TWI697396B - A thermoplastic unidirectional fiber prepreg and molding application thereof - Google Patents

Abstract

Present invention is related to a thermoplastic unidirectional fiber prepreg and molding application thereof. The unidirectional fibers are impregnated with thermoplastic monomers and followed by molding of the prepreg under in-situ polymerization. This invention is able to solve the problems of insufficient impregnation and low mechanical strength of conventional thermoplastic composites during manufacturing and secondary molding processes. In addition, the degree of polymerization can be controlled by adjusting the quantity of an activator and a catalyst, reaction temperature, and the reaction time of in-situ polymerization to achieve higher mechanical strength and wear-resistance ability of final products.

Description

Thermoplastic unidirectional fiber prepreg and molding method of molded body

A method for forming a fiber prepreg and its molded body, especially a method for forming a thermoplastic unidirectional fiber prepreg and its molded body.

The light weight and high strength of carbon fiber make carbon fiber prepreg one of the common raw materials suitable for making high-performance composite molded objects. Carbon fiber prepreg is mainly made of carbon fiber yarn and epoxy resin compound impregnation. After penetration, it is heated and processed to solidify. The epoxy resin impregnated carbon fiber prepreg has excellent mechanical properties and high strength.

However, the disadvantage of the current carbon fiber prepreg impregnated with thermosetting epoxy resin is that it cannot be processed twice after molding, and it is difficult to recycle. However, it is necessary to use a thermoplastic resin impregnated with better secondary processing and recycling characteristics. Carbon fiber prepreg, but it is difficult to break through the problems of poor carbon fiber impregnation, dry yarn, random yarn, and gaps between fibers caused by poor fluidity of the molten thermoplastic resin, which in turn affects the quality and appearance of subsequent processed molded products , And the lack of impregnation results in poor bonding between the fiber and resin interface, resulting in a decrease in the mechanical strength of the finished product.

At present, there is no high-quality carbon fiber prepreg that can have secondary processing and recycling characteristics, and the carbon fibers can be continuously arranged in a single direction, with good resin impregnation, and will not cause the problem of carbon fiber dry yarn, chaotic yarn, or gaps between the fibers. Produced, and can provide molded products with excellent quality, high mechanical strength and beautiful appearance.

In order to solve the aforementioned problems that the thermosetting epoxy resin impregnated carbon fiber prepreg cannot be processed twice, and it is also difficult to recycle, and the poor fluidity of the molten thermoplastic resin caused by the poor carbon fiber impregnation, dry yarn, messy The shortcomings of the gaps between yarns and fibers. The present invention provides a thermoplastic unidirectional fiber prepreg and a molding method for its molded body. It not only uses a thermoplastic resin with secondary processing characteristics as the fiber impregnation material, but also improves the existing Various technical bottlenecks of thermosetting epoxy resins and thermoplastic resins, and provide molded products with quality, strength and beautiful appearance.

A thermoplastic unidirectional fiber prepreg of the present invention comprises: a sheet formed by arranging a plurality of fibers in substantially the same direction; and at least part of the surface of the sheet or a part of the inter-fiber is covered with a thermoplastic precursor.

Wherein, the fiber is carbon fiber or glass fiber; the thermoplastic is nylon polymerized with endoamide; and the precursor of the thermoplastic contains endoamide.

Wherein, the thermoplastic precursor further includes an active agent and a catalyst.

Wherein, the active agent is an isocyanate and its derivatives; and the catalyst is an alkali metal salt.

Wherein, the alkali metal salt is an alkali metal salt generated from the thermoplastic precursor.

Preferably, the thermoplastic precursor is distributed on the sheet in the form of powder or fluid.

The present invention further provides a molding method of a molded body of a thermoplastic unidirectional fiber prepreg. The steps include: providing a sheet of force on a plurality of yarn bundles, and making the plurality of yarn bundles advance in the same direction; using friction control and tension Adjust and expand the plurality of yarn bundles by air impact method, so that the plurality of yarn bundles are expanded into a plurality of fiber yarns in the horizontal direction, and a thermoplastic precursor is distributed on the surface of the expanded plurality of yarn bundles and/ Or between fiber yarns; using an entire bundle arranging device to arrange the plurality of yarn bundles at intervals before and/or after unfolding the plurality of yarn bundles; heating and pressing the plurality of yarn bundles with a hot pressing module to make The thermoplastic resin precursor is fixed on the plurality of yarns to form a thermoplastic unidirectional fiber prepreg; the thermoplastic unidirectional fiber prepreg is polymerized in situ and simultaneously processed and formed.

Wherein, the step of polymerizing the thermoplastic unidirectional fiber prepreg in situ and simultaneously processing and forming includes: laminating a plurality of the thermoplastic unidirectional fiber prepregs in a mold; and pouring the thermoplastic precursor in a fluid state Into the sealed mold, the thermoplastic precursor includes an activator and a catalyst; the injected fluid state of the thermoplastic precursor, the activator and the catalyst, and the plurality of yarn bundles spread out The thermoplastic precursor on the surface and/or between the fiber yarns reacts to form the thermoplastic, which is solidified and formed into a molded body of the thermoplastic unidirectional fiber prepreg.

Wherein, the aforementioned active agent and the catalyst are firstly mixed with a small amount of the thermoplastic precursor in a fluid state, and then mixed with the thermoplastic precursor in other fluid states and poured into the mold.

More preferably, the processing and molding may be thermocompression molding; wherein, when the thermoplastic precursor is distributed on the surface of the unfolded plurality of yarn bundles and/or between the fiber yarns, the thermoplastic precursor further includes a Active agent and a catalyst.

More preferably, in the aforementioned manufacturing process, the ratio of the thermoplastic precursor and the fiber contained in the thermoplastic unidirectional fiber prepreg can be controlled by adjusting the entire bundle arrangement device and the gap of the hot pressing module.

According to the above description, the present invention has the following advantages:

1. The present invention uses the thermoplastic precursor (or as a reactive monomer) as the material for fiber impregnation, and when it is to be processed into a molded product later, an active agent and a catalyst are added to participate in the mixing in the prepreg stage or the molding stage according to the processing requirements , And then carry out the in-situ polymerization reaction and curing molding process of polymerizing the thermoplastic, to improve the existing thermoplastic polymer because of the lack of impregnation in the secondary processing process of directly impregnating the polymer with the polymer and the post-processing molding, and the fiber and resin interface bonding Poor, leading to the disadvantage of decreased mechanical properties.

2. The present invention can further control the degree of polymerization of the thermoplastic through the addition of active agent and catalyst, reaction temperature and polymerization time during in-situ polymerization, control the molecular weight of polymer synthesis polymerization, and achieve control reaction processing according to the needs of molded products Advantages of time, mechanical strength and wear resistance.

3. In the yarn spreading stage, the present invention uses the combination of the yarn spreading fabric module, the whole bunch arrangement device and the hot pressing module, and the adjustment of the spreading yarn fabric in the process, so that the yarn bundle can be spread and evenly distributed. Effectively control the content of plastic in the yarn bundle, and after polymerization processing, high-quality unidirectional fiber-reinforced composite sheets with both processability, beauty and applicability can be obtained. The present invention successfully introduces the thermoplastic resin with secondary molding characteristics and better recyclability into the impregnation molding system, which is a major breakthrough in the field and conforms to the trend of green environmental protection manufacturing process. .

The so-called thermoplastic unidirectional fiber prepreg in the present invention is mainly a prepreg composite sheet or composite board, and the materials include carbon fiber, glass fiber, etc., and the fibers suitable for the molding process are not beyond the scope of the present invention; and the present invention The yarn bundle is a bundle composed of a plurality of same or different fiber yarns arranged in substantially the same direction.

Please refer to Fig. 1, a method for forming a molded body of a thermoplastic unidirectional fiber prepreg of the present invention. The steps of the first preferred embodiment of the present invention include: Step S1: Provide a plurality of yarn bundles, and combine the plurality of yarns The yarn bundles are arranged at intervals and advance in the same direction. Step S2: Use friction control, tension adjustment and air impact to unfold a plurality of the yarn bundles, so that the plurality of yarn bundles are expanded in the horizontal direction into a plurality of fiber yarns arranged in substantially the same direction. The driving objects are distributed on the surface of a plurality of unfolded yarn bundles and/or between the fiber yarns thereof. The thermoplastic precursor is preferably in a powder state evenly distributed on the surface of the plurality of yarn bundles and/or its fiber yarns; the thermoplastic precursor may also be called a monomer, which is the polymerization of the thermoplastic And step S3: use an entire bundle arranging device to arrange the plurality of yarn bundles at intervals before and/or after unfolding the plurality of yarn bundles; Step S4: spread the plurality of yarn bundles to A hot pressing module heats and presses, so that the thermoplastic precursor is fixed on a plurality of the yarn surfaces and/or between the fiber yarns to become a thermoplastic unidirectional fiber prepreg; Step S5: the thermoplastic unidirectional The fiber prepreg is polymerized in situ and processed into a molded body at the same time.

Among them, the processing and molding types described in step S5 of the present invention include, but are not limited to, resin injection molding or hot press molding. The current existing methods for processing and molding prepregs can be used in the present invention. The following first illustrates the method and steps of resin transfer molding: Step S6: Lay a plurality of the thermoplastic unidirectional fiber prepregs in a mold; Step S7: Fill the fluid state of the thermoplastic precursor into the sealed In the mold, the thermoplastic precursor in the fluid state contains at least an activator and a catalyst. Preferably, in this embodiment, in order to make a small amount of the activator and the catalyst uniformly dispersed, the active And the catalyst are mixed with a small amount of the thermoplastic precursor, and then mixed with the thermoplastic precursor in a fluid state and poured into the mold to react; Step S8: the active agent and the catalyst are mixed with the precursor The fluid thermoplastic precursor and the thermoplastic precursor distributed on the surface of the yarn and/or between the fiber yarns react to form the thermoplastic, and are cured between the laminated thermoplastic unidirectional fiber prepregs, It becomes the molded body of the thermoplastic unidirectional fiber prepreg. The active agent and the catalyst in this step promote the reaction polymerization of the injected fluid state thermoplastic precursor and the thermoplastic precursor placed on the surface of the yarn and/or between the fiber yarns, which can also be called in-situ polymerization Reaction (In-situ polymerization); and steps S6 to S8 can also be referred to as Resin Transfer Molding (RTM).

Next, when the processing and molding method described in step S5 of the present invention is selected as hot pressing molding, the molding method is basically the same as the hot pressing molding method in the prior art, but only when the active agent and the catalyst are added, it is not It is added during the processing and shaping step, but when the thermoplastic precursor powder needs to be distributed on the surface of the plurality of yarn bundles and/or its fiber yarns earlier than the aforementioned step S2, it needs to be combined with the active The agent and the catalyst are added together and distributed on the plurality of yarn bundles.

The thermoplastic precursor used in the present invention is preferably a lactam, such as caprolactam (CPL), which is a synthetic precursor monomer of the thermoplastic resin nylon 6, which has a solid state at room temperature and is heated up. It only needs to be a high-flow liquid state to 70 degrees or above, and with the device of the present invention, the thermoplastic precursor can be evenly distributed among the plurality of strands of the yarn bundles and their fiber yarns, and the present invention The thermoplastic is a thermoplastic nylon resin polymerized by lactam, such as nylon 6 or nylon 12. The active agent used in the present invention is preferably isocyanate and its derivatives, such as hexamethylene diisocyanate (Hexamethylene diisocyanate, HDI), diphenylmethylene diisocyanate (MDI), and the The catalyst is preferably an alkali metal salt, and more preferably an alkali metal salt generated from the thermoplastic precursor, such as caprolactam sodium salt, caprolactam lithium salt or caprolactam potassium salt; The alkali metal salt of caprolactam is formed by reacting alkali metal or its hydride or its hydroxide with caprolactam (CPL), which can react better with the thermoplastic precursor of the present invention Sex, making the reaction more complete.

The present invention uses the thermoplastic precursor as a fiber impregnation material, and adds activators and catalysts in the impregnation stage or molding stage according to processing requirements, and then performs the process of polymerizing the thermoplastic and curing and molding, improving the existing thermoplastic polymer because of the direct The disadvantages of insufficient impregnation and decreased mechanical properties caused by the secondary processing process of polymerized polymer impregnation and post-processing molding. The present invention can further control the degree of polymerization of the thermoplastic through the addition of active agent and catalyst, reaction temperature, and polymerization time, that is, control the molecular weight of polymer synthesis polymerization, and adjust the reaction processing time and mechanical strength according to the requirements of the molded product. And the advantages of wear resistance and other characteristics.

Furthermore, corresponding to the aforementioned steps S1 to S4, the present invention provides the following description of the equipment for its implementation.

Please refer to Figure 2a, the first preferred embodiment of the device according to the process sequence at least includes: a yarn spreading fabric module 70 and a hot pressing module 100, before and/or after the yarn spreading fabric module 70 A whole bunch arrangement device X is provided.

Please refer to FIG. 2b. Another embodiment of the present invention is under the setting of the spreading cloth module 70, the hot pressing module 100, and the entire bundle arrangement device X of the first preferred embodiment of the aforementioned device. Furthermore, a yarn bundle tension control module 20 is arranged in front of the yarn spreading fabric module 70, or a yarn bundle processing module 40 is arranged before and/or after the yarn spreading cloth module 70. A winding device 110 is arranged after the pressing module 100 to enhance the effect of the present invention in regulating the spread of the yarn bundle and the impregnation of the thermoplastic resin.

Steps S1 to S4 of the molding method of the present invention preferably use continuous process equipment. The following describes the setup and use of the aforementioned modules or devices.

Please refer to FIG. 2b. First, the yarn bundle tension control module 20 includes a creel 21 and a plurality of tension control brackets 22. The tension control bracket 22 is disposed on the creel 20. The tension control bracket 22 can accommodate a yarn The bundle 10 is fixed on the top, and also has the function of monitoring and controlling the tension of the yarn bundle; the specific preferred implementation is that the yarn bundle 10 will be wound on a yarn tube first, which has a hollow cylindrical shape and can be tight It is sleeved on the tension control bracket 22 and linked with it, so that the bobbin wrapped with the yarn bundle 10 can adjust the tension of the yarn bundle 10 according to the degree of resistance given by the tension control bracket 22; the present invention The yarn bundle 10 is composed of multiple fiber yarns. The yarn bundle 10 used in this embodiment is a carbon fiber yarn bundle, but other yarn bundles that can be made into a sheet can also be used, such as glass fiber yarn bundles; preferably The tension control bracket 22 provides tension monitoring by setting a tension sensor, and the tension control method can be to provide an electric motor on the tension control bracket 22, and the tension control bracket 22 is automatically rotated through the electric motor and the yarn is linked. The tube can increase or decrease the degree of tension or tension of the yarn bundle 10 to achieve the effect of tension control. In addition to the aforementioned electric control, the tension can also be manually adjusted manually, which is not limited here. The yarn bundle tension control module 20 needs the function of tension control. The main reason is that the yarn bundle 10 enters the subsequent process at a different angle, which will cause a tension difference. At this time, the yarn bundle tension control module 20 can adjust accordingly The tension degree of each of the plurality of yarn bundles 10 is made uniform, so that each fiber yarn in the yarn bundle 10 can be spread, and a relatively even yarn spreading effect is obtained. However, the yarn bundle tension control of the present invention When the module 20 uses the equipment provided by the present invention, it is only necessary to adjust the yarn bundle tension and then set accordingly, and it is not used to limit the equipment device of the present invention to include the yarn bundle tension control module 20.

3a to 3b, the yarn spreading fabric module 70 of the present invention is provided with a receiving groove 71, a plurality of yarn spreading guide rods 73 and a plurality of air inlets 75, and a plurality of the yarn spreading guide rods 73 are arranged at On the side groove wall of the accommodating groove 71, the air inlet 75 is arranged at the bottom of the accommodating groove 71, and the accommodating groove 71 contains the thermoplastic precursor H, and the thermoplastic precursor H can be in powder form or fluid form.

Please refer to FIG. 3b. When the thermoplastic precursor H is in a powder form, the air inlet 75 of this embodiment is preferably a perforated plate 74 higher than the bottom of the containing groove 71 However, it is set lower than the position of the spreading guide rod 73, the porous plate 74 is provided with a plurality of the air inlet holes 75, the size of the air inlet holes 75 is smaller than the thermoplastic precursor H, so that the thermoplastic precursor The object H can be contained above the perforated plate 74. The bottom of the containing groove 71 is provided with an air passage 77. After an air flow A passes through the air passage 77, it drives the thermoplastic plastic forward through the air inlet 75 The object H forms a rolling effect like a water stream, so that the passing yarn bundle 10 can evenly wet the thermoplastic precursor H.

The yarn spreading cloth module 70 mainly provides the functions of spreading yarn and fabric. There are two main mechanisms for spreading yarn. The first is that when the yarn bundle 10 passes through the spreading guide rod 73, it is in contact with the spreading guide rod 73. The frictional force and tension generated between the two to achieve yarn spreading: the second is to use the airflow A provided by the air inlet 75 to make the thermoplastic precursor H scatter in the containing groove 71, and penetrate the airflow A and the thermoplastic The plastic precursor H impacts the yarn bundle 10 to expand the yarn bundle 10, and the friction and tension between the yarn bundle 10 and the yarn spreading guide 73 allow the yarn bundle 10 to be more expanded. Further, the present invention can also achieve the effect of increasing or decreasing the tension of the yarn bundle 10 through the position, angle, diameter and number of the yarn spreading guide rod 73 arranged in the accommodating groove 71, which helps to adjust the The spread of yarn bundle 10

The fabric spreading mechanism of the yarn spreading fabric module 70 is that the friction between the yarn bundle 10 and the yarn spreading guide 73 causes the yarn bundle 10 to generate a surface electrostatic charge, which can make the thermoplastic The driver H can be adsorbed on the surface of the yarn bundle 10 to complete the cloth process.

The advantage of the yarn spreading fabric module 70 of the present invention is that it can spread the yarn bundle 10 and pre-spread the thermoplastic precursor H into the fibers of the yarn bundle 10 at the same time, which improves the subsequent thermoforming performance. Impregnation, reaching or close to the effect of the existing thermosetting resin process; and the thermoplastic precursor H can be evenly distributed in the yarn bundle 10, and it can overcome the uneven film thickness and resin ratio when the subsequent hot pressing is formed into a sheet. Uneven distribution, dry yarn (no resin), gaps between resins or fibers, breakage, etc.

Then, the yarn bundle 10 passes through the yarn spreading fabric module 70 and then enters the hot pressing module 100, which is preferably a heatable rolling mechanism, and spreads the yarn bundle 10 in its radial direction. Pressure is applied in the direction and heat-pressed to form a thermoplastic unidirectional fiber prepreg S. The heatable rolling mechanism used in this embodiment can be a double-steel-belt hot press or a heated press roller (Roller) .

Please refer to FIG. 4, the present invention can be provided with the entire bundle arrangement device X before and/or behind the spreading fabric module 70. The first embodiment of the entire bundle arrangement device X is a multi-groove bundle arrangement. It includes an upper roller 91 and a lower roller 93. The surfaces of the upper roller 91 and the lower roller 93 are provided with a plurality of protrusions 94 and recesses 95 corresponding to the protrusions and recesses. The protrusions 94 and the recesses 95 restrict the yarn bundle 10 Therefore, the problem of turning over or turning over of the yarn bundle 10 is reduced, and the total spreading width of the yarn bundle 10 and the yarn bundle spacing are evened.

Through the plurality of convex parts 94 and concave parts 95 of the entire bundle arrangement device X, the yarn bundle 10 can be arranged neatly, and the resin content (Resin content, RC) can be adjusted according to the thermoplastic unidirectional fiber prepreg S to be molded. %), fiber Areal Weight (Fiber Areal Weight, FAW (g/m ² )) and width, etc., and control the spacing and uniformity of fiber yarns.

The aforementioned method of adjusting resin content (Resin content, RC ratio, RC%) and fiber Areal Weight (FAW (g/m2)) per unit area, for example, can pass through the thermoplastic precursor on the yarn bundle 10 The H distribution control and the pressing gap control of the hot pressing module 100 (the excess resin can be squeezed out and the thickness can be controlled) can achieve the control of the ratio of the thermoplastic precursor H to the yarn bundle 10 and the thickness of the sheet Efficacy; or it is also possible to fix the pressing pitch of the hot pressing module 100 at the rear (that is, when the thickness of the thermoplastic unidirectional fiber prepreg S is fixed), on each convex portion 94 of the upper roller 91 and the lower roller 93 Increasing the number of yarn bundles 10 in both and recesses 95 can increase the yarn content of the thermoplastic unidirectional fiber prepreg S fiber that is subsequently molded, and the RC ratio will be significantly reduced; on the contrary, reduce each of the protrusions 94 and recesses 95 The yarn bundle 10 in the middle can increase the RC ratio and control the fiber weight per unit area (FAW).

The aforementioned multi-groove aligning mechanism of the aligning device X is an embodiment of the upper and lower double roller type. Its advantage is that the upper roller 91 and the lower roller 93 can directly clamp the restraining effect formed by the pressing force. The yarn bundle 10 from the yarn bundle tension control module 20 is still maintained at the original level for processing operations, so as to prevent the equipment from generating additional tension on the yarn bundle 10, and reduce the continuous process tension accumulation and cause the yarn bundle 10 to break The problem.

In addition to the aforementioned double roller form, the second embodiment of the entire beam arrangement device X can also be in the form of a single roller. The so-called single roller form is roughly the same as the aforementioned double roller, but only the upper roller 91 or the lower roller 93 is used as The yarn bundle 10 is arranged in a position-limiting mechanism, but at this time, in order to prevent the yarn bundle 10 from being unable to remain confined in the concave portion 95, preferably, at least the concave portion 95 of the single roller is set higher or lower than the front end. From the original horizontal position of the yarn bundle 10, the yarn bundle 10 can be confined in the recess 95 and bundled due to an angle with the original horizontal position. In addition, the pitch of the yarn bundle 10 can be adjusted by replacing the roller set with different width dimensions of the convex portion 94.

The third embodiment of the whole bunch arranging device X includes an adjustable needle comb group 50 and a smoothing roller group. As shown in FIG. 5, the adjustable needle comb group 50 includes a plurality of wires perpendicular to the horizontal direction of the yarn bundle 10 The needle comb 51 is preferably arranged in a zigzag (or W-shaped) form at intervals, and the spacing distance of the needle comb 51 can be adjusted, so that the spacing of the yarn bundle 10 can be increased or decreased according to requirements, It is avoided that a plurality of the yarn bundles 10 are arranged too close together and squeeze and overlap each other to affect the yarn spreading effect. The smoothing roller set preferably includes two rollers arranged corresponding to each other and having a flat surface. The yarn bundle 10 is received from the adjustable needle comb assembly 50, because the yarn bundle 10 passes through the adjustable needle comb assembly 50. At this time, the fiber may be turned and crushed due to contact friction. Therefore, the yarn bundle 10 can be flattened and trimmed by subsequently setting the flattening roller set to achieve a flattening effect.

In addition, the main purpose of the entire bundle arranging device X of this embodiment is to arrange the yarn bundles 10 at even intervals, and the yarn bundles 10 are kept at appropriate intervals by the entire bundle arranging devices, so as to avoid mutual squeezing and affecting yarn spreading, or It is avoided that the yarn bundle 10 is too separated to cause gaps or breaks in subsequent sheet products, and the spreading yarn width has a positive relationship with the amount of precursor H that covers the thermoplastic. The even distance between the yarn bundles 10 is achieved to achieve uniformity. Spreading the yarn contributes to the degree of impregnation of the yarn bundle 10. In addition to the three different configurations of the entire bundle arranging device X as described above, the arrangement order and the arrangement order can also be adjusted according to the characteristics of each embodiment of the entire bundle arranging device X or the yarn spreading requirements of the yarn bundle 10 The type of use, the use of three sets of entire bundle arranging devices, so that each of the plurality of yarn bundles 10 can achieve the best yarn spreading effect.

Furthermore, the present invention can also be provided with the yarn bundle processing module 40 before and/or after the yarn spreading fabric module 70. The first preferred embodiment is to provide the yarn bundle processing module 40 before the yarn spreading fabric module 70. The yarn bundle processing module 40 mainly aims to remove the sizing agent and moisture on the surface of the yarn bundle 10 before the unprocessed treatment, so as to be used in the subsequent cloth manufacturing process. Since the surface of generally commercially available carbon fibers contains slurry, if the yarn is spread directly, the yarn bundle 10 is prone to sticking, making the yarn bundle 10 difficult to unfold, which affects the uniformity and thickness of the fiber yarn after the yarn spreading. For example, if the yarn bundle processing module 40 is installed before the yarn spreading fabric module 70, the sizing agent and moisture on the surface of the yarn bundle 10 can be removed first, so as to avoid the influence of the surface sizing agent on the yarn spreading effect. The yarn bundle processing module 40 can be, but is not limited to, hot air, electric heating plate, electric heating tube or infrared lamp (IR lamp).

The second preferred embodiment of the yarn bundle processing module 40 is arranged behind the yarn spreading fabric module 70, and the main purpose is to avoid the powdery thermoplastic precursor H attached to the surface of the yarn bundle 10 in When it falls during the subsequent manufacturing process, the yarn bundle processing module 40 is used for heating, and the heating temperature is preferably higher than the melting temperature of the thermoplastic precursor H in a short time to make the thermoplastic precursor H in powder form It can be temporarily attached to the surface of the yarn bundle 10 or pre-melted between the fiber yarns of the yarn bundle 10, and can also be heated at this time to shrink the overspread yarn bundle to the required width.

In addition, in the present invention, before the yarn bundle 10 enters the yarn spreading fabric module 70, the yarn bundles 10 may be arranged at intervals by a porous bundle group 30, as shown in FIG. 6, the porous bundle group 30 It includes a plate 31 and a plurality of yarn guide openings 32 spaced apart thereon. By passing a plurality of the yarn bundles 10 out of the yarn guide opening 32, the yarn bundle tension control module 20 will be different from each other. The yarn bundles 10 in a direction or a horizontal position are gathered and arranged regularly and advance in the same direction to facilitate the implementation of the subsequent yarn spreading process. The peripheral wall of the yarn guide 32 is preferably made of a wear-resistant but smooth surface material, such as porcelain eye, Teflon material, etc., which can withstand the friction of the yarn bundle 10 and prevent the yarn bundle 10 from breaking.

The first way of the interval distribution of the yarn guide openings 32 is that the two yarn guides 32 form a group, and the groups are arranged tightly and regularly in the manner of upper left and lower right or lower right and upper left. The second method is multiple guides. The yarn openings 32 are equidistant and arranged on the same horizontal surface, which can achieve the aforementioned purpose of gathering and regularly arranging the yarn bundles 10 and advancing in the same direction, and the present invention is not limited herein.

Finally, the winding device 110 is provided after the hot pressing module 100 to wind the thermoplastic unidirectional fiber prepreg S for subsequent transportation or processing.

The above descriptions are only examples of preferred embodiments of the present invention and are not intended to limit the scope of rights claimed by the present invention. All other equivalent changes or modifications made without departing from the spirit of the present invention should be included in this The invention is within the scope of patent application.

10 Yarn bundle 20 Yarn bundle tension control module 21 Yarn rack 22 Tension control bracket 30 Multi-hole whole bundle group 31 Plate 32 Yarn guide 40 Yarn bundle processing module 50 Adjustable needle comb group 51 Needle comb 70 Spread yarn cloth mold Group 71 accommodating groove 73 yarn spreading guide 74 perforated plate 75 air inlet 77 air passage 91 upper roller 93 lower roller 94 convex portion 95 concave portion 100 hot pressing module 110 winding device A air flow H thermoplastic precursor S thermoplastic Unidirectional fiber prepreg X bundle arrangement device

Figure 1 is a flow chart of the steps of a preferred embodiment of the molding method of the present invention. 2a and 2b are schematic diagrams of preferred embodiments of the equipment corresponding to steps S1 to S4 in the forming method of the present invention. 3a and 3b are schematic diagrams of a preferred embodiment of the yarn spreading fabric module of the present invention. 4 is a schematic diagram of the first preferred embodiment of the entire beam arrangement device of the present invention. Fig. 5 is a schematic diagram of a third preferred embodiment of the entire beam arrangement device of the present invention. Fig. 6 is a schematic diagram of a preferred embodiment of the porous integrated beam group of the present invention.

Claims (12)

A thermoplastic unidirectional fiber prepreg, comprising: a sheet formed by arranging a plurality of fibers in substantially the same direction; and at least part of the surface of the sheet or a part of the inter-fibers with a thermoplastic precursor. For example, the thermoplastic unidirectional fiber prepreg of item 1 of the scope of patent application, wherein: the fiber is carbon fiber or glass fiber; the thermoplastic is nylon polymerized with endoamide; and the precursor of the thermoplastic plastic contains endoamide . For example, the thermoplastic unidirectional fiber prepreg in the second item of the scope of patent application, the thermoplastic precursor further includes an active agent and a catalyst. For example, the thermoplastic unidirectional fiber prepreg of item 3 in the scope of patent application, the active agent is isocyanate and its derivatives; and the catalyst is an alkali metal salt. For example, the thermoplastic unidirectional fiber prepreg of item 4 in the scope of patent application, the alkali metal salt is the alkali metal salt generated from the thermoplastic precursor. For example, the thermoplastic unidirectional fiber prepreg of item 1, 2, 3, 4, or 5 in the scope of patent application, the thermoplastic precursor is placed on the sheet in the form of powder or fluid. A method for forming a molded body of a thermoplastic unidirectional fiber prepreg, the steps including: providing a sheet of force on a plurality of yarn bundles, and making the plurality of yarn bundles advance in the same direction; using friction control, tension adjustment and air impact Expand the plurality of yarn bundles so that the plurality of yarn bundles are respectively expanded into a plurality of fiber yarns in the horizontal direction, and at the same time, a thermoplastic precursor is distributed on the surface of the plurality of unfolded yarn bundles and/or fiber yarns Between; using a whole bundle arrangement device before and/or after unfolding the plurality of yarn bundles, the plurality of yarn bundles are arranged at intervals; the plurality of yarn bundles are heated and pressurized with a hot pressing module to drive the thermoplastic The material is fixed on the plurality of yarns to become a fiber prepreg thermoplastic unidirectional fiber prepreg; and the thermoplastic unidirectional fiber prepreg is polymerized in situ and processed into a shape at the same time. For example, the method for forming a molded body of a thermoplastic unidirectional fiber prepreg in the scope of the patent application, wherein the step of polymerizing the fiber prepreg thermoplastic unidirectional fiber prepreg in situ and simultaneously processing and molding includes: The fiber prepreg thermoplastic unidirectional fiber prepreg is laminated in a mold; the fluid state of the thermoplastic precursor is poured into the sealed mold, and the thermoplastic precursor includes an active agent and a catalyst And the thermoplastic precursor in the fluid state, the activator and the catalyst, and the thermoplastic precursor on the surface of the yarn bundles and/or between the fiber yarns that are poured into the fluid react to generate the thermoplastic The plastic is cured and formed into the molded body of the thermoplastic unidirectional fiber prepreg. For example, the molding method of thermoplastic unidirectional fiber prepreg in the scope of the patent application, the active agent and the catalyst are mixed with a small amount of the thermoplastic precursor in a fluid state, and then mixed with other fluid states. The thermoplastic precursor is mixed and poured into the mold. For example, the molding method of thermoplastic unidirectional fiber prepreg in the seventh item of the scope of patent application, the processing and molding is hot press molding; wherein the thermoplastic precursor is distributed on the surface of the unfolded plurality of yarn bundles and When/or between fiber yarns, the thermoplastic precursor further includes an active agent and a catalyst. For example, the molding method of thermoplastic unidirectional fiber prepreg in the 8th or 9th item of the scope of patent application can control the content of the thermoplastic unidirectional fiber prepreg by adjusting the entire bundle arrangement device and the gap of the hot pressing module. The thermoplastic precursor to fiber ratio. For example, the molding method of thermoplastic unidirectional fiber prepreg in the tenth item of the patent application can control the thermoplasticity contained in the thermoplastic unidirectional fiber prepreg by adjusting the entire bundle arrangement device and the gap of the hot pressing module. The ratio of plastic precursor to fiber yarn.

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