WO2022017105A1 - 一种自承压连续线性的树脂基纤维增强预浸料 - Google Patents

一种自承压连续线性的树脂基纤维增强预浸料 Download PDF

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Publication number
WO2022017105A1
WO2022017105A1 PCT/CN2021/101499 CN2021101499W WO2022017105A1 WO 2022017105 A1 WO2022017105 A1 WO 2022017105A1 CN 2021101499 W CN2021101499 W CN 2021101499W WO 2022017105 A1 WO2022017105 A1 WO 2022017105A1
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Prior art keywords
prepreg
continuous
tube blank
resin
self
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PCT/CN2021/101499
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English (en)
French (fr)
Inventor
仝伟
仝娜
徐发春
龚玉洁
宋宁宁
包慧
茆顺壮
李涛
刘学东
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江苏易鼎电力科技有限公司
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Publication of WO2022017105A1 publication Critical patent/WO2022017105A1/zh

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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]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/521—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement before the die
    • 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
    • B29C70/542—Placing or positioning the reinforcement in a covering or packaging element before or during moulding, e.g. drawing in a sleeve
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/683—Pretreatment of the preformed part, e.g. insert

Definitions

  • the high-strength fiber composite material profile produced by bundling a plurality of long high-strength fibers and impregnating them with resin has high tensile strength, low stretchability, light weight, and excellent corrosion resistance. Therefore, it is being widely used in bridges, concrete structures, power lines, etc.
  • the process of preparing high-strength fiber composite material profiles is as follows: first, continuous fiber materials such as carbon fibers are twisted and fixed together, and then fully impregnated through the epoxy resin dipping tank of the base material, and then extruded and formed. The pulled-out bundled product finally passes through the curing chamber to allow the resin to be fully hardened indoors, such as the carbon fiber composite stranded wire manufacturing method and equipment disclosed in Chinese patent CN101295564B, and the fiber composite stranded cable disclosed in CN201933348U .
  • CN105304189A uses the pultrusion technology to make a composite wire with a diameter of 1.7-4.0mm, uses the longitudinal wrapping welding technology to coat the wire with stainless steel with a thickness of 0.1-0.2mm, and then twists a plurality of stainless steel armored wires.
  • the load-bearing profile of this structure solves the contradiction between easy bending and anti-breakage, but in the process of twisting into a cable, the profile is forcibly deformed from a straight line to a helix, because the profile with an armored layer is formed.
  • the production of composite materials is made by continuous pultrusion technology of composite materials.
  • the continuous fiber material impregnated with resin must be cured in the cavity mold, during the curing process, the continuous fiber material impregnated with resin will be carried out between the cavity mold where it is located. Relative movement, if the cross-sectional shape, size or space shape of the cavity mold is deformed in the process of their relative movement, it will inevitably cause the relative movement to be unsmooth or even stop, and the above-mentioned low viscosity viscosity cannot be controlled in the process.
  • the present invention provides a self-supporting continuous linear resin-based fiber reinforced prepreg.
  • the continuous deformation composite material profile can be continuously prepared, and the availability of the continuous deformation composite material profile can be guaranteed.
  • a preparation method of a continuously deformed composite material profile comprises the following steps performed in sequence:
  • Prepreg is obtained by impregnating continuous longitudinal fibers with resin, and metal is continuously welded or extruded to obtain a tube blank.
  • the preparation of the prepreg and the preparation of the tube blank may or may not be performed at the same time.
  • the prepreg is continuously brought into the tube blank to obtain the material to be deformed.
  • the prepreg may or may not be filled with the inlet of the tube blank.
  • Part of the excess resin in the material is squeezed out.
  • part of the excess resin in the prepreg is left in the tube blank or flows out of the tube blank in a vertical flow.
  • this step can preliminarily control the volume ratio of continuous longitudinal fibers and resin.
  • the spatial shape of the tube blank can be either linear or It can be transformed into a two-dimensional plane curve, such as a plane wave, or a three-dimensional space curve, such as a helix, and because the prepreg and the tube blank are driven synchronously, the cross-section of the material to be formed and/or
  • the spatial shape can be deformed differently in different sections, and the whole is continuous, but different cross-sectional shapes or areas are different, and different sections have different spatial shapes. It is worth noting that the tube blank is rolled or Drawing and forming into a tube with a designed cross-section and space shape, the diameter of the tube is reduced. Because the excess resin in the prepreg is squeezed out one or more times, the volume ratio of continuous longitudinal fibers in the prepreg is increased and further controlled.
  • this step can be performed immediately at the same site at the end of step S3., or it can be performed at the same site or other sites at a design interval, and finally form the metal pipe of the profile armor layer, in this step It exists as a cavity mold required for prepreg curing and molding.
  • the function of the cavity mold also includes the functions of limiting the generation of air bubbles during the cross-linking and curing process of the prepreg, eliminating air bubbles and accurately expelling excess resin.
  • step S5 is also included, disassembling the armoring layer to obtain a bare core material.
  • the armoring layer can be stripped from the outer surface of the core material by using an online tool, etc.
  • the core material is actually a continuous deformation composite material profile, but only In the present invention, for the sake of clarity, the so-called continuous deformation composite material profiles firstly refer to linear continuous review materials including metal armor layers. These composite material profiles can be wound regardless of whether they include metal armor layers or not. in trays for packaging, storage, transportation, installation and use.
  • the term "continuous" in the present invention is intended to emphasize that the above method is suitable for preparing composite material profiles that can theoretically extend infinitely, so it is different from using a fixed cavity mold that moves relative to the prepreg to prepare long Preparation method of strip-shaped composite material profile.
  • the "deformation” mentioned in the present invention is intended to emphasize that the above-mentioned method is not only applicable to the preparation of all linear continuous composite material profiles with the same cross-sectional shape and size that can be prepared in the prior art, but also applicable to the preparation of various sections and/or spatial shapes. Different continuous review material profiles are not limited to being only applicable to the preparation of continuous review material profiles with different sections and/or spatial shapes.
  • the "profile” in the present invention is intended to emphasize that the above-mentioned method is suitable for the preparation of various continuous composite materials with fixed cross-sectional characteristics, including cables, regardless of whether the package contains a metal armor layer.
  • step S6 is also included to reuse the removed armor layer as the metal required for S1 welding or extrusion.
  • the energy saving, environmental protection and simplicity of the continuous deformation composite profile preparation process can be further improved.
  • the linear speed at which the prepreg is brought into the tube blank is equal to the linear speed of the metal welded or extruded tube blank, so as to ensure that the prepreg remains relatively stationary with the tube blank since it enters the tube blank .
  • the cross-sectional shape of the material to be formed in step S3 includes one or more of a circle, an ellipse, a gourd shape, and a polygon
  • the spatial shape of the material to be formed includes a straight line, a two-dimensional plane curve , one or more of three-dimensional space curve types.
  • the volume ratio of the continuous longitudinal fibers in the material to be formed is 60%-80% of the total volume of the prepreg. Further preferably, the volume ratio of the continuous longitudinal fibers can be controlled at 75%-80%.
  • the continuous longitudinal fibers include one or more of glass fibers, carbon fibers, boron fibers, aramid fibers, silicon carbide fibers, and basalt fibers.
  • the present invention also provides a cable-type continuous deformation composite material profile, which has a curvilinear space shape and can be coiled, and includes a core material and an armoring layer, and the armoring layer is attached to the core.
  • the outer surface of the material, the core material includes continuous longitudinal fibers and resin, wherein the volume ratio of the continuous longitudinal fibers is 60%-80% of the total volume of the core material, and the armor layer material includes at least A layer of metal. Further preferably, the volume ratio of the continuous longitudinal fibers can be controlled at 75%-80%.
  • the present invention provides a continuous deformation composite material cable that can theoretically extend infinitely.
  • the spatial shape of the cable-type continuous deformation composite material profile includes one or both of a two-dimensional plane curve type and a three-dimensional space curve type
  • the cross-sectional shape of the cable-type continuous deformation composite material profile includes a circular shape One or more of , oval, gourd, and polygon, and the cross-sectional size at different positions is the same or different.
  • the present invention also provides a bare continuous deformation composite material profile, which has a curvilinear space shape and can be coiled, including a core material, the core material
  • the material includes continuous longitudinal fibers and resin, wherein the volume ratio of the continuous longitudinal fibers is 60%-80% of the total volume of the core material. Further preferably, the volume ratio of the continuous longitudinal fibers can be controlled at 75%-80%.
  • the present invention provides a continuous deformation composite material cable that can theoretically extend infinitely.
  • the cable-type continuous deformation composite material profile or the exposed continuous deformation composite material profile has a tensile strength of 1200-4000 MPa, a linear expansion coefficient of 0.6-8 ⁇ 10 -6 1/°C, and an elastic modulus of 120 -240GPa.
  • the manufacturing process of the continuous deformation composite material profile in this scheme is as follows: impregnating continuous longitudinal fibers with resin to obtain a prepreg, continuously welding or extruding metal to obtain a tube blank; and continuously bringing the prepreg into the tube blank, To obtain the material to be deformed, the linear speed at which the prepreg is brought into the tube blank is equal to the linear speed of the metal welded or extruded tube blank, so as to ensure that the prepreg is kept with the tube blank from the time it enters the tube blank Relatively static, at this time, the prepreg is subjected to the first stage of pressure at the mouth of the tube blank. When the prepreg is full, part of the excess resin in the prepreg is squeezed out.
  • Part of the excess resin in the prepreg is left in the tube blank or flows out of the tube blank in a vertical flow to control the volume ratio of continuous longitudinal fibers and resin.
  • the prepreg enters the tube blank; using existing The driving device synchronously drives the prepreg and the tube blank of the material to be deformed.
  • the tube blank is rolled or drawn into a tube with a designed section, and the transverse section of the tube blank is reduced, that is, the shell of the material to be formed is rolled or drawn.
  • the size and shape of the section of the tube blank (referring to the cross section perpendicular to the longitudinal direction of the continuous longitudinal fibers) can be changed, and the shape can be made into a circle or an ellipse or a Gourd-shaped or polygonal, wherein the polygon can be an equilateral polygon, a scalene polygon, a convex polygon, or a concave polygon.
  • the pipe blank is rolled or drawn one or more times, the pipe diameter is reduced , the prepreg in the tube is infiltrated, and the mixed air and excess resin are re-extruded, so that the proportion of the fiber volume in the tube can be increased and further controlled.
  • the tube and the prepreg are relatively static and pulled. Synchronous drive, through the action of mold or other pressure, the spatial shape of the tube blank can be either linear, or can be transformed into a two-dimensional plane curve such as a plane wave, or a three-dimensional space curve such as a spiral , and because the prepreg and the tube blank are driven synchronously, the cross-section and/or spatial form of the material to be formed can be deformed differently in different sections, forming a continuous whole, but with different cross-sectional shapes or areas Different, different paragraphs have different spatial shapes; then, heating the material to be formed can trigger the prepreg in the tube to complete cross-linking and curing, and obtain continuous continuous deformation composite profiles of the same or different spatial shapes; the continuous The deformable composite material profile includes the core material formed by cross-linking and curing of the prepreg and the armor layer formed by the deformation of the tube blank.
  • the armor layer can be disassembled to be suitable for different occasions, or the armor can be retained layer to protect the core
  • Continuously deformed composite profiles can be used as overhead conductors for transmission and distribution lines, load-bearing power transmission conductors for electrified railways, catenary conductors, and prestressed cables for civil engineering.
  • the existing pultrusion technology is: the fiber impregnated with resin is extruded and mixed with air and excess resin at the entrance of the cavity mold to make the fiber volume content in the cavity mold meet the design requirements, and then pass through the three heating temperature zones of the cavity mold ( Infiltration, gelation, curing) to complete the production of the product, the technical process of this application is: in the process of drawing the tube blank into a tube, the resin-impregnated fibers are extruded and mixed with the air and excess resin at the entrance of the cavity die.
  • the fiber volume content in the cavity mold meets the design requirements, and at the same time, it ensures that the prepreg and the tube are always relatively static, and the continuous deformation of the profile is realized.
  • the prepreg is subjected to two-stage extrusion to squeeze out the excess resin, leaving only the volume content of the resin required for bonding, which increases the volume ratio of continuous longitudinal fibers and increases the condition of the composite profile in a given cross-sectional area.
  • the key performance indicators such as the strength and winding characteristics of the composite profile are reduced, and the resin content in the profile is reduced, which reduces the price of the product.
  • the tube blank is rolled or drawn to form the tube.
  • the excess resin is slightly displaced.
  • the prepreg as a whole does not move relative to the tube blank.
  • the tube blank is rolled or drawn into a tube to apply pressure to the internal prepreg to avoid resin bubbles and extrude excess resin.
  • the prepreg and the tube blank or the shaped tube are driven synchronously, and after the tube blank is rolled or drawn into the desired spatial shape to form a tube, it is heated to trigger the cross-linking and curing of the prepreg.
  • the prepreg of this solution starts and completes the curing process relatively statically in the shaped tube, and realizes that the composite material profile includes a cross-section.
  • the armoring layer can be retained or removed, and the continuous deformation composite material profiles without armoring layers prepared by this scheme can avoid the contradiction between easy bending and anti-breakage.
  • the metal in this scheme is formed from the tube blank to the shaped tube and then to the armoring layer.
  • the tube blank stage it plays the role of combining the prepreg and initially controlling the volume ratio of continuous longitudinal fibers and resin volume;
  • the prepreg In the process of deforming the tube blank into a shaped tube, it further extrudes the prepreg, completes exhaust, extrusion and other functions; after it is formed into a shaped tube, it is heated to trigger and complete the prepreg in it.
  • cross-linking and curing it acts as a cavity mold for resin curing; and in the final continuous deformation composite material profile, it acts as an armor to protect the internal composite material.
  • Fig. 1 is the preparation process flow chart of continuous fiber composite material profile in the prior art
  • Figure 2 is a schematic diagram of the preparation process flow of the continuous deformation composite material profile in this scheme
  • a preparation method of a continuous deformation composite material profile 2, as shown in Figure 2 includes the following steps performed in sequence:
  • the traction device 3 Synchronously drive the prepreg and the tube blank 8 of the material to be deformed by the traction device 3, change the cross-section of the tube blank 8 or/and deform the space form of the tube blank 8 through the drawing or rolling process, and obtain a continuous
  • the volume ratio of the continuous longitudinal fibers 12 in the material to be formed is 60%-80% of the total volume of the prepreg
  • the tube blank 8 and the prepreg are relatively static at this time
  • the rolling or drawing die 6 changes the size or shape of the section of the tube blank 8, and the section shape can be made into a circle or an ellipse or a gourd or a polygon, and the polygon can be an equilateral polygon or an unequal side Polygons, which can be convex polygons or concave polygons, etc., and the shape of the tube blank 8 in space is deformed by the action of the mold, such as a one-dimensional linear shape, a two-dimensional plane wave shape, or
  • the material to be formed is heated by the heating device 5 to obtain the continuous deformation composite material 2 of the same or different spatial forms, including the core material and the tube blank formed by the cross-linking and curing of the prepreg 8 Armor layer formed by deformation;
  • the above-mentioned composite material profiles are wound into disks by a winding device.
  • a preparation method of a continuous deformation composite material profile 2, as shown in Figure 2 includes the following steps performed in sequence:
  • the metal strip 13 is radially shaped by the guide roller and the longitudinal wrapping die and welded by the continuous welding machine 7 to obtain the tube blank 8;
  • the material to be formed is heated by the heating device 5 to obtain the continuous deformation composite material 2 of the same or different spatial forms, the tensile strength of which is 1200-4000MPa, and the coefficient of linear expansion is 0.6-8 ⁇ 10 ⁇ 6 1/°C, the elastic modulus is 120-240GPa, and the continuous deformation composite material profile 2 includes a core material formed by cross-linking and curing of the prepreg and an armor layer formed by the deformation of the tube blank 8;
  • the dismantling method can be mechanical dismantling method
  • a preparation method of a continuous deformation composite material profile 2, as shown in Figure 2 includes the following steps performed in sequence:
  • the continuous longitudinal fibers 12 are impregnated with resin 9 to obtain a prepreg, wherein the raw material contains 40 parts of continuous longitudinal fibers 12 and 50 parts of resin 9, and the continuous longitudinal fibers 12 include a mixture of silicon carbide fibers and basalt fibers;
  • the material 13 is radially formed by the guide roller and the longitudinal wrapping die and welded by the continuous welding machine 7 to obtain the tube blank 8;
  • the traction device 3 Synchronously drive the prepreg and the tube blank 8 of the material to be deformed by the traction device 3, change the cross-section of the tube blank 8 or/and deform the space form of the tube blank 8 through a drawing or rolling process, and obtain a continuous
  • the volume ratio of the continuous longitudinal fibers 12 in the material to be formed is 75%-80% of the total volume of the prepreg
  • the tube blank 8 and the prepreg are relatively static at this time
  • the cross-sectional size and shape of the tube blank 8 can be changed by rolling or drawing die 6, and the cross-sectional shape can be made into a circle or an ellipse or a gourd or a polygon, wherein the polygon can be an equilateral polygon or an unequal side Polygons, which can be convex polygons or concave polygons, etc., and the shape of the tube blank 8 in space is deformed by the action of the mold, such as a one-dimensional linear shape,
  • the material to be formed is heated by the heating device 5 to obtain the continuous deformation composite material 2 of the same or different spatial forms, the tensile strength of which is 1200-4000MPa, and the coefficient of linear expansion is 0.6-8 ⁇ 10 ⁇ 6 1/°C, the elastic modulus is 120-240GPa, the continuous deformation composite material profile 2 includes the core material formed by cross-linking and curing the prepreg and the armor layer formed by the deformation of the tube blank 8 .
  • the dismantling method may be a mechanical dismantling method.
  • the dismantled armoring layer is reused as the metal 13 required for welding or extrusion in step S1, and the recovery step may include melting after mechanical dismantling, as a metal raw material for extrusion; or after dismantling into a roll, As welded metal strip.
  • the above-mentioned composite material profiles are wound into disks by a winding device.
  • a cable-type continuous deformation composite material profile prepared according to the method of the present solution is characterized in that it has a curved space shape and can be coiled, and includes a core material and an armoring layer, and the armoring layer is attached to the core material.
  • the core material includes continuous longitudinal fibers and resin, wherein the volume ratio of the continuous longitudinal fibers is 60%-80% of the total volume of the core material, and the armor layer material includes at least one layer metal.
  • the cross-sectional shape of the core material includes one or more of a circle, an ellipse, a gourd-shaped, and a polygon, the cross-sectional size at different positions is the same or different, and the curved space shape includes a two-dimensional plane curve and a three-dimensional space. One or both of the curves.
  • a bare continuous deformation composite material profile prepared according to the method of the present solution is characterized in that it has a curved space shape and can be coiled, and includes a core material, and the core material includes continuous longitudinal fibers and resins, wherein the continuous The volume ratio of the longitudinal fibers is 60%-80% of the total volume of the core material.
  • the cross-sectional shape of the core material includes one or more of a circle, an ellipse, a gourd-shaped, and a polygon, the cross-sectional size at different positions is the same or different, and the curved space shape includes a two-dimensional plane curve and a three-dimensional space.
  • the curvilinear types Its tensile strength is 1200-4000MPa, its linear expansion coefficient is 0.6-8 ⁇ 10 -6 1/°C, and its elastic modulus is 120-240GPa.
  • the continuous longitudinal fibers 12 impregnated with resin 9 are extruded and mixed with air and excess resin 9 at the entrance of the cavity mold under the drive of traction, so that the volume content of the continuous longitudinal fibers 12 in the cavity mold reaches Design requirements, and sequentially infiltrate, gel, and solidify through the three heating temperature zones of the cavity mold, and complete the production of the product by pulling the traction device.
  • the heating and curing device 111 is the cavity mold, because the product must be cured in the cavity mold and move relatively , so the production of continuous deformation composite material profiles that can be deformed in both cross-section and space shape cannot be realized.

Abstract

本发明公开一种自承压连续线性的树脂基纤维增强预浸料，其制备方法包括依次进行的以下步骤：S1.用树脂浸渍连续纵向纤维得到预浸料，将金属连续焊接或挤包得到管坯；S2.将预浸料连续带入管坯，得到待变型材料；S3.同步驱动待变形材料的预浸料及管坯，通过拉拔或辊压工艺改变管坯截面或/并通过模具作用变形管坯空间形态，得到连续的相同或不同空间形态的待成型材料，可以连续制备连续形变复合材料型材，而连续形变复合材料型材的可得性可以保障需要综合各方面性能要求的复合材料价值工程设计所需。

Description

一种自承压连续线性的树脂基纤维增强预浸料 技术领域
本申请是申请号为202010710421.9、申请日为2020.07.22的中国发明专利《一种连续形变复合材料型材及其制备方法》的分案申请，本发明涉及复合材料领域，具体涉及一种自承压连续线性的树脂基纤维增强预浸料。
 背景技术
通过将多根长条的高强度纤维汇集成束，并使树脂浸渗于其中而制作的高强度纤维复合材料型材的拉伸强度高、伸缩性低、且轻量、且耐蚀性优异，因此，正在被广泛应用于桥梁、混凝土结构物、输电线等。
 技术问题
现有技术中，制备高强度纤维复合材料型材的工艺过程如下：先将连续的碳纤维等纤维材料绞合固定在一起，然后穿过基底材料环氧树脂浸胶槽充分浸渍，接着由挤压成型模拉出，拉出后的束状产品最后再经过固化室，让树脂在室内发生充分硬化，如中国专利CN101295564B公开的碳纤维复合绞线制造方法及设备、CN201933348U公开的纤维复合型绞合线缆。这些制作方法有一个共同的绕不开的难题：预浸料中的树脂在加热交联固化时，要依次经历低粘度粘流态、凝胶态和玻璃态，预浸料表面紧密缠绕的丝带，并不能阻止其绞合成缆或加热时发生严重变形，导致树脂的渗出，且因保压不足而在固化反应时产生气泡；此外，树脂渗透将导致线材发生粘连固化，绞合结构将失去本应具备的卷绕特性，抗折损能力差。
为了提高线材抗折损能力，CN105304189A利用拉挤技术制作直径1.7-4.0mm复合线材，利用纵包焊管技术对线材铠装厚0.1-0.2mm的不锈钢，再将多根有不锈钢铠装的线材绞合而成，这种结构的承力型材解决了易弯曲和抗折损的矛盾，但是绞合成线缆过程中型材是由直线形态强行弹性变形为螺旋线的，因为带有铠装层的型材的制作是利用复合材料连续拉挤技术而成，由于浸渍了树脂的连续纤维材料必须在腔模中固化，而固化过程中这些浸渍了树脂的连续纤维材料会与其所处的腔模之间进行相对的运动，如果在它们相对运动的过程中对腔模的截面形状、大小或腔模的空间形态进行变形，必将导致所述相对运动不畅乃至停止，且工艺上无法控制上述低粘度粘流态、凝胶态或玻璃态的树脂的固化过程，所以不能实现连续形变复合材料型材的制备。
另一方面，由于现有技术中连续纤维复合材料型材制备方法中，通常被称为预浸料的浸渍了树脂的连续纤维材料，在被拉入挤压成型模时，多余的一部分树脂仅仅为挤压成型模模口边缘或前置的滤胶装置被动过滤，故固化成型的型材中树脂的体积占比往往超过了实际产品性能所需，即降低了给定截面积条件下复合材料型材的强度和卷绕特性等关键性能指标，又增加了产品的成本和重量。
 技术解决方案
为解决上述问题，本发明提供一种自承压连续线性的树脂基纤维增强预浸料，利用该制备方法，可以连续制备连续形变复合材料型材，而连续形变复合材料型材的可得性可以保障需要综合各方面性能要求的复合材料价值工程设计所需 。
本发明的技术方案是，一种连续形变复合材料型材的制备方法，包括依次进行的以下步骤：
S1.用树脂浸渍连续纵向纤维得到预浸料，将金属连续焊接或挤包得到管坯。预浸料的制备和管坯的制备可以同时或不同时执行。
S2.将所述预浸料连续带入所述管坯，得到待变型材料，在该步骤中，预浸料可以塞满或不塞满管坯的入口，在塞满的情形下，预浸料中部分多余的树脂被排挤掉。在不塞满的情形下，预浸料中部分多余的树脂被留在管坯中或以垂流的形式流出管坯，无论怎样，该步骤可以初步控制连续纵向纤维和树脂的体积比关系。
S3.同步驱动待变形材料的预浸料及管坯，通过拉拔或辊压工艺改变所述管坯截面或/并通过模具作用变形所述管坯空间形态，得到连续的相同或不同空间形态的待成型材料，在该步骤中，管坯截面（指与连续纵向纤维所述的纵向相垂直的横截面）的大小、形状都可以被改变，其中形状可以被制成圆形或椭圆形或葫芦形或多边形，其中多边形可以是等边多边形，也可以是不等边多边形，可以是凸多边形，也可以是凹多边形，在该步骤中，管坯的空间形态，既可以是直线型的，也可以被改造成二维平面曲线型的如平面波浪型，或三维空间曲线型的如螺旋线型，而且，因为预浸料和管坯被同步驱动，故所述待成型材料的截面和/或空间形态可以在不同的段落进行不同的变形处理，形成整体是连续的，但不同截面形状或面积不同，不同段落空间形态不同的状态，值得说明的是，管坯经一次或多次辊压或拉拔，成型为设计截面和空间形态的型管，其管径被减缩，因预浸料中多余树脂被一次或多次排挤掉，其内连续纵向纤维体积占比得到提高和进一步的控制。
S4.加热所述待成型材料，得到连续的相同或不同空间形态的所述连续形变复合材料型材，包括所述预浸料经交联固化形成的芯材和所述管坯经变形形成的铠装层，该步骤即可以在S3.步骤结束时在同一个场地立即执行，也可以经设计间隔一段时间在同一个场地或其他场地执行，最终构成型材铠装层的金属管，在该步骤中是作为预浸料固化成型所需的腔模而存在的，所述腔模的功能，同时包含了限制预浸料交联固化过程中产生气泡及排除气泡和精确排挤多余树脂的作用。
优选地，还包括步骤S5，拆解所述铠装层，得到裸露的芯材。通过适当温度的控制和金属材料成分的选择，可以使用在线的刀具等装备将所述铠装层从所述芯材外表面剥除，该芯材实际上也是一种连续形变复合材料型材，只是在本发明中，为了说明得更清楚，所谓连续形变复合材料型材首先是指包含了金属铠装层的线性的连续复核材料，无论是否包含金属铠装层，这些复合材料型材都可以被卷绕成盘，以便包装、存储、运输、安装和使用。
需要说明的是，本发明所述的“连续”，旨在强调上述方法适用于制备理论上可以无限延伸的复合材料型材，因此区别于使用相对于所述预浸料运动的固定腔模制备长条形复合材料型材的制备方法。本发明所述的“形变”，旨在强调上述方法不仅适用于制备现有技术已能制备的所有截面形状和尺寸相同的直线型连续复合材料型材，也适用于制备各部截面和/或空间形态不同的连续复核材料型材，而不限定其仅仅适用于制备各部截面和/或空间形态不同的连续复核材料型材。本发明所述的“型材”，旨在强调上述方法适用于制备包括线缆在内的各种具有固定截面特征的连续复合材料，不管其包不包含金属铠装层。
优选地，还包括步骤S6将所述被拆除的铠装层回用为S1焊接或挤包所需的金属。通过这样的回用，可以进一步提升连续形变复合材料型材制备工艺的节能性、环保性和简便性。
优选地，所述预浸料带入所述管坯内部的线速度与所述金属焊接或挤包成型管坯的线速度相等，以保证预浸料自进入管坯开始与管坯保持相对静止。
优选地，步骤S3中所述待成型材料的截面形状包括圆形、椭圆形、葫芦形、多边形中的一种或几种，所述待成型材料的空间形态包括直线型、二维平面曲线型、三维空间曲线型中的一种或几种。
优选地，所述待成型材料中连续纵向纤维的体积占比为预浸料总体积的60%-80%。进一步优选地，可以将连续纵向纤维的体积占比控制在75%-80%。
优选地，所述连续纵向纤维包括玻璃纤维、碳纤维、硼纤维、芳纶纤维、碳化硅纤维、玄武岩纤维中的一种或几种。
因为上述方法发明的获得，本发明还提供一种线缆式连续形变复合材料型材，其具有曲线空间形态并可盘绕，包括芯材、铠装层，所述铠装层贴设于所述芯材外表面，所述芯材材料包括连续纵向纤维和树脂，其中，所述连续纵向纤维的体积占比为所述芯材材料总体积的60%-80%，所述铠装层材料包括至少一层金属。进一步优选地，可以将连续纵向纤维的体积占比控制在75%-80%。与现有技术中具有曲线空间形态的复合材料型材相比，其区别之处主要在于本发明提供的是理论上可无限延伸的连续形变复合材料线缆。
优选地，所述线缆式连续形变复合材料型材的空间形态包括二维平面曲线型、三维空间曲线型中的一种或两种，所述线缆式连续形变复合材料型材截面形状包括圆形、椭圆形、葫芦形、多边形中的一种或几种，其不同位置的截面大小相同或不同。
由于上述线缆式连续形变复合材料型材的铠装层可被拆除，故本发明还提供一种裸露的连续形变复合材料型材，其具有曲线空间形态并可盘绕，包括芯材，所述芯材材料包括连续纵向纤维和树脂，其中，所述连续纵向纤维的体积占比为所述芯材材料总体积的60%-80%。进一步优选地，可以将连续纵向纤维的体积占比控制在75%-80%。与现有技术中具有曲线空间形态的复合材料型材相比，其区别之处主要在于本发明提供的是理论上可无限延伸的连续形变复合材料线缆。
优选地，所述线缆式连续形变复合材料型材或裸露的连续形变复合材料型材的抗拉强度为1200-4000MPa，线膨胀系数为0.6-8×10 -6 1/℃，弹性模量为120-240GPa。
本方案中连续形变复合材料型材的制作过程为，用树脂浸渍连续纵向纤维得到预浸料，将金属连续焊接或挤包得到管坯；并将所述预浸料连续带入所述管坯，得到待变型材料，所述预浸料带入所述管坯内部的线速度与所述金属焊接或挤包成型管坯的线速度相等，以保证预浸料自进入管坯开始与管坯保持相对静止，此时，预浸料在管坯口受到第一段压力，预浸料在塞满的情形下，预浸料中部分多余的树脂被排挤掉，在不塞满的情形下，预浸料中部分多余的树脂被留在管坯中或以垂流的形式流出管坯，以控制连续纵向纤维和树脂的体积比，排出部分树脂后，预浸料进入管坯内部；利用现有的驱动装置同步驱动待变形材料的预浸料及管坯，管坯经辊压或拉拔成型为设计截面的管，对管坯的横向截面进行减缩，即待成型材料的外壳，在辊压或拉拔的第二段压力作用下，管坯截面（指与连续纵向纤维所述的纵向相垂直的横截面）的大小、形状都可以被改变，其中形状可以被制成圆形或椭圆形或葫芦形或多边形，其中多边形可以是等边多边形，也可以是不等边多边形，可以是凸多边形，也可以是凹多边形，由于管坯经一次或多次辊压或拉拔，管径被减缩，管内的预浸料实现浸润、再次挤出混入的空气和多余的树脂，使管内的纤维体积占比得到提高和进一步的控制，另一方面，此时管与预浸料相对静止并被牵引同步驱动，经过模具或其他的压力作用，管坯的空间形态，既可以是直线型的，也可以被改造成二维平面曲线型的如平面波浪型，或三维空间曲线型的如螺旋线型，而且，因为预浸料和管坯被同步驱动，故所述待成型材料的截面和/或空间形态可以在不同的段落进行不同的变形处理，形成整体是连续的，但不同截面形状或面积不同，不同段落空间形态不同的状态；然后，加热所述待成型材料，可触发管内预浸料完成交联固化，得到连续的相同或不同空间形态的所述连续形变复合材料型材；所述连续形变复合材料型材包括所述预浸料经交联固化形成的芯材和所述管坯经变形形成的铠装层，可以将铠装层拆解以适用于不同场合，也可保留所述铠装层，以保护芯材。
通过以上过程实现对复合材料型材的连续形变，去除多余树脂，提升连续纵向纤维体积占比，使得型材具有更好的弯曲、耐压、抗冲击、抗折损、耐候特性，本方案所制备的连续变形复合材料型材可用作输配电线路的架空导线及电气化铁路承力送电导线、接触网导线、土木工程的预应力拉索等。
现有拉挤技术是：浸渍树脂的纤维在腔模的入口处挤出混入的空气和多余的树脂使腔模内的纤维体积含量达到设计要求，并依次通过腔模的三个加热温区（浸润、凝胶、固化）完成制品的制作，本申请的技术过程是：管坯拉拔变成管的过程中完成了浸渍树脂的纤维在腔模的入口处挤出混入的空气和多余的树脂使腔模内的纤维体积含量达到设计要求，同时保证了预浸料与管之间始终保持相对静止，并实现型材的连续形变。
 有益效果
本发明的有益效果在于：
1.预浸料受到两段挤压作用，挤掉多余树脂，仅保留所需起到粘接作用的树脂体积含量，提高了连续纵向纤维体积占比，增加复合材料型材在给定截面积条件下复合材料型材的强度和卷绕特性等关键性能指标，同时降低了型材中树脂的含量，降低了产品的价格。
2.本方案中，预浸料进入管坯后，管坯通过辊压或拉拔成型管，此过程中，除了因为管坯变形导致其内预浸料变形而使多余的树脂被排挤略有移动以外，预浸料整体与管坯没有相对运动，一方面管坯辊压或拉拔成型为型管对内部的预浸料施加压力，避免树脂气泡产生并挤出多余树脂，另一方面，预浸料和管坯或型管被同步驱动，待管坯被辊压或拉拔为预想的空间形态成型管后，再进行加温，触发预浸料交联固化。相较于现有技术中预浸料边相对于腔模运动边交联固化的做法，本方案的预浸料在已定型管中相对静止地开始合完成固化过程，实现了复合材料型材包括截面形状、大小以及空间形态的连续变形的可实施性。
3.通过本方案制备的型材，铠装层可以选择保留或去除，通过本方案制备的无铠装层的连续形变复合材料型材能避免易弯曲和抗折损的矛盾。
4.本方案中的金属从形成管坯到型管再到铠装层，在管坯阶段，其起到结合预浸料并初步控制连续纵向纤维体积占比和树脂体积占比的作用；在从管坯变形为型管的过程中，其起到进一步挤压预浸料，完成排气、挤胶等作用；在成型为型管后，当被加温以触发和完成其中的预浸料发生交联固化的过程中，其起到树脂固化成型的腔模的作用；而在最终的连续形变复合材料型材中，其起到了保护内部复合材料的铠装作用。
5.由于本方案中预浸料与管坯或型管没有相对运动，一方面避免现有技术中预浸料在腔膜中由于相对运动而产生的预浸料材料表面缺陷，提高了产品质量，降低了生产成本，另一方面，避免了预浸料与腔膜相对运动不畅乃至停止而导致无法控制低粘度粘流态、凝胶态或玻璃态的树脂的固化过程的问题，因此可以实现复合材料型材的连续形变。
6.一方面是由于预浸料与管坯或型管没有相对运动，不会因为相互摩擦而产生任何制备型材的困难问题，另一方面由于管坯成型管后，管内部的预浸料连同管本身呈直线或期待的螺旋线等空间曲线，可定时定点进入交联固化阶段，相较于现有技术中腔膜固定，预浸料必须在腔膜中边运动边完成固化过程的做法，本方案的型材生产不仅工艺灵活，而且制备速度大幅提升，提高了工艺生产效率。
 附图说明
图1为现有技术中连续纤维复合材料型材的制备工艺流程图；
图2为本方案中连续形变复合材料型材的制备工艺流程示意图；
图中：12. 连续纵向纤维；9.树脂；13.金属；7.焊机；8.管坯；6.辊压或拉拔模；2. 连续形变复合材料型材；3.牵引装置；5.加热装置；111.加热固化装置。
 本发明的最佳实施方式
为了使本发明所述的内容更加便于理解，下面结合具体实施方式对本发明所述的技术方案做进一步的说明，但是本发明不仅限于此。
实施例1
一种连续形变复合材料型材2的制备方法，如图2所示，包括依次进行的以下步骤：
S1.将连续纵向纤维12浸渍树脂9，得预浸料，其中原料含有50份连续纵向纤维12，50份树脂9，所述连续纵向纤维12包括玻璃纤维、碳纤维的混合物；将金属13通过导辊及纵包模径向成型并通过连续焊机7焊接，得管坯8；
S2.放出所述预浸料连续进入所述管坯8内，得待变型材料，所述预浸料带入所述管坯8内部的线速度与S1所述金属13焊接或挤包成型管坯8的线速度相等，预浸料塞满管坯8的入口，预浸料中部分多余的树脂9被排挤掉；
S3.通过牵引装置3同步驱动待变形材料的预浸料及管坯8，通过拉拔或辊压工艺改变所述管坯8截面或/并通过模具作用变形所述管坯8空间形态，得到连续的相同或不同空间形态的待成型材料，所述待成型材料中连续纵向纤维12的体积占比为预浸料总体积的60%-80%，此时管坯8与预浸料相对静止，辊压或拉拔模6改变所述管坯8截面的大小或形状，截面形状可以被制成圆形或椭圆形或葫芦形或多边形，其中多边形可以是等边多边形，也可以是不等边多边形，可以是凸多边形，也可以是凹多边形等，并通过模具作用变形所述管坯8空间形态，如一维的直线型、二维的平面波浪型，或三维空间曲线型的如螺旋线型等；
S4. 通过加热装置5加热所述待成型材料，得到连续的相同或不同空间形态的所述连续形变复合材料型材2，包括所述预浸料经交联固化形成的芯材和所述管坯8经变形形成的铠装层；
通过收卷装置将上述复合材料型材进行收卷成盘。
 本发明的实施方式
实施例2
一种连续形变复合材料型材2的制备方法，如图2所示，包括依次进行的以下步骤：
S1.将连续纵向纤维12浸渍树脂9，得预浸料，其中原料含有30份连续纵向纤维12，50份树脂9，所述连续纵向纤维12包括硼纤维、芳纶纤维、碳化硅纤维的混合物；将金属带材13通过导辊及纵包模径向成型并通过连续焊机7焊接，得管坯8；
S2.放出所述预浸料连续进入所述管坯8内，得待变型材料，所述预浸料带入所述管坯8内部的线速度与S1所述金属13焊接或挤包成型管坯8的线速度相等，预浸料不塞满的情形下，预浸料中部分多余的树脂9被留在管坯8中或以垂流的形式流出管坯8；
S3. 通过牵引装置3同步驱动待变形材料的预浸料及管坯8，通过拉拔或辊压工艺改变所述管坯8截面或/并通过模具作用变形所述管坯8空间形态，得到连续的相同或不同空间形态的待成型材料，所述待成型材料中连续纵向纤维12的体积占比为预浸料总体积的60%-80%，此时管坯8与预浸料相对静止，辊压或拉拔模6改变所述管坯8截面尺寸和形状，截面形状可以被制成圆形或椭圆形或葫芦形或多边形，其中多边形可以是等边多边形，也可以是不等边多边形，可以是凸多边形，也可以是凹多边形等，并通过模具作用变形所述管坯8空间形态，如一维的直线型、二维的平面波浪型，或三维空间曲线型的如螺旋线型等；
 S4. 通过加热装置5加热所述待成型材料，得到连续的相同或不同空间形态的所述连续形变复合材料型材2，其抗拉强度为1200-4000MPa，线膨胀系数为0.6-8×10 -6 1/℃，弹性模量为120-240GPa，所述连续形变复合材料型材2包括所述预浸料经交联固化形成的芯材和所述管坯8经变形形成的铠装层；
S5. 拆除所述铠装层，得到裸露的芯材。拆除方式可以为机械拆除法；
最后，通过收卷装置将上述复合材料型材进行收卷成盘。
实施例3
一种连续形变复合材料型材2的制备方法，如图2所示，包括依次进行的以下步骤：
S1.将连续纵向纤维12浸渍树脂9，得预浸料，其中原料含有40份连续纵向纤维12，50份树脂9，所述连续纵向纤维12包括碳化硅纤维、玄武岩纤维的混合物；将金属带材13通过导辊及纵包模径向成型并通过连续焊机7焊接，得管坯8；
S2.放出所述预浸料连续进入所述管坯8内，得待变型材料，所述预浸料带入所述管坯8内部的线速度与S1所述金属13焊接或挤包成型管坯8的线速度相等，预浸料塞满管坯8的入口，预浸料中部分多余的树脂9被排挤掉；
S3. 通过牵引装置3同步驱动待变形材料的预浸料及管坯8，通过拉拔或辊压工艺改变所述管坯8截面或/并通过模具作用变形所述管坯8空间形态，得到连续的相同或不同空间形态的待成型材料，所述待成型材料中连续纵向纤维12的体积占比为预浸料总体积的75%-80%，此时管坯8与预浸料相对静止，通过辊压或拉拔模6改变所述管坯8截面尺寸和形状，截面形状可以被制成圆形或椭圆形或葫芦形或多边形，其中多边形可以是等边多边形，也可以是不等边多边形，可以是凸多边形，也可以是凹多边形等，并通过模具作用变形所述管坯8空间形态，如一维的直线型、二维的平面波浪型，或三维空间曲线型的如螺旋线型等；
 S4. 通过加热装置5加热所述待成型材料，得到连续的相同或不同空间形态的所述连续形变复合材料型材2，其抗拉强度为1200-4000MPa，线膨胀系数为0.6-8×10 -6 1/℃，弹性模量为120-240GPa，所述连续形变复合材料型材2包括所述预浸料经交联固化形成的芯材和所述管坯8经变形形成的铠装层。
S5. 拆除所述铠装层，得到裸露的芯材。拆除方式可以为机械拆除法。
S6. 将所述被拆除的铠装层回用为步骤S1焊接或挤包所需的金属13，所述回收步骤可以包括机械拆除后熔融，作为挤包的金属原料；或拆除后成卷，作为焊接的金属带材。
通过收卷装置将上述复合材料型材进行收卷成盘。
实施例4
按照本方案方法制备的一种线缆式连续形变复合材料型材，其特征在于，其具有曲线空间形态并可盘绕，包括芯材、铠装层，所述铠装层贴设于所述芯材外表面，所述芯材材料包括连续纵向纤维和树脂，其中，所述连续纵向纤维的体积占比为所述芯材材料总体积的60%-80%，所述铠装层材料包括至少一层金属。其中，所述芯材截面形状包括圆形、椭圆形、葫芦形、多边形中的一种或几种，不同位置的截面大小相同或不同，所述曲线空间形态包括二维平面曲线型和三维空间曲线型中的一种或两种。
实施例5
按照本方案方法制备的一种裸露的连续形变复合材料型材，其特征在于，其具有曲线空间形态并可盘绕，包括芯材，所述芯材材料包括连续纵向纤维和树脂，其中，所述连续纵向纤维的体积占比为所述芯材材料总体积的60%-80%。其中，所述芯材截面形状包括圆形、椭圆形、葫芦形、多边形中的一种或几种，不同位置的截面大小相同或不同，所述曲线空间形态包括二维平面曲线型和三维空间曲线型中的一种或两种。其抗拉强度为1200-4000MPa，线膨胀系数为0.6-8×10 -6 1/℃，弹性模量为120-240GPa。
对比例1
现有技术如图1所示，在牵引的驱动下浸渍树脂9的连续纵向纤维12在腔模的入口处挤出混入的空气和多余的树脂9使腔模内的连续纵向纤维12体积含量达到设计要求，并依次通过腔模的三个加热温区浸润、凝胶、固化，通过牵引装置牵引完成制品的制作，其中加热固化装置111就是腔模，由于制品必须在腔模中固化并相对运动，所以不能实现截面和空间形态均可变形的连续形变复合材料型材的制作。
以上详细描述了本发明的具体实施例。综上可见，利用本专利方法可以连续制备连续形变复合材料型材，而连续形变复合材料型材的可得性可以保障需要综合各方面性能要求的复合材料价值工程设计所需。
应当理解，本领域的普通技术人员无需创造性劳动就可以根据本发明的构思作出诸多修改和变化。因此，凡本技术领域的技术人员以本发明构思在现有技术上通过逻辑分析、推理或者有限的实验可以得到的技术方案，都应在本发明所确定的保护范围内。

Claims (5)

  1. 一种自承压连续线性的树脂基纤维增强预浸料，其特征在于，制备方法包括依次进行的以下步骤：
    S1.用树脂（9）浸渍连续纵向纤维（12）得到预浸料，将金属（13）连续焊接或挤包得到管坯（8）；
    S2.将所述预浸料连续带入所述管坯（8），得到待变型材料；
    S3.同步驱动待变形材料的预浸料及管坯（8），通过拉拔或辊压工艺改变所述管坯（8）截面或/并通过模具作用变形所述管坯（8）空间形态，得到连续的相同或不同空间形态的待成型材料。
  2. 根据权利要求1所述的一种自承压连续线性的树脂基纤维增强预浸料，其特征在于，所述预浸料带入所述管坯（8）内部的线速度与所述金属（13）焊接或挤包成型管坯（8）的线速度相等。
  3. 根据权利要求1所述的一种自承压连续线性的树脂基纤维增强预浸料，其特征在于，步骤S3中所述待成型材料的截面形状包括圆形、椭圆形、葫芦形、多边形中的一种或几种，所述待成型材料的空间形态包括直线型、二维平面曲线型、三维空间曲线型中的一种或几种。
  4. 根据权利要求1所述的一种自承压连续线性的树脂基纤维增强预浸料，其特征在于，所述待成型材料中连续纵向纤维（12）的体积占比为预浸料总体积的60%-80%。
  5. 根据权利要求1所述的一种自承压连续线性的树脂基纤维增强预浸料，其特征在于，所述连续纵向纤维（12）包括玻璃纤维、碳纤维、硼纤维、芳纶纤维、碳化硅纤维、玄武岩纤维中的一种或几种。
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