WO2025130855A1 - 一种拉挤卷管成型方法和系统 - Google Patents

一种拉挤卷管成型方法和系统 Download PDF

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Publication number
WO2025130855A1
WO2025130855A1 PCT/CN2024/139883 CN2024139883W WO2025130855A1 WO 2025130855 A1 WO2025130855 A1 WO 2025130855A1 CN 2024139883 W CN2024139883 W CN 2024139883W WO 2025130855 A1 WO2025130855 A1 WO 2025130855A1
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WIPO (PCT)
Prior art keywords
carbon fiber
tube body
curing
appearance layer
composite material
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Pending
Application number
PCT/CN2024/139883
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English (en)
French (fr)
Inventor
曹亚周
张亚东
葛继文
陈旭
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CRRC Qingdao Sifang Co Ltd
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CRRC Qingdao Sifang Co Ltd
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Publication of WO2025130855A1 publication Critical patent/WO2025130855A1/zh
Anticipated expiration legal-status Critical
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Classifications

    • 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
    • B29C70/40—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
    • B29C70/525—Component parts, details or accessories; Auxiliary operations
    • 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
    • B29C70/525—Component parts, details or accessories; Auxiliary operations
    • B29C70/528—Heating or cooling
    • 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
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2023/00—Tubular articles
    • B29L2023/22—Tubes or pipes, i.e. rigid

Definitions

  • the heated and cured tube body is post-processed to produce a handrail made of carbon fiber composite material.
  • the step before the step of rolling a plurality of carbon fiber material layers into a carbon fiber roll material, the step includes:
  • the carbon fiber material is laid on a plurality of cloths to form a plurality of carbon fiber material layers, wherein the plurality of carbon fiber material layers include a 1200 gram quad-axial carbon fiber cloth, a 1000 gram carbon fiber unidirectional cloth and a 1000 gram quad-axial carbon fiber cloth.
  • the step of injecting and impregnating epoxy resin into the carbon fiber coil and heating and curing the carbon fiber composite material to form a profile includes:
  • the mixed liquid of the curing agent and the accelerator and the epoxy resin are respectively injected and impregnated into the carbon fiber coil;
  • the carbon fiber coil is heated and cured in three heating zones respectively, and the temperatures of the three heating zones are increased in sequence.
  • the method before the step of injecting and infiltrating the mixed solution of curing agent and accelerator and epoxy resin into the carbon fiber roll respectively, the method further includes:
  • the injection temperature of the mixed liquid of the curing agent and the accelerator and the epoxy resin is controlled below 60°C by a water cooling device to reduce the viscosity of the epoxy resin to a preset low value.
  • the method before the step of laying the appearance layer prepreg on the pipe body, the method further includes:
  • the first non-porous separator is removed.
  • the method further includes:
  • the steps of wrapping the vacuum auxiliary material on the appearance layer prepreg and heating and curing include:
  • a breathable felt and a vacuum bag are laid on the outside of the second non-porous isolation film, and vacuuming and heating and curing are performed.
  • the present application also provides a pultrusion coiled tube forming system, which adopts any of the pultrusion coiled tube forming methods as described above, including a carbon fiber composite material tube body preparation mechanism and an appearance layer coiled tube curing mechanism, and the carbon fiber composite material tube body preparation mechanism includes:
  • a preforming mold used for rolling a plurality of carbon fiber material layers into a carbon fiber coil
  • a molding die assembly is used to inject and infiltrate epoxy resin into the carbon fiber coil, and heat and cure it to form a carbon fiber composite material profile;
  • a pultrusion module is used to pultrude the heated and cured profile into a tube body of carbon fiber composite material
  • the appearance layer coil curing mechanism includes:
  • Appearance layer laying module used for laying the appearance layer prepreg onto the tube body
  • the exterior layer heating and curing module is used to wrap the vacuum auxiliary material on the exterior layer prepreg and heat and cure it;
  • the post-processing module is used to post-process the heated and cured tube body to produce a handrail made of carbon fiber composite material.
  • the forming die assembly includes:
  • the injection mold is used to inject and infiltrate epoxy resin into the carbon fiber coil
  • the molding mold is an integrated structure with the injection mold and is used to heat and cure the carbon fiber coil impregnated with epoxy resin to make a profile of the carbon fiber composite material.
  • the carbon fiber composite material tube preparation mechanism further includes:
  • a material rack used for conveying a carbon fiber material layer to the preforming mold
  • the cutting module is used to cut off the tube body pulled out by the pultrusion module.
  • the pultrusion coiled tube forming method includes: rolling a plurality of carbon fiber material layers into a carbon fiber coiled material, injecting and impregnating epoxy resin into the carbon fiber coiled material, and heating and curing to form a carbon fiber composite material profile, pultruding the heated and cured profile into a carbon fiber composite material tube body, laying the appearance layer prepreg on the tube body, wrapping the vacuum auxiliary material on the appearance layer prepreg, and heating and curing, and post-processing the heated and cured tube body to form a carbon fiber composite material handrail.
  • the pultrusion coiled tube forming method adopted in the present application is used to form a carbon fiber composite material handrail. Specifically, the carbon fiber composite material tube body is first prepared by a glue injection pultrusion forming process, and then the appearance layer is laid on the outer layer of the tube body for coiled tube curing forming.
  • the pultrusion coiled tube forming method of the present application has a simple forming process and high forming efficiency, which can not only achieve a good appearance effect of the handrail, but also improve the overall stiffness and strength compared with the stainless steel handrail, and can also reduce the weight by 30%.
  • FIG1 is a flow chart of a pultruded coiled tube forming method according to an embodiment of the present application
  • FIG2 is a schematic diagram of the dimensions of a handrail in an embodiment of the present application.
  • FIG3 is a schematic diagram of the ply structure of the handrail rod in an embodiment of the present application.
  • FIG4 is a schematic diagram of the paving of the exterior layer of the handrail in an embodiment of the present application.
  • FIG5 is a pipe rolling process diagram of the handrail rod in an embodiment of the present application.
  • FIG6 is a schematic diagram of a carbon fiber composite material tube body preparation mechanism of a pultrusion roll tube forming system in an embodiment of the present application.
  • 10-handrail 11-tube, 111-1000g four-axial carbon fiber cloth, 112-1000g carbon fiber unidirectional cloth, 113-1200g four-axial carbon fiber cloth, 12-appearance layer prepreg, 13-second non-porous isolation membrane, 14-breathable felt, 15-vacuum bag;
  • 100-carbon fiber composite material tube preparation mechanism 101-material rack, 102-preforming mold, 103-molding mold assembly, 1031-injection mold, 1032-molding mold, 104-pultrusion module, 1041-traction unit, 105-cutting module.
  • Figure 1 is a flow chart of the pultrusion coiled tube forming method in the embodiment of the present application
  • Figure 2 is a schematic diagram of the handrail rod size in the embodiment of the present application
  • Figure 3 is a schematic diagram of the layup structure of the handrail rod in the embodiment of the present application
  • Figure 4 is a schematic diagram of the appearance layer paving of the handrail rod in the embodiment of the present application
  • Figure 5 is a coiling process diagram of the handrail rod in the embodiment of the present application
  • Figure 6 is a schematic diagram of the carbon fiber composite material tube body preparation mechanism of the pultrusion coiled tube forming system in the embodiment of the present application.
  • pultrusion coiling method used in this application is used to form a carbon fiber composite handrail 10. Specifically, a carbon fiber composite tube body 11 is first prepared by a glue injection pultrusion process, and then an appearance layer is laid on the outer layer of the tube body 11 for coiling and curing.
  • the pultruded coiled tube forming method of the present application has a simple forming process and high forming efficiency, which can not only achieve a good appearance effect of the handrail 10, but also improve the overall stiffness and strength compared to the stainless steel handrail 10, and can also reduce the weight by 30%.
  • the step before the step of rolling a plurality of carbon fiber material layers into a carbon fiber roll material, the step includes:
  • the carbon fiber material is laid on a plurality of cloths to form a plurality of carbon fiber material layers, wherein the plurality of carbon fiber material layers include a 1200-gram quad-axial carbon fiber cloth, a 1000-gram carbon fiber unidirectional cloth, and a 1000-gram quad-axial carbon fiber cloth.
  • the handrail bar 10 of the carbon fiber composite material formed in this embodiment is a hollow circular tube structure
  • the outer diameter of the handrail bar 10 is 35 mm
  • the wall thickness is 5.5 mm
  • the length of the carbon fiber composite material handrail bar 10 is 1000 mm
  • the carbon fiber composite material handrail bar 10 is layered with 1200 g four-axial carbon fiber cloth 113, 1000 g carbon fiber unidirectional cloth 112 and 1000 g four-axial carbon fiber cloth 111, and the fiber volume content of each part is 62.8%.
  • the carbon fiber coil is layered from the inside to the outside with 1000 g four-axial carbon fiber cloth 111, 1000 g carbon fiber unidirectional cloth 112 and 1200 g four-axial carbon fiber cloth 113.
  • the step of injecting and impregnating epoxy resin into the carbon fiber coil and heating and curing the carbon fiber composite material to form a profile includes:
  • the mixed liquid of the curing agent and the accelerator and the epoxy resin are respectively injected and impregnated into the carbon fiber coil;
  • the carbon fiber coil is heated and cured in three heating zones respectively, and the temperatures of the three heating zones are increased in sequence.
  • this embodiment adopts a glue injection infiltration method and simultaneously uses a three-stage heating method (120° C.-150° C.-160° C.).
  • the ratio of the two is 96:4, pump the mixed liquid of curing agent and accelerator into the injection machine B pump, and at the same time pump the epoxy resin into the injection machine A pump, adjust the A and B pumps to inject resin and curing agent into the mold at the same time, and the output flow rate is 50g/min each.
  • the heating plates on the molding mold 1032 respectively plug in the thermocouple, insert the cable into the sockets at both ends of the heating plate, turn on the equipment, turn on the equipment heating zone, and the heating plate is divided into three curing zones. According to the process requirements, the temperature of the first curing zone is set to 120°C, the temperature of the second curing zone is set to 150°C, and the temperature of the third curing zone is set to 160°C.
  • the method before the step of injecting and infiltrating the mixed solution of curing agent and accelerator and epoxy resin into the carbon fiber roll respectively, the method further includes:
  • the injection temperature of the mixed liquid of the curing agent and the accelerator and the epoxy resin is controlled below 60°C by a water cooling device to reduce the viscosity of the epoxy resin to a preset low value.
  • a water cooling area is set in the mold injection section to control the viscosity of the epoxy resin.
  • the specific operation is: turn on the water cooling equipment, and the cooling water circulates through the pipeline to cool the front end of the molding mold 1032, so that the temperature of the mold injection section is controlled below 60°C (the viscosity of the epoxy resin is the lowest at this time).
  • the viscosity of the epoxy resin is reduced to a minimum value, so that the epoxy resin can evenly and fully fill the fiber material, thereby ensuring the molding quality of the carbon fiber composite material handrail bar 10.
  • the profile extrusion speed is set to 80-90 mm/min, the extrusion module 104 is turned on, and the fiber and resin materials are solidified and formed according to the preset heating temperature and traction speed. Under the traction of the pultrusion module 104, the profile is pulled out of the mold.
  • the step before the step of laying the appearance layer prepreg 12 onto the tube body 11, the step further includes:
  • the first non-porous separator is removed.
  • a layer of adhesive film may be laid before laying the appearance layer prepreg 12 .
  • the surface of the cut carbon fiber composite material tube body 11 is also polished.
  • the carbon fiber composite material tube body 11 is first clamped and fixed on the polishing tool, and the outer surface of the pultruded handrail 10 is roughly polished with sandpaper with a mesh number of about 120, and then the outer surface of the carbon fiber composite material tube body 11 is finely polished with sandpaper with a mesh number of more than 200, and polished until there is no bright spot on the outer surface of the tube body 11, and the whole should be smooth without bumps and burrs. Finally, it is cleaned with a wiping cloth and anhydrous ethanol until there is no grinding dust and other pollutants on the outer surface of the tube body 11.
  • the film cut to size is laid on the outer surface of the tube body 11 (the number of film layers is 1).
  • a certain gap must be left at the joint of the film, and the joint is parallel to the axis of the tube body 11.
  • the width of the joint is not more than 0.5mm. Overlapping, wrinkling, twisting, and foreign matter inclusion of the film are not allowed.
  • the tube body 11 is wrapped with the first non-porous isolation film, and then vacuumed and compacted.
  • the vacuum compaction time is ⁇ 15min and the vacuum degree is ⁇ -0.090MPa (before the next step, the first non-porous isolation film used for vacuuming needs to be removed).
  • the back of the appearance layer prepreg 12 is pasted with release paper and the front is pasted with a release film.
  • first remove the release paper on the back keep the release film on the front
  • after laying the appearance layer prepreg 12 on the surface of the film remove the release film on the front of the appearance layer prepreg 12.
  • a certain gap must be left at the joint of the appearance layer prepreg 12, and the joint must be parallel to the axis of the tube body 11.
  • the width of the joint is not greater than 0.3mm. It is not allowed to overlap, wrinkle, twist, fiber disorder, foreign matter inclusion, etc.
  • the tube body 11 is wrapped with the second non-porous isolation film 13 and vacuum compacted.
  • the vacuum compaction time is ⁇ 15 minutes and the vacuum degree is ⁇ -0.090 MPa.
  • the following steps are further included:
  • the tube body 11 is wrapped with the second non-porous isolation film 13, and after vacuuming and compacting, the vacuum auxiliary material (including the second non-porous isolation film 13) is removed, and the surface state of the appearance layer prepreg 12 is observed to confirm that the appearance layer prepreg 12 has no overlap, no wrinkles, no twisting, no fiber disorder, no exposed tube body 11 and film, and no foreign matter.
  • the steps of wrapping the vacuum auxiliary material on the appearance layer prepreg 12 and heating and curing include:
  • the tube body 11 on which the appearance layer prepreg 12 is laid is wrapped with a second non-porous isolation film 13, and the second non-porous isolation film 13 is closely attached to the appearance layer prepreg 12, and no appearance layer prepreg 12 is exposed;
  • the air-permeable felt 14 and the vacuum bag 15 are laid on the outside of the second non-porous separator 13, and vacuuming and heating and curing are performed.
  • the tube body 11 after confirming that the laying effect of the appearance layer prepreg 12 on the tube body 11 meets the preset requirements, it also includes bag making before the appearance layer is cured and curing the appearance layer.
  • Bag making requirements before curing of the exterior layer During the process of making the vacuum bag 15, the breathable felt 14 is not allowed to come into direct contact with the tube body 11. The distance between the breathable felt 14 and the tube body 11 needs to be controlled at about 30 mm. The second non-porous isolation film 13 and the vacuum bag 15 should be smooth as a whole, and wrinkles and twists of the vacuum auxiliary materials should be minimized.
  • Appearance layer curing The tube body 11 of the bag is cured and formed in a curing furnace.
  • the curing requirements are as follows:
  • Vacuum Vacuum the whole process until the curing process is completed, and the vacuum degree of the vacuum system is ⁇ -0.095MPa. After the process is completed, stop vacuuming and do not release the negative pressure.
  • the cured product is post-processed, including: removing the vacuum auxiliary material on the surface of the carbon fiber composite handrail 10, cleaning the flash and residual glue around it, and not allowing knock damage and serious surface scratches to the product surface.
  • the present application provides a pultrusion coiled tube forming system, which adopts the pultrusion coiled tube forming method described in the above specific embodiment, including a carbon fiber composite material tube body preparation mechanism 100 and an appearance layer coiled tube curing mechanism. Among them:
  • the carbon fiber composite material tube preparation mechanism 100 includes a preforming die 102, a forming die assembly 103 and a pultrusion module 104.
  • the preforming die 102 is used to roll a plurality of carbon fiber material layers into a carbon fiber coil
  • the forming die assembly 103 is used to inject and infiltrate epoxy resin into the carbon fiber coil, and heat and cure it to form a carbon fiber composite material profile
  • the pultrusion module 104 is used to pultrude the heated and cured profile into a carbon fiber composite material tube 11.
  • the appearance layer coil curing mechanism includes an appearance layer paving module, an appearance layer heating and curing module and a post-processing module.
  • the appearance layer paving module is used to pave the appearance layer prepreg 12 onto the tube body 11
  • the appearance layer heating and curing module is used to wrap the vacuum auxiliary material on the appearance layer prepreg 12 and heat and cure it
  • the post-processing module is used to post-process the heated and cured tube body 11 to produce a handrail 10 made of carbon fiber composite material.
  • the molding die assembly 103 includes a glue injection die 1031 and a molding die 1032, wherein the glue injection die 1031 is used to inject and infiltrate epoxy resin into the carbon fiber coil, and the molding die 1032 and the glue injection die 1031 are an integrated structure, and the molding die 1032 is used to heat and cure the carbon fiber coil infiltrated with epoxy resin to make a profile of a carbon fiber composite material.
  • the molding die 1032 is composed of an upper mold plate and a lower mold plate, and in order to make the mold have a certain heat capacity and ensure uniform and stable heating, the cross-section of the molding die 1032 is designed to be 10 times the cross-sectional area of the pultruded product.
  • the pultrusion module 104 may include one traction unit 1041 or at least two traction units 1041 , for example, two traction units 1041 are provided, and the two traction units 1041 are used to pull the tube body 11 to move at corresponding traction speeds.
  • the carbon fiber composite material tube body preparation mechanism 100 also includes a material rack 101 and a cutting module 105.
  • the material rack 101 is used to transport the carbon fiber material layer to the preforming mold 102.
  • the cutting module 105 is arranged at the end of the carbon fiber composite material tube body preparation mechanism 100. The cutting module 105 is used to cut off the tube body 11 pulled out by the pultrusion module 104.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

一种拉挤卷管成型方法和系统，拉挤卷管成型方法包括：将若干碳纤维料层卷制成碳纤维卷料，将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材，将加热固化后的型材拉挤制成碳纤维复合材料的管体(11)，将外观层预浸料(12)铺贴至管体(11)上，在外观层预浸料(12)上包裹真空辅材，并进行加热固化，对加热固化后的管体进行后处理制成碳纤维复合材料的扶手杆(10)。拉挤卷管成型方法，成型工艺简单、成型效率高，不仅能够实现扶手杆(10)良好的外观效果，而且相较不锈钢扶手杆能够提高整体刚度和强度，同时还能够减重30％。

Description

一种拉挤卷管成型方法和系统
本申请要求于2023年12月20日提交中国专利局、申请号为202311764447.1、发明名称为“一种拉挤卷管成型方法和系统”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及扶手杆成型技术领域，特别涉及一种拉挤卷管成型方法和采用该拉挤卷管成型方法的拉挤卷管成型系统。
背景技术
目前，轨道车辆车内扶手杆通常使用304不锈钢材质管材经过表面喷塑制备而成，装配时，扶手杆与顶板和底板通过各安装座焊接成一体。然而，在实现本发明的过程中，发明人发现现有技术中至少存在如下问题：现有体系中，扶手杆的制造过程复杂，制造出的扶手杆重量较重，且金属材质的扶手杆内部容易存在锈蚀等问题，导致扶手杆的使用寿命大大降低。
因此，本领域技术人员有必要适时提供一种成型工艺简单、成型效率高、且能够提高扶手杆整体刚度和强度、降低扶手杆整体重量的拉挤卷管成型方法。
发明内容
本申请的目的是提供一种拉挤卷管成型方法和系统，该拉挤卷管成型方法成型工艺简单、成型效率高、且能够提高扶手杆整体刚度和强度、降低扶手杆整体重量。
为实现上述目的，本申请提供一种拉挤卷管成型方法，包括：
将若干碳纤维料层卷制成碳纤维卷料；
将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材；
将加热固化后的型材拉挤制成碳纤维复合材料的管体；
将外观层预浸料铺贴至管体上；
在外观层预浸料上包裹真空辅材，并进行加热固化；
对加热固化后的管体进行后处理制成碳纤维复合材料的扶手杆。
在一些实施例中，将若干碳纤维料层卷制成碳纤维卷料的步骤之前，包括：
将碳纤维材料铺设至若干布料上制成若干碳纤维料层，若干碳纤维料层包括1200克重四轴向碳纤维布、1000克重碳纤维单向布以及1000克重四轴向碳纤维布。
在一些实施例中，将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材的步骤，包括：
将固化剂和促进剂的混合液以及环氧树脂分别注射并浸润至碳纤维卷料中；
将碳纤维卷料分别经过三段加热区域进行加热固化，且三段加热区域的温度依次递增。
在一些实施例中，将固化剂和促进剂的混合液以及环氧树脂分别注射并浸润至碳纤维卷料中的步骤之前，还包括：
通过水冷设备将固化剂和促进剂的混合液以及环氧树脂的注射温度控制在60℃以下，以将环氧树脂的粘度降至预设低值。
在一些实施例中，将外观层预浸料铺贴至管体上的步骤之前，还包括：
将胶膜铺贴至管体的外表面；
通过第一无孔隔离膜包裹铺贴胶膜的管体，并进行抽真空压实；
将第一无孔隔离膜去除。
在一些实施例中，将外观层预浸料铺贴至管体上的步骤之后，还包括：
对管体上外观层预浸料的表面状态进行检查；
确认管体上外观层预浸料的铺贴效果满足预设要求。
在一些实施例中，在外观层预浸料上包裹真空辅材，并进行加热固化的步骤包括：
通过第二无孔隔离膜包裹铺贴外观层预浸料的管体，并保证第二无孔隔离膜与外观层预浸料紧密贴合，无外观层预浸料裸露；
在第二无孔隔离膜的外部铺设透气毡和真空袋，并进行抽真空及加热固化。
本申请还提供一种拉挤卷管成型系统，采用如上述任一项的拉挤卷管成型方法，包括碳纤维复合材料管体制备机构和外观层卷管固化机构，碳纤维复合材料管体制备机构包括：
预成型模具，用于将若干碳纤维料层卷制成碳纤维卷料；
成型模具组件，用于将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材；
拉挤模块，用于将加热固化后的型材拉挤制成碳纤维复合材料的管体；
外观层卷管固化机构包括：
外观层铺贴模块，用于将外观层预浸料铺贴至管体上；
外观层加热固化模块，用于在外观层预浸料上包裹真空辅材，并进行加热固化；
后处理模块，用于对加热固化后的管体进行后处理制成碳纤维复合材料的扶手杆。
在一些实施例中，成型模具组件包括：
注胶模具，用于将环氧树脂注射并浸润至碳纤维卷料中；
成型模具，与注胶模具为一体式结构，用于对浸润环氧树脂的碳纤维卷料进行加热固化，以制成碳纤维复合材料的型材。
在一些实施例中，碳纤维复合材料管体制备机构还包括：
料架，用于向所述预成型模具输送碳纤维料层；
切割模块，用于切断由所述拉挤模块拉挤出的管体。
相对于上述背景技术，本申请实施例所提供的拉挤卷管成型方法，包括：将若干碳纤维料层卷制成碳纤维卷料，将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材，将加热固化后的型材拉挤制成碳纤维复合材料的管体，将外观层预浸料铺贴至管体上，在外观层预浸料上包裹真空辅材，并进行加热固化，对加热固化后的管体进行后处理制成碳纤维复合材料的扶手杆。可以看出，本申请采用的拉挤卷管成型方法，用于成型碳纤维复合材料的扶手杆，具体地，先通过注胶拉挤成型工艺制备碳纤维复合材料的管体，然后在管体的外层铺贴外观层进行卷管固化成型，采用本申请的拉挤卷管成型方法，成型工艺简单、成型效率高，不仅能够实现扶手杆良好的外观效果，而且，相较不锈钢扶手杆能够提高整体刚度和强度，同时还能够减重30％。
附图说明
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请的实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据提供的附图获得其他的附图。
图1为本申请实施例中拉挤卷管成型方法的流程图；
图2为本申请实施例中扶手杆尺寸示意图；
图3为本申请实施例中扶手杆的铺层结构示意图；
图4为本申请实施例中扶手杆的外观层铺贴示意图；
图5为本申请实施例中扶手杆的卷管工艺图；
图6为本申请实施例中拉挤卷管成型系统的碳纤维复合材料管体制备机构示意图。
其中：
10-扶手杆、11-管体、111-1000克重四轴向碳纤维布、112-1000克重碳纤维单向布、113-1200克重四轴向碳纤维布、12-外观层预浸料、13-第二无孔隔离膜、14-透气毡、15-真空袋；
100-碳纤维复合材料管体制备机构、101-料架、102-预成型模具、103-成型模具组件、1031-注胶模具、1032-成型模具、104-拉挤模块、1041-牵引单元、105-切割模块。
具体实施方式
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
为了使本技术领域的技术人员更好地理解本申请方案，下面结合附图和具体实施方式对本申请作进一步的详细说明。
需要说明的是，下文所述的“上端、下端、左侧、右侧”等方位词都是基于说明书附图所定义的。
请参考图1至图6，图1为本申请实施例中拉挤卷管成型方法的流程图；图2为本申请实施例中扶手杆尺寸示意图；图3为本申请实施例中扶手杆的铺层结构示意图；图4为本申请实施例中扶手杆的外观层铺贴示意图；图5为本申请实施例中扶手杆的卷管工艺图；图6为本申请实施例中拉挤卷管成型系统的碳纤维复合材料管体制备机构示意图。
本申请实施例所提供的拉挤卷管成型方法，包括：
S1：将若干碳纤维料层卷制成碳纤维卷料；
S2：将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材；
S3：将加热固化后的型材拉挤制成碳纤维复合材料的管体11；
S4：将外观层预浸料12铺贴至管体11上；
S5：在外观层预浸料12上包裹真空辅材，并进行加热固化；
S6：对加热固化后的管体11进行后处理制成碳纤维复合材料的扶手杆10。
可以看出，本申请采用的拉挤卷管成型方法，用于成型碳纤维复合材料的扶手杆10。具体地，先通过注胶拉挤成型工艺制备碳纤维复合材料的管体11，然后在管体11的外层铺贴外观层进行卷管固化成型。
采用本申请的拉挤卷管成型方法，成型工艺简单、成型效率高，不仅能够实现扶手杆10良好的外观效果，而且，相较不锈钢扶手杆10能够提高整体刚度和强度，同时还能够减重30％。
在一些实施例中，将若干碳纤维料层卷制成碳纤维卷料的步骤之前，包括：
将碳纤维材料铺设至若干布料上制成若干碳纤维料层，若干碳纤维料层包括1200克重的四轴向碳纤维布、1000克重的碳纤维单向布以及1000克重的四轴向碳纤维布。
具体地，本实施例中所成型的碳纤维复合材料的扶手杆10为空心圆管结构，扶手杆10的外径为35mm，壁厚为5.5mm，碳纤维复合材料扶手杆10长度为1000mm，并且，碳纤维复合材料扶手杆10使用1200克重四轴向碳纤维布113、1000克重碳纤维单向布112以及1000克重四轴向碳纤维布111进行铺层，各部位纤维体积含量为62.8％。比如，碳纤维卷料由内到外设置铺层有1000克重四轴向碳纤维布111、1000克重碳纤维单向布112和1200克重四轴向碳纤维布113。
在一些实施例中，将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材的步骤，包括：
将固化剂和促进剂的混合液以及环氧树脂分别注射并浸润至碳纤维卷料中；
将碳纤维卷料分别经过三段加热区域进行加热固化，且三段加热区域的温度依次递增。
在本实施例中，为保证双组份环氧树脂材料能够均匀、充分填充纤维材料，本实施例采用注胶式浸润方式，同时使用三段加热方式加热(120℃-150℃-160℃)。
具体地，注胶时，使用电子秤称取固化剂和促进剂10kg搅拌混合，二者比例为96:4，将固化剂和促进剂的混合液泵入注射机B泵中，同时将环氧树脂泵入注胶机A泵中，调节A、B泵同时向模具注射树脂及固化剂，输出流量各为50g/min。加热固化时，将加热板分别安装在成型模具1032上，插上热电偶，把电缆插入加热板的两端插口处，开启设备，把设备加热区打开，加热板分为三个固化区，按照工艺要求把第一固化区的温度设为120℃，第二固化区的温度设为150℃，第三固化区的温度设为160℃。
在一些实施例中，将固化剂和促进剂的混合液以及环氧树脂分别注射并浸润至碳纤维卷料中的步骤之前，还包括：
通过水冷设备将固化剂和促进剂的混合液以及环氧树脂的注射温度控制在60℃以下，以将环氧树脂的粘度降至预设低值。
需要说明的是，在模具注胶段设置水冷却区域用于控制环氧树脂黏度，具体操作为：开启水冷设备，冷却水通过管路循环给成型模具1032前端降温，使模具注胶段温度控制在60℃以下(此时环氧树脂黏度最低)。
如此一来，将环氧树脂的粘度降至最低值，以使环氧树脂能够均匀、充分填充纤维材料，从而保证碳纤维复合材料扶手杆10的成型质量。
为保证碳纤维复合材料制品的固化度，结合双组份环氧树脂的DSC曲线，型材拉挤速度设置为80-90mm/min，开启拉挤模块104，按照预设得加热温度及牵引速度，纤维及树脂材料固化成型，在拉挤模块104的牵引下，型材被牵引出模具。
如此一来，在经过加工切断工艺后，即可制备出符合要求的碳纤维复合材料的管体11。
在一些实施例中，将外观层预浸料12铺贴至管体11上的步骤之前，还包括：
将胶膜铺贴至管体11的外表面；
通过第一无孔隔离膜包裹铺贴胶膜的管体11，并进行抽真空压实；
将第一无孔隔离膜去除。
可以理解的是，为了保证管体11外层的树脂量足够，可以在铺贴外观层预浸料12之前，铺贴一层胶膜。
当然，根据实际需要，在铺贴胶膜之前，还包括对截取好的碳纤维复合材料的管体11进行表面打磨处理。具体地，首先将碳纤维复合材料的管体11夹持固定在打磨工装上，使用目数为120左右的砂纸对拉挤扶手杆10外表面进行粗磨，再使用目数200以上的砂纸对碳纤维复合材料的管体11外表面进行细磨，打磨至管体11外表面无光亮处，整体应顺滑，无凸点和毛刺存在，最后使用擦拭布和无水乙醇对其进行清洁，至管体11外表面无打磨粉尘和其他污染物。
之后，将按尺寸裁切好的胶膜铺贴在管体11的外表面(胶膜铺层数为1层)，胶膜对接处需留有一定的缝隙，且对接缝与管体11轴线平行，对接缝宽度不大于0.5mm，不允许出现胶膜搭接、褶皱、扭曲、异物夹杂等情况。
胶膜铺贴完成后，用第一无孔隔离膜包裹管体11，然后进行抽真空压实，抽真空压实时间≥15min，真空度≤-0.090MPa(在进行下一步操作前，需去除抽真空所用的第一无孔隔离膜)。
需要说明的是，外观层预浸料12背面贴有离型纸，正面贴有隔离膜，在铺贴时，先除去背面的离型纸，保留正面的隔离膜，将外观层预浸料12铺贴于胶膜表面之后，再除去外观层预浸料12正面的隔离膜。外观层预浸料12对接处需留有一定的缝隙，且对接缝必须与管体11轴线平行，对接缝宽度不大于0.3mm，不允许出现外观层预浸料12搭接、褶皱、扭曲、纤维错乱、异物夹杂等情况。
外观层预浸料12铺贴完成后，用第二无孔隔离膜13包裹管体11，进行抽真空压实，抽真空压实时间≥15min，真空度≤-0.090MPa。
在一些实施例中，将外观层预浸料12铺贴至管体11上的步骤之后，还包括：
对管体11上外观层预浸料12的表面状态进行检查；
确认管体11上外观层预浸料12的铺贴效果满足预设要求。
也就是说，用第二无孔隔离膜13包裹管体11，并在抽真空压实后，除去真空辅料(包括第二无孔隔离膜13在内)，观察外观层预浸料12的表面状态，确认外观层预浸料12无搭接、无褶皱、无扭曲、无纤维错乱、无管体11和胶膜裸露、无异物夹杂等情况。
在一些实施例中，在外观层预浸料12上包裹真空辅材，并进行加热固化的步骤包括：
通过第二无孔隔离膜13包裹铺贴外观层预浸料12的管体11，并保证第二无孔隔离膜13与外观层预浸料12紧密贴合，无外观层预浸料12裸露；
在第二无孔隔离膜13的外部铺设透气毡14和真空袋15，并进行抽真空及加热固化。
也就是说，在确认管体11上外观层预浸料12的铺贴效果满足预设要求后，还包括外观层固化前制袋和外观层固化。
外观层固化前制袋要求：制真空袋15过程中，不允许透气毡14与管体11发生直接接触，透气毡14与管体11之间距离需控制在30mm左右，第二无孔隔离膜13和真空袋15应整体顺滑，尽量减少真空辅料出现褶皱、扭曲等情况。
外观层固化：将制好袋的管体11在固化炉中进行固化成型，固化要求如下：
a.真空：全程抽真空直至固化过程结束，真空系统真空度≤-0.095MPa。过程结束后，停止抽真空，不卸负压。
b.温度：以空气温度为参考基准，以(90±5)℃/h的速度升温至(90±5)℃，并保温0.5h；继续以(90±5)℃/h的速度升温至(130±5)℃，并保温2.0h，保温结束后，以-(180±5)℃/h的速度降温至空气温度低于50℃，固化过程结束。
c.待空气温度降至室温后，拆卸连接管线，从固化炉中取出产品。
在外观层固化结束后，还包括对固化产品的后处理，具体包括：将碳纤维复合材料扶手杆10表面的真空辅材去除，清理四周飞边及残胶，不允许对产品表面造成敲击损伤和严重表面划伤。
本申请所提供的一种拉挤卷管成型系统，采用上述具体实施例所描述的拉挤卷管成型方法，包括碳纤维复合材料管体制备机构100和外观层卷管固化机构。其中：
碳纤维复合材料管体制备机构100包括预成型模具102、成型模具组件103和拉挤模块104。其中，预成型模具102用于将若干碳纤维料层卷制成碳纤维卷料，成型模具组件103用于将环氧树脂注射并浸润至碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材，拉挤模块104用于将加热固化后的型材拉挤制成碳纤维复合材料的管体11。
外观层卷管固化机构包括外观层铺贴模块、外观层加热固化模块和后处理模块。其中，外观层铺贴模块用于将外观层预浸料12铺贴至管体11上，外观层加热固化模块用于在外观层预浸料12上包裹真空辅材，并进行加热固化，后处理模块用于对加热固化后的管体11进行后处理制成碳纤维复合材料的扶手杆10。
进一步地，成型模具组件103包括注胶模具1031和成型模具1032，其中，注胶模具1031用于将环氧树脂注射并浸润至碳纤维卷料中，成型模具1032与注胶模具1031为一体式结构，成型模具1032用于对浸润环氧树脂的碳纤维卷料进行加热固化，以制成碳纤维复合材料的型材。其中，成型模具1032由上模板、下模板组成，为使模具具有一定的热容，保证加热均匀、稳定，成型模具1032的横截面设计为拉挤制品横截面积的10倍。
拉挤模块104可以包括一个牵引单元1041或者至少两个牵引单元1041，比如设置两个牵引单元1041，两个牵引单元1041用于以相应的牵引速度牵引管体11移动。
此外，碳纤维复合材料管体制备机构100还包括料架101和切割模块105，料架101用于向预成型模具102输送碳纤维料层，切割模块105设于碳纤维复合材料管体制备机构100的末端，切割模块105用于切断由拉挤模块104拉挤出的管体11。
需要说明的是，在本说明书中，诸如第一和第二之类的关系术语仅仅用来将一个实体与另外几个实体区分开来，而不一定要求或者暗示这些实体之间存在任何这种实际的关系或者顺序。
以上对本申请所提供的拉挤卷管成型方法和拉挤卷管成型系统进行了详细介绍。本文中应用了具体个例对本申请的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本申请的方案及其核心思想。应当指出，对于本技术领域的普通技术人员来说，在不脱离本申请原理的前提下，还可以对本申请进行若干改进和修饰，这些改进和修饰也落入本申请权利要求的保护范围内。

Claims (10)

  1. 一种拉挤卷管成型方法，其特征在于，包括：
    将若干碳纤维料层卷制成碳纤维卷料；
    将环氧树脂注射并浸润至所述碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材；
    将加热固化后的所述型材拉挤制成碳纤维复合材料的管体；
    将外观层预浸料铺贴至所述管体上；
    在所述外观层预浸料上包裹真空辅材，并进行加热固化；
    对加热固化后的所述管体进行后处理制成碳纤维复合材料的扶手杆。
  2. 如权利要求1所述的拉挤卷管成型方法，其特征在于，所述将若干碳纤维料层卷制成碳纤维卷料的步骤之前，包括：
    将碳纤维材料铺设至若干布料上制成若干碳纤维料层，所述若干碳纤维料层包括1200克重四轴向碳纤维布、1000克重碳纤维单向布以及1000克重四轴向碳纤维布。
  3. 如权利要求1所述的拉挤卷管成型方法，其特征在于，所述将环氧树脂注射并浸润至所述碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材的步骤，包括：
    将固化剂和促进剂的混合液以及环氧树脂分别注射并浸润至所述碳纤维卷料中；
    将所述碳纤维卷料分别经过三段加热区域进行加热固化，且所述三段加热区域的温度依次递增。
  4. 如权利要求3所述的拉挤卷管成型方法，其特征在于，所述将固化剂和促进剂的混合液以及环氧树脂分别注射并浸润至所述碳纤维卷料中的步骤之前，还包括：
    通过水冷设备将固化剂和促进剂的混合液以及环氧树脂的注射温度控制在60℃以下，以将环氧树脂的粘度降至预设低值。
  5. 如权利要求1-4任意一项所述的拉挤卷管成型方法，其特征在于，所述将外观层预浸料铺贴至所述管体上的步骤之前，还包括：
    将胶膜铺贴至所述管体的外表面；
    通过第一无孔隔离膜包裹铺贴所述胶膜的所述管体，并进行抽真空压实；
    将所述第一无孔隔离膜去除。
  6. 如权利要求1-4任意一项所述的拉挤卷管成型方法，其特征在于，所述将外观层预浸料铺贴至所述管体上的步骤之后，还包括：
    对所述管体上外观层预浸料的表面状态进行检查；
    确认所述管体上外观层预浸料的铺贴效果满足预设要求。
  7. 如权利要求1-4任意一项所述的拉挤卷管成型方法，其特征在于，所述在所述外观层预浸料上包裹真空辅材，并进行加热固化的步骤包括：
    通过第二无孔隔离膜包裹铺贴所述外观层预浸料的所述管体，并保证所述第二无孔隔离膜与所述外观层预浸料紧密贴合，无所述外观层预浸料裸露；
    在所述第二无孔隔离膜的外部铺设透气毡和真空袋，并进行抽真空及加热固化。
  8. 一种拉挤卷管成型系统，采用如权利要求1-7任意一项所述的拉挤卷管成型方法，其特征在于，包括碳纤维复合材料管体制备机构和外观层卷管固化机构，所述碳纤维复合材料管体制备机构包括：
    预成型模具，用于将若干碳纤维料层卷制成碳纤维卷料；
    成型模具组件，用于将环氧树脂注射并浸润至所述碳纤维卷料中，并进行加热固化制成碳纤维复合材料的型材；
    拉挤模块，用于将加热固化后的所述型材拉挤制成碳纤维复合材料的管体；
    所述外观层卷管固化机构包括：
    外观层铺贴模块，用于将外观层预浸料铺贴至所述管体上；
    外观层加热固化模块，用于在所述外观层预浸料上包裹真空辅材，并进行加热固化；
    后处理模块，用于对加热固化后的所述管体进行后处理制成碳纤维复合材料的扶手杆。
  9. 如权利要求8所述的拉挤卷管成型系统，其特征在于，所述成型模具组件包括：
    注胶模具，用于将环氧树脂注射并浸润至所述碳纤维卷料中；
    成型模具，与所述注胶模具为一体式结构，用于对浸润环氧树脂的所述碳纤维卷料进行加热固化，以制成碳纤维复合材料的型材。
  10. 如权利要求8所述的拉挤卷管成型系统，其特征在于，所述碳纤维复合材料管体制备机构还包括：
    料架，用于向所述预成型模具输送碳纤维料层；
    切割模块，用于切断由所述拉挤模块拉挤出的管体。
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