grooves with a large number, stress concentration is easily caused under the action of tensile stress, so that fiber breakage is caused, and production is unstable.
Through comprehensive investigation, the improvement of the fiber wettability and the production efficiency of long fibers in an impregnation die in the prior art is still not improved.
Disclosure of Invention
In view of the above, the present invention aims to provide a molding apparatus and a process for a long fiber-reinforced thermoplastic resin composite material, which can solve at least one of the following problems: (1) the wettability is poor; (2) high fracture rate and poor reliability.
The purpose of the invention is mainly realized by the following technical scheme:
the invention provides a forming device of a long fiber reinforced thermoplastic resin composite material, which comprises an airflow fiber opening device, a mechanical spreading roller and a fiber infiltration forming device which are sequentially arranged, wherein the fiber infiltration forming device comprises a molten resin impregnation die, and a counter pressure roller and a tension roller which are sequentially arranged are arranged in the molten resin impregnation die.
Further, the molten resin impregnation die has a trapezoidal structure, and the area of the upper surface of the trapezoidal structure is larger than the area of the lower surface of the trapezoidal structure.
Furthermore, the forming device of the long fiber reinforced thermoplastic resin composite material also comprises a fiber concave pipe passage, the fiber concave pipe passage is arranged in front of the air flow fiber opening device, and the fiber bundle enters the fiber concave pipe passage and then passes through the air flow fiber opening device.
Furthermore, the fiber concave pipe channels are distributed with concave channels which are arranged in parallel, and the number of the concave channels is multiple.
Furthermore, the fiber infiltration forming device also comprises a fiber inlet module and a fiber outlet module, wherein the fiber inlet module is connected with one end of the molten resin impregnation die, and the fiber outlet module is connected with the other end of the molten resin impregnation die.
Further, the distance between two rollers of the counter-pressure roller is not more than 1 mm.
Furthermore, the molding device of the long fiber reinforced thermoplastic resin composite material also comprises a screw extruder, a cooling and shaping device and a cutting unit, wherein the screw extruder is connected with a feed inlet of the molten resin impregnation die.
In another aspect, the present invention further provides a molding process of a long fiber reinforced thermoplastic resin composite material, the molding process comprising the steps of:
step 1, a fiber bundle passes through a concave fiber pipe channel and then sequentially passes through an airflow fiber opening device and a mechanical opening roller for opening fiber to obtain pre-dispersed and heated fiber;
and 3, after the soaked fibers pass through a fiber outlet module and enter a cooling and shaping device, entering a cutting unit to obtain the long fiber reinforced thermoplastic resin composite material.
Further, in the step 1, the gas velocity of the gas flow fiber opening device is not lower than 10 m/s.
Further, in the step 1, the heating temperature of the mechanical spreading roller is 200-350 ℃.
Compared with the prior art, the invention can realize at least one of the following beneficial effects:
(1) according to the forming device of the long fiber reinforced thermoplastic resin composite material, the air-flow fiber opening device and the mechanical opening roller are sequentially arranged, so that fiber bundles are guaranteed to be respectively subjected to air-flow fiber opening and mechanical fiber opening, fibers can be twisted open to the maximum extent, and good precondition is provided for infiltration of resin.
(2) The inside of the molten resin impregnation die comprises the counter-pressure rollers and the tension rollers which are sequentially arranged, so that after the fiber bundles enter the molten resin impregnation die, the counter-pressure rollers can firstly adjust the pressure and the distance and can twist and press the entered fiber bundles open again in the environment full of resin melt, so that the resin can quickly and fully infiltrate among the fiber yarns, and the infiltration of the molten resin into the fiber bundles is absolutely improved; meanwhile, the counter-pressure roller has a rotating function, can provide power for the fiber bundles in the impregnation die, provides traction force for the fibers in the middle area of the device through the counter-pressure roller, provides traction force for the fibers in the rear area of the device through the cutting unit, provides operation power for the fibers due to the traction force of the two parts, reduces the phenomenon of stress concentration of the fiber bundles in the middle of a production stroke, can reduce or reduce fiber breakage (for example, the breakage rate is less than 1%, and is far lower than the existing breakage rate and is more than 7%), and improves the reliability and stability of production.
(3) The structure of molten resin impregnation mould is the trapezoidal body, and the upper portion of the area that the upper surface area of trapezoidal body is greater than the area of lower surface is big, the little structure setting in lower part can show the melt pressure that reduces the regional molten resin of mould inward flange and the regional melt pressure inequality of mould center, has eliminated the appearance of marginal resin to uneven phenomenon of fibre parcel and yellow material strip.
(4) The forming process of the long fiber reinforced thermoplastic resin composite material ensures the pre-dispersion and heating effects of the fibers by controlling the gas speed of the gas flow fiber splitting device and the heating temperature of the mechanical spreading roller, provides good conditions for complete infiltration, and ensures the high infiltration of the long fiber reinforced thermoplastic resin composite material, for example, the infiltration rate is more than 96 percent and is far higher than that produced by the existing production equipment (the center position in the fiber bundle in the existing produced product is basically free of resin, the resin does not infiltrate the fibers in the center, and the infiltration rate is generally lower than 70 percent).
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and drawings.
Drawings
The drawings are only for purposes of illustrating particular embodiments and are not to be construed as limiting the invention, wherein like reference numerals are used to designate like parts throughout.
FIG. 1 is a schematic configuration diagram of a molding apparatus for a long fiber-reinforced thermoplastic resin composite material of the present invention;
FIG. 2 is a scanning electron microscope image of a long fiber-reinforced thermoplastic resin composite material of example 1 of the present invention.
Reference numerals:
1-fiber bundle; 2-a fibre female tube channel; 3-airflow fiber opening device; 4-mechanical unwinding roller; 5-fiber feeding module; 6-pair of compression rollers; 7-molten resin impregnation of the mould; 8-a tension roller; 9-screw extruder; 10-fiber outlet module; 11-cooling and shaping device; 12-cutting unit.
Detailed Description
The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form a part hereof, and which together with the embodiments of the invention serve to explain the principles of the invention.
The invention provides a forming device of a long fiber reinforced thermoplastic resin composite material, which comprises an airflow fiber opening device 3, a mechanical spreading roller 4 and a fiber infiltration forming device which are sequentially arranged as shown in figure 1, wherein the fiber infiltration forming device comprises a molten resin impregnation die 7, and a counter pressure roller 6 and a tension roller 8 which are sequentially arranged are arranged in the molten resin impregnation die 7.
Compared with the prior art, the forming device for the long fiber reinforced thermoplastic resin composite material provided by the invention has the advantages that the fiber bundles are ensured to be twisted open to the maximum extent in the modes of airflow opening and mechanical opening respectively through the airflow opening device and the mechanical opening roller which are sequentially arranged, and good precondition is provided for the infiltration of resin; the inside of the molten resin impregnation die comprises counter-pressure rollers and tension rollers which are sequentially arranged, so that after the fiber bundles enter the molten resin impregnation die, the counter-pressure rollers can firstly twist and press the entering fiber bundles open again in an environment filled with resin melt through pressure (along with the change of the distance between the rollers, the extrusion force on the fibers also changes, namely the smaller the distance is, the larger the pressure is, the larger the distance is, the smaller the pressure is) and the adjustable counter-pressure rollers, so that the resin can quickly and fully infiltrate the fiber bundles, and the infiltration of the molten resin into the fiber bundles is absolutely improved; meanwhile, the compression roller has a rotating function, power can be provided for the fiber bundle inside the impregnation die, the phenomenon of stress concentration of the fiber bundle in the middle of the production stroke is reduced, fiber breakage can be reduced, and the production reliability and stability and production efficiency are improved.
It should be noted that the structure of the molten resin impregnation mold 7 is a trapezoid, the area of the upper surface of the trapezoid is larger than that of the lower surface, illustratively, the upper surface and the lower surface of the trapezoid are both square, the side length of the upper surface is larger than that of the lower surface, the structure arrangement with large upper part and small lower part can significantly reduce the unevenness of the melt pressure of the molten resin in the edge region of the mold and the melt pressure in the center region of the mold, and eliminate the uneven wrapping of the fiber by the edge resin and the yellow stripe (the existing molten resin impregnation mold is generally a cuboid, the upper and lower dimensions are consistent, after a period of use, the usage amount of the molten resin in the edge of the interior of the mold of the cuboid is found to be lower than that in the middle region of the mold, so that the molten resin is likely to accumulate for a long time in the edge of the interior of the mold of the cuboid, and the resin is aged in a high temperature state, Yellowing, resulting in the surface resin of the fibers passing through this region being aged resin, resulting in a yellow strand product).
Specifically, the inside of molten resin impregnation mould 7 is equipped with melt pressure real-time supervision device, can real-time supervision mould internal melt pressure, ensures not to lead to the fact the fibre fracture because of melt pressure is too high, and pressure is low excessively and lack the material.
Specifically, two sides of molten resin impregnation mould 7 that are on a parallel with fibre traffic direction can be dismantled, set up like this and can guarantee to install the tow inside the mould fast before production, on the other hand when the tow because other reasons appear fibre fracture, conglomeration etc. reason in the mould and cause the mould to block up, can open the mould fast and clear up.
Specifically, the distance between the two rolls of the counter press roll 6 is not more than 1mm because if the distance between the two rolls of the counter press roll 6 is more than 1mm, the effect of pressing the fiber bundle with the resin is poor and the effect of providing the traction force is insignificant.
Specifically, the forming device of the long fiber reinforced thermoplastic resin composite material further comprises a fiber concave pipe passage 2, the fiber concave pipe passage 2 is arranged in front of the airflow fiber opening device 3, and the fiber bundle 1 enters the fiber concave pipe passage 2 and then passes through the airflow fiber opening device 3.
Specifically, the fiber concave pipe channel 2 is distributed with a plurality of concave channels which are arranged in parallel, one concave channel can pass through a single fiber bundle or a plurality of fiber bundles, and the content change of the fiber can be controlled by controlling the single fiber bundle or the plurality of fiber bundles to enter a production line through the fiber concave pipe channel, so that the fiber content can be controlled.
Specifically, the length of the air outlet of the air flow opening device 3 is larger than the width of the fiber bundle 1.
Specifically, the number of the mechanical spreading rollers 4 is controlled to be not less than 3 because if the number of the mechanical spreading rollers 4 is less than 3, the spreading effect of the mechanical spreading rollers is very poor and cannot produce the synergistic spreading effect with the air-jet spreading device 3.
Specifically, the mechanical spreading roller 4 may be an open type mechanical spreading roller, and a heating device is provided inside the mechanical spreading roller 4 to preheat the fibers, so as to prevent the fibers from being deformed due to a temperature difference with the resin after entering the molten resin impregnation mold 7.
Further, the fiber infiltration forming device further comprises a fiber inlet module 5 and a fiber outlet module 10, wherein the fiber inlet module 5 is movably connected with one end of the molten resin impregnation die 7 (can be disassembled and is convenient to maintain and replace), the fiber outlet module 10 is movably connected with the other end of the molten resin impregnation die 7 (can be disassembled and is convenient to maintain and replace), and a feed inlet is formed in the top of the molten resin impregnation die 7.
Specifically, the distance between the fiber feeding module 5 and the mechanical spreading roller 4 is too large, so that the temperature of the preheated fibers is easily reduced, and the fibers are not favorably combined with the resin in the molten resin impregnation die 7. (the two substances have large temperature difference and poor compatibility), therefore, the distance between the fiber feeding module 5 and the mechanical unwinding roller 4 is controlled to be not more than 0.15 m.
Concretely, go out fine module 10 and distribute a row of circular port export, the fibre goes out from the circular port export and gets into cooling setting device 11, and the diameter of circular port export is 1mm ~ 5 mm.
Specifically, the molding device for the long fiber reinforced thermoplastic resin composite material further comprises a screw extruder 9, a cooling and shaping device 11 and a cutting unit 12, wherein the screw extruder 9 is connected with a feed port of the molten resin impregnation die 7, the screw extruder 9 is used for preparing molten resin, and then the molten resin is fed into the molten resin impregnation die 7 through the feed port; the counter-pressure roller 6 provides traction for the fibres in the molten resin impregnation mould 7, the cutting unit 12 provides traction for the fibres in the rear region of the apparatus, the presence of both portions of traction simultaneously providing operating power for the fibres, reducing the phenomenon of stress concentrations.
Specifically, the tension roller 8 is a cone with a circular arc top end, that is, the top end of the tension roller 8 is circular arc, so that the fiber bundle is not subjected to a sharp steering force when passing through the tension roller, the steering force is soft when the fiber bundle passes through the tension roller, and meanwhile, the provided tension provides conditions for further improving the wettability of the resin. The number of the tension rollers 8 is plural, the plural tension rollers 8 are alternately arranged in the inner bottom surface and the upper bottom surface (i.e., the top surface) of the molten resin impregnation die 7 in this order, the height of the tension roller 8 is not less than 1/2 of the inner height of the molten resin impregnation die 7, illustratively, the number of the tension rollers 8 is 3, and the arrangement positions are the lower bottom surface, the top surface, and the lower bottom surface in this order.
Specifically, the screw extruder 9 is a single or twin screw extruder.
Specifically, the cooling and shaping device 11 is water-cooled or air-cooled.
Specifically, the cutting unit 12 has a function of drawing and dicing.
The invention also provides a forming process of the long fiber reinforced thermoplastic resin composite material, which comprises the following steps:
step 1, a fiber bundle passes through a concave fiber pipe channel and then sequentially passes through an airflow fiber opening device and a mechanical opening roller for opening fiber to obtain pre-dispersed and heated fiber; the fiber bundle is widened and thinned under the action of air flow fiber opening and mechanical fiber opening, so that the fiber pre-dispersion effect is achieved, and the fiber is preheated after passing through a mechanical spreading roller;
and 3, after the soaked fibers pass through a fiber outlet module and enter a cooling and shaping device, entering a cutting unit to obtain the long fiber reinforced thermoplastic resin composite material.
Specifically, in the step 1, the gas speed of the gas flow fiber opening device is too low, and the fiber opening effect is avoided; the gas velocity is too high and the fiber bundle is blown off, blown away, etc. Therefore, in order to ensure the effect of fiber pre-dispersion, the gas speed of the gas flow fiber opening device is controlled to be not lower than 10m/s, and exemplarily, the gas speed is 10-60 m/s.
Specifically, in step 1, since the present invention can be applied to a large number of resins and fibers, for example, the resin may be general-purpose plastic, such as polyethylene and polypropylene, or engineering plastic, such as nylon, polycarbonate, or even high temperature resin such as polyetheretherketone, and therefore, the resins with different melting temperatures correspond to different fiber temperatures, and therefore, the heating temperature of the mechanical unwinding roller is adjusted and changed according to the corresponding resin. Therefore, the heating temperature of the mechanical spreading roller is controlled to be 200-350 ℃.
Specifically, in step 2, in order to prevent the fibers from being broken, the rotating speed of the counter-pressure roller is controlled to be consistent with the running speed of the cutting unit.
Example 1
The present embodiment provides a molding apparatus for a long fiber-reinforced thermoplastic resin composite material, including: the fiber sizing machine comprises a fiber concave pipe channel 2, an airflow fiber opening device 3, a mechanical spreading roller 4, a fiber infiltration forming device, a cooling and shaping device 11 and a cutting unit 12 which are distributed in sequence; the fiber infiltration forming device comprises a fiber inlet module 5, a molten resin impregnation die 7 and a fiber outlet module 10, wherein the molten resin impregnation die 7 comprises a counter-pressure roller 6 and tension rollers 8 which are sequentially arranged, and the number of the tension rollers 8 is 3.
When the method is implemented, the fiber bundle 1 enters a fiber concave pipe channel 2, then passes through an airflow fiber opening device 3, then passes through a mechanical spreading roller 4, then passes through a fiber infiltration forming device, passes through a cooling and shaping device 11, and then enters a cutting unit 12 to obtain a long fiber reinforced thermoplastic resin composite material; the fiber bundle which is preheated and unfolded in the fiber infiltration forming device enters a molten resin impregnation die 7 through a fiber inlet module 5, the infiltrated fiber bundle enters the next step after passing through a fiber outlet module 10, and the molten resin is prepared through a screw extruder 9 positioned at the upper part of the molten resin impregnation die 7.
In addition, concave channels which are arranged in parallel are distributed on the fiber concave channel 2, the number of the concave channels is 40, and one concave channel passes through a single 2400TEX glass fiber bundle; the length of an airflow outlet of the airflow fiber opening device 3 is larger than the width of the fiber bundle 1, and the air speed is 10 m/s; the number of the mechanical unwinding rolls 4 was 3, and the heating temperature was 220 ℃. The fiber feeding module 5 is movably connected with the molten resin impregnation die 7 and can be detached, and the distance between the fiber feeding module 5 and the mechanical spreading roller 4 is 0.1 m. The structure of the molten resin impregnation die 7 is a trapezoid, the upper surface and the lower surface of the trapezoid are both square, the side length of the upper surface is larger than that of the lower surface, a melt pressure real-time monitoring device is arranged in the molten resin impregnation die 7, and two side surfaces of the molten resin impregnation die, which are parallel to the fiber running direction, can be detached; the distance between the two opposite compression rollers 6 is 0.4mm, and the rotating speed of the opposite compression rollers 6 is consistent with the running speed of the cutting unit 12; the tension roller 8 is a conical body with a circular arc top end, and is sequentially arranged on the inner lower bottom surface and the upper bottom surface of the molten resin impregnation die 7, and the height of the tension roller 8 is 3/5 of the internal height of the molten resin impregnation die 7; the screw extruder 9 is a single screw extruder, and the resin is polypropylene; the fiber outlet module 10 is provided with a row of 40 circular hole outlets, and the diameter of each outlet is 1.5 mm; the cooling and shaping device 11 adopts a water cooling mode; the cutting unit 12 has a function of drawing and dicing.
The molding process of the long fiber-reinforced thermoplastic resin composite material of the present embodiment includes the steps of:
(a)40 glass fiber bundles 1 pass through a fiber concave pipe channel 2, then pass through an airflow fiber splitting device 3, then pass through a mechanical spreading roller 4, and the fiber passes through the airflow fiber splitting and mechanical fiber splitting effects, so that the width of the fiber bundle is increased, the thickness of the fiber bundle is reduced, the fiber pre-dispersion effect is achieved, and the fiber is preheated through the mechanical spreading roller 4;
(b) the pre-dispersed and heated fibers enter a molten resin impregnation die 7 through a fiber inlet module 5, the fibers are strongly extruded in an environment filled with molten resin after passing through a counter-pressure roller 6, on one hand, the molten resin is rapidly dispersed on each fiber filament, on the other hand, the purposes of further dispersion and stress dissipation of the fibers are achieved, the production efficiency of the material is improved, and the fibers and the molten resin are fully contacted, soaked and coated under the action of a tension roller 8;
(c) after passing through the fiber outlet module 10, the completely infiltrated fiber enters the cooling and shaping device 11, and then enters the cutting unit 12 to obtain the long fiber reinforced thermoplastic resin composite material.
The long fiber-reinforced thermoplastic resin composite material obtained in this example had a fiber content of 50%, as shown in fig. 2, when observed by a scanning electron microscope: the outer sides of the fibers of the long fiber reinforced thermoplastic resin composite material are basically completely wrapped by resin, and the infiltration rate is more than 98 percent; the breaking rate of the fiber is less than 1 percent.
Example 2
This example provides a molding apparatus for a long fiber-reinforced thermoplastic resin composite material, which has the same overall structure as the apparatus of example 1, except that:
concave channels which are arranged in parallel are distributed on the fiber concave channel 2, the number of the concave channels is 20, and two 24K carbon fiber bundles pass through one concave channel; the gas velocity of the airflow fiber opening device 3 is 15 m/s; the number of the mechanical spreading rollers 4 is 4, and the heating temperature is 280 ℃; the distance between the fiber feeding module 5 and the mechanical spreading roller 4 is 0.15 m; the distance between the two opposite compression rollers 6 is 0.8 mm; the height of the tension roller 8 is 2/3 of the internal height of the molten resin impregnation die 7; the screw extruder 9 is a twin-screw extruder, and the resin used is polyamide 66; the fiber outlet module 10 is provided with a row of 20 circular hole outlets, and the diameter of each outlet is 3 mm; the cooling and shaping device 11 is air-cooled.
The molding process of the long fiber-reinforced thermoplastic resin composite material of the present embodiment includes the steps of:
(a)40 fiber bundles 1 pass through a fiber concave pipe channel 2, then pass through an airflow fiber opening device 3, then pass through a mechanical unfolding roller 4, and the fiber passes through the effects of airflow fiber opening and mechanical fiber opening, so that the width of the fiber bundle is increased, the thickness of the fiber bundle is reduced, the fiber pre-dispersion effect is achieved, and the fiber is preheated by the mechanical unfolding roller 4;
(b) the pre-dispersed and heated fibers enter a molten resin impregnation die 7 through a fiber inlet module 5, the fibers are strongly extruded in an environment filled with molten resin after passing through a counter-pressure roller 6, on one hand, the molten resin is rapidly dispersed on each fiber filament, on the other hand, the purposes of further dispersion and stress dissipation of the fibers are achieved, the production efficiency of the material is improved, and the fibers and the molten resin are fully contacted, soaked and coated under the action of a tension roller 8;
(c) after passing through the fiber outlet module 10, the completely infiltrated fiber enters the cooling and shaping device 11, and then enters the cutting unit 12 to obtain the long fiber reinforced thermoplastic resin composite material.
The long fiber-reinforced thermoplastic resin composite material obtained in this example had a fiber content of 40%, and was observed by a scanning electron microscope: the outer sides of the fibers of the long fiber reinforced thermoplastic resin composite material are basically completely wrapped by resin, and the infiltration rate is more than 97 percent; the breaking rate of the fiber is less than 1 percent.
Example 3
This example provides a molding apparatus for a long fiber-reinforced thermoplastic resin composite material, which has the same overall structure as the apparatus of example 1, except that:
concave channels which are arranged in parallel are distributed on the fiber concave channel 2, the number of the concave channels is 20, and one concave channel passes through 3 2400tex glass fiber bundles; the gas velocity of the airflow fiber opening device 3 is 15 m/s; the number of the mechanical spreading rollers 4 is 5, and the heating temperature is 220 ℃; the distance between the fiber feeding module 5 and the mechanical spreading roller 4 is 0.12 m; the distance between the two opposite compression rollers 6 is 1 mm; the height of the tension roller 8 is 3/5 of the internal height of the molten resin impregnation die 7; the screw extruder 9 is a single screw extruder, and the resin used is high-density polyethylene; the fiber outlet module 10 is provided with a row of 20 circular hole outlets, and the diameter of each outlet is 5 mm; the cooling and shaping device 11 is air-cooled.
The molding process of the long fiber-reinforced thermoplastic resin composite material of the present embodiment includes the steps of:
(a)60 fiber bundles 1 pass through a fiber concave pipe channel 2, then pass through an airflow fiber opening device 3, then pass through a mechanical unfolding roller 4, and the fiber passes through the effects of airflow fiber opening and mechanical fiber opening, so that the width of the fiber bundle is increased, the thickness of the fiber bundle is reduced, the fiber pre-dispersion effect is achieved, and the fiber is preheated by the mechanical unfolding roller 4;
(b) the pre-dispersed and heated fibers enter a molten resin impregnation die 7 through a fiber inlet module 5, the fibers are strongly extruded in an environment filled with molten resin after passing through a counter-pressure roller 6, on one hand, the molten resin is rapidly dispersed on each fiber filament, on the other hand, the purposes of further dispersion and stress dissipation of the fibers are achieved, the production efficiency of the material is improved, and the fibers and the molten resin are fully contacted, soaked and coated under the action of a tension roller 8;
(c) after passing through the fiber outlet module 10, the completely infiltrated fiber enters the cooling and shaping device 11, and then enters the cutting unit 12 to obtain the long fiber reinforced thermoplastic resin composite material.
The long fiber-reinforced thermoplastic resin composite material obtained in this example had a fiber content of 60%, and was observed by a scanning electron microscope: the outer sides of the fibers of the long fiber reinforced thermoplastic resin composite material are basically completely wrapped by resin, and the infiltration rate is more than 96 percent; the breaking rate of the fiber is less than 1 percent.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention.
Claims (8)
1. The forming device of the long fiber reinforced thermoplastic resin composite material is characterized by comprising an airflow fiber opening device (3), a mechanical unfolding roller (4) and a fiber infiltration forming device which are sequentially arranged, wherein the fiber infiltration forming device comprises a fiber inlet module (5), a molten resin impregnation die (7) filled with resin melt and a fiber outlet module (10), and the molten resin impregnation die (7) internally comprises a counter-pressure roller (6) and a tension roller (8) which are sequentially arranged;
the counter-pressure roller (6) can twist and press apart the entering fiber bundles again in the environment filled with the resin melt; the structure of the molten resin impregnation die (7) is a trapezoid body, the area of the upper surface of the trapezoid body is larger than that of the lower surface of the trapezoid body, the upper surface and the lower surface are both square, and two side surfaces parallel to the running direction of the fibers can be detached;
the distance between the fiber feeding module (5) and the mechanical spreading roller (4) is not more than 0.15 m; the tension roller (8) is a cone with a circular arc top end.
2. The long fiber-reinforced thermoplastic resin composite molding device according to claim 1, characterized in that the long fiber-reinforced thermoplastic resin composite molding device further comprises a fiber concave pipe passage (2), the fiber concave pipe passage (2) is provided before the air-flow splitting device (3), and the fiber bundle (1) passes through the air-flow splitting device (3) after entering the fiber concave pipe passage (2).
3. The molding apparatus for a long fiber-reinforced thermoplastic resin composite material according to claim 2, wherein the fiber concave pipe passages (2) are distributed with concave passages arranged in parallel, and the number of the concave passages is plural.
4. The long fiber-reinforced thermoplastic resin composite molding apparatus according to claim 1, wherein the distance between both rolls of the counter roll (6) is not more than 1 mm.
5. The long fiber-reinforced thermoplastic resin composite molding apparatus according to claim 1, further comprising a screw extruder (9), a cooling and setting device (11), and a cutting unit (12), wherein the screw extruder (9) is connected to a feed port of the molten resin impregnation die (7).
6. A molding process of a long fiber-reinforced thermoplastic resin composite material, characterized by using the molding apparatus of any one of claims 1 to 5, the molding process comprising the steps of:
step 1, a fiber bundle passes through a concave fiber pipe channel and then sequentially passes through an airflow fiber opening device and a mechanical opening roller for opening fiber to obtain pre-dispersed and heated fiber;
step 2, the pre-dispersed and heated fibers enter a molten resin impregnation die through a fiber inlet module, and the fibers are subjected to compression roller and tension roller to obtain soaked fibers;
and 3, after the soaked fibers pass through a fiber outlet module and enter a cooling and shaping device, entering a cutting unit to obtain the long fiber reinforced thermoplastic resin composite material.
7. The process for molding a long fiber-reinforced thermoplastic resin composite material according to claim 6, wherein in the step 1, the gas velocity of the gas flow spreading device is not less than 10 m/s.
8. The molding process of the long fiber-reinforced thermoplastic resin composite material according to claim 6 or 7, wherein the heating temperature of the mechanical spreading roll in the step 1 is 200 to 350 ℃.
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| CN112976405B (en) * | 2021-02-06 | 2022-11-08 | 台州维一新材料有限公司 | Online forming method of long fiber reinforced thermoplastic resin product |
| CN113232331B (en) * | 2021-06-03 | 2022-10-14 | 山东国维复合材料科技有限公司 | Continuous production equipment for thermoplastic composite material |
| CN114179251B (en) * | 2021-11-23 | 2023-03-14 | 成都飞机工业（集团）有限责任公司 | System and method for preparing continuous fiber reinforced thermoplastic composite prepreg filaments |
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