CN111844521A - Melt impregnation device and preparation method of continuous fiber reinforced thermoplastic prepreg tape - Google Patents

Abstract

The invention provides a melting and dipping device and a preparation method of a continuous fiber reinforced thermoplastic prepreg tape, wherein the device comprises a creel, a filament dividing system, a heating system, a dipping system, a plurality of homogenizing rollers, a polishing roller and a drawing system which are sequentially arranged, the heating system comprises a heating channel and a plurality of electric heating blowers, the dipping system comprises a dipping roller, an extrusion porous neck mold and an extruder, the extrusion porous neck mold is arranged below the dipping roller and comprises an arc porous neck mold I and an arc porous neck mold II, a shallow cavity is formed by matching the arc porous neck mold I and a groove of the dipping roller, and the extruder is communicated with the arc porous neck mold II; the fiber belt which is drawn by the drawing system and enters the filament separating system bypasses from the upper part of the impregnation roller, and the fiber belt which bypasses the impregnation roller enters a space between the power roller pairs to form the prepreg belt after passing through the plurality of homogenizing rollers. The invention realizes the impregnation of the high-viscosity polyether ether ketone resin melt on the continuous fiber bundle, and simultaneously ensures the fiber impregnation degree of the impregnation belt and the preparation continuity.

Description

Translated fromChinese

连续纤维增强热塑性预浸带的熔融浸渍装置与制备方法Melt impregnation device and preparation method of continuous fiber reinforced thermoplastic prepreg tape

技术领域technical field

本发明属于连续纤维增强热塑性复合材料领域，尤其是涉及一种连续纤维增强热塑性预浸带的熔融浸渍装置与制备方法。The invention belongs to the field of continuous fiber reinforced thermoplastic composite materials, in particular to a melt impregnation device and a preparation method of a continuous fiber reinforced thermoplastic prepreg tape.

背景技术Background technique

连续碳纤维增强热塑性复合材料在制备工艺与成型速率方面具有明显的优势，如可直接熔融焊接、成型速率高(热固性复合材料的10倍以上)、优异的断裂韧性、高力学性能、可回收利用、不易燃烧、发烟率与毒性低以及可以室温长期储存等，在航空航天、汽车等工业得到快速的应用发展。近几年来，热塑性复合材料在商业航空器领域的应用出现新的转折点，即热塑性复合材料已被用于大尺寸的航空部件(如机舱)的制备，这将对商业航空器的发展起到重要的促进作用。Continuous carbon fiber reinforced thermoplastic composites have obvious advantages in preparation process and molding rate, such as direct fusion welding, high molding rate (more than 10 times that of thermoset composites), excellent fracture toughness, high mechanical properties, recyclability, It is not easy to burn, has low smoke rate and toxicity, and can be stored at room temperature for a long time. It has been rapidly applied and developed in aerospace, automobile and other industries. In recent years, there has been a new turning point in the application of thermoplastic composites in the field of commercial aircraft, that is, thermoplastic composites have been used in the preparation of large-scale aviation components (such as cabins), which will play an important role in the development of commercial aircraft. effect.

航空航天用热塑性碳纤维复合材料主要为连续碳纤维增强聚醚醚酮类高性能树脂(如聚醚醚酮、聚醚酮酮等)复合材料或连续碳纤维增强聚亚苯基硫醚类高性能树脂复合材料，该类热塑性树脂体系同通用树脂不同，熔融温度高，且熔体粘度大，对纤维的熔融浸渍极其困难，制约了相应预浸带的制备。现有的热塑性预浸带(材料)浸渍装置与制备方法，主要是通过胶槽浸渍纤维束，浸胶或非浸胶纤维直接在金属辊或浸渍模具表面产生相对运动来实现预浸带的制备，但会出现纤维无法将胶槽内树脂完全带走，剩余树脂在持续高温下回发生降解，导致材料性能下降，同时降解树脂(如碳化)也会影响对纤维的浸渍；而纤维与金属辊或模具表面发生相对运动，由于聚醚醚酮类树脂熔体或聚亚苯基硫醚类树脂熔体粘度高，该类相对运动会导致纤维与树脂熔体产生较大的剪切力，并可能带来纤维损伤、断裂等问题。Aerospace thermoplastic carbon fiber composite materials are mainly continuous carbon fiber reinforced polyether ether ketone high-performance resin (such as polyether ether ketone, polyether ketone ketone, etc.) composite material or continuous carbon fiber reinforced polyphenylene sulfide high-performance resin composite. This kind of thermoplastic resin system is different from general resins, with high melting temperature and high melt viscosity, and it is extremely difficult to melt and impregnate fibers, which restricts the preparation of corresponding prepreg tapes. Existing thermoplastic prepreg tape (material) impregnation device and preparation method mainly realizes the preparation of prepreg tape by impregnating fiber bundles in a glue tank, and dipping or non-dipping fibers directly produce relative motion on the surface of a metal roller or an impregnating mold , but it will appear that the fiber cannot completely take away the resin in the glue tank, and the remaining resin will degrade under continuous high temperature, resulting in a decrease in material properties, and the degraded resin (such as carbonization) will also affect the impregnation of the fiber; while the fiber and the metal roller Or relative motion occurs on the surface of the mold. Due to the high viscosity of the polyether ether ketone resin melt or the polyphenylene sulfide resin melt, such relative motion will cause a large shear force between the fiber and the resin melt, and may Bring about fiber damage, breakage and other problems.

因此，有必要设计一种新型的浸渍装置，并基于该装置发展一种针对高温高熔融粘度树脂熔体热塑性的连续纤维预浸带制备方法来避免利用胶槽浸渍纤维束，以及避免浸胶或非浸胶纤维直接在金属辊或浸渍模具表面产生相对运动。Therefore, it is necessary to design a new type of impregnation device, and based on the device to develop a continuous fiber prepreg tape preparation method for high temperature and high melt viscosity resin melt thermoplastic to avoid the use of glue tanks to impregnate fiber bundles, and to avoid dipping or The relative motion of the non-impregnated fibers occurs directly on the surface of the metal roll or dipping die.

发明内容SUMMARY OF THE INVENTION

有鉴于此，针对聚醚醚酮类或聚亚苯基硫醚类热塑性树脂熔体粘度高、难于浸渍纤维的问题，本发明旨在提出一种连续纤维增强热塑性预浸带的熔融浸渍装置与制备方法，通过控制树脂在浸渍辊均匀涂覆、在纤维张力作用下实现树脂熔体浸渍纤维、均化辊提高纤维与树脂分布、上光辊固化成型的预浸带。In view of this, in view of the problems of high melt viscosity of polyether ether ketone or polyphenylene sulfide thermoplastic resin and difficulty in impregnating fibers, the present invention aims to provide a melt impregnation device and a continuous fiber reinforced thermoplastic prepreg tape. The preparation method comprises the following steps: controlling resin to be uniformly coated on an impregnating roller, impregnating fibers with resin melt under the action of fiber tension, improving the distribution of fibers and resins by a homogenizing roller, and curing a prepreg tape formed by a glazing roller.

为达到上述目的，本发明的技术方案是这样实现的：In order to achieve the above object, the technical scheme of the present invention is achieved in this way:

一种连续纤维增强热塑性预浸带的熔融浸渍装置，包括依次设置的纱架、分丝系统、加热系统、浸渍系统、若干均化辊、上光辊和牵拉系统，A melt impregnation device for continuous fiber reinforced thermoplastic prepreg tape, comprising a creel, a yarn splitting system, a heating system, an impregnation system, a plurality of homogenizing rollers, a glazing roller and a drawing system arranged in sequence,

所述的加热系统包括升温通道和若干电热吹风机，若干电热吹风机均匀分布在升温通道的上下方，在升温通道内对应每一电热吹风机处设有一热电偶，所述热电偶检测升温通道内的风温；The heating system includes a heating channel and a plurality of electric heating blowers, the plurality of electric heating hair dryers are evenly distributed above and below the heating channel, and a thermocouple is arranged in the heating channel corresponding to each electric heating blower, and the thermocouple detects the wind in the heating channel. temperature;

所述的浸渍系统包括浸渍辊、挤出多孔口模和与连接挤出多孔口模的挤出机，所述的挤出多孔口模设置在浸渍辊的下方，浸渍辊表面设有凹槽，浸渍辊通过传动轴与电机连接，所述的挤出多孔口模包括一体成型的且上下布置的弧形多孔口模一和弧形多孔口模二，所述的弧形多孔口模一与浸渍辊的凹槽之间形成浅腔，所述的挤出机经由挤出机连接管与弧形多孔口模二连通；The dipping system includes a dipping roll, an extrusion porous die and an extruder connected to the extrusion porous die, the extrusion porous die is arranged below the dipping roll, and the surface of the dipping roll is provided with grooves, The dipping roller is connected to the motor through a transmission shaft. The extrusion porous die includes an arc-shaped porous die 1 and an arc-shapedporous die 2 which are integrally formed and arranged up and down. The arc-shaped porous die 1 and the impregnation die A shallow cavity is formed between the grooves of the roller, and the extruder is communicated with the second arc-shaped porous die through the extruder connecting pipe;

若干均化辊平行布置，所述均化辊低于浸渍辊的中心布置，所述上光辊为动力对辊，包括上下布置且配合使用的凹辊和凸辊，凹辊上设有容纳预浸带的凹槽，凹辊的凹槽与凸辊的凸起配合，动力对辊的两端通过弹簧提供辊间压力；Several homogenizing rollers are arranged in parallel, the homogenizing roller is arranged below the center of the dipping roller, the glazing roller is a power pair of rollers, including a concave roller and a convex roller arranged up and down and used together. The grooves of the dip belt, the grooves of the concave rollers are matched with the protrusions of the convex rollers, and the power provides the inter-roller pressure to the two ends of the rollers through springs;

牵拉系统牵拉自纱架退纱进入分丝系统后的纤维带在穿过升温通道后自浸渍辊的上方绕过，绕过浸渍辊的纤维带经过多个均化辊后进入动力对辊之间成型预浸带。The fiber tape drawn by the pulling system after unwinding from the creel and entering the spinning system passes through the heating channel and bypasses the dipping roller. Forming prepreg tapes between.

进一步的，所述弧形多孔口模二与弧形多孔口模一由多孔钢板隔开，且弧形多孔口模一的上表面也为多孔钢板。Further, the second arc-shaped porous die and the first arc-shaped porous die are separated by a porous steel plate, and the upper surface of the first arc-shaped porous die is also a porous steel plate.

进一步的，所述浸渍辊和所有均化辊均为能调速、控温的动力辊。Further, the dipping roll and all homogenizing rolls are power rolls capable of speed regulation and temperature control.

进一步的，在浸渍辊和均化辊的外围设有降低浸渍辊与均化辊散热的保温系统，所述保温系统为由陶瓷纤维毯制成的保温箱。Further, an insulation system for reducing the heat dissipation of the dipping roll and the homogenizing roll is provided on the periphery of the dipping roll and the homogenizing roll, and the insulation system is an insulation box made of a ceramic fiber blanket.

进一步的，所述纱架前端设有对纤维束提供预张力的预张力装置。Further, the front end of the creel is provided with a pretension device for providing pretension to the fiber bundle.

进一步的，所述均化辊表面进行抛光镀铬镜面处理，所述上光辊上设有冷却结构。Further, the surface of the homogenizing roller is polished and chrome-plated and mirror-finished, and the glazing roller is provided with a cooling structure.

进一步的，在弧形多孔口模的底部包裹有加热套。Further, a heating jacket is wrapped around the bottom of the arc-shaped porous die.

一种利用上述熔融浸渍装置制备连续纤维增强热塑性预浸带的方法，具体包括以下步骤：A method for preparing a continuous fiber reinforced thermoplastic prepreg tape utilizing the above-mentioned melt impregnation device, specifically comprising the following steps:

步骤一、多束纤维束以一定预张力下从纱架退纱后进入分丝系统，分丝系统将纤维束分丝成厚度均一宽度恒定的纤维带；Step 1. The multi-strand fiber bundles are withdrawn from the creel under a certain pre-tension and then enter the spinning system, and the spinning system divides the fiber bundles into fiber ribbons with uniform thickness and constant width;

步骤二、纤维带进入加热系统，纤维带升温至浸渍温度，纤维带由牵拉系统牵拉进入浸渍系统；Step 2, the fiber belt enters the heating system, the fiber belt is heated to the impregnation temperature, and the fiber belt is pulled by the pulling system into the impregnation system;

步骤三、挤出机将树脂熔体挤入弧形多孔口模二，随着挤入树脂熔体量的增多，弧形多孔口模二内的树脂熔体经孔进入弧形多孔口模一内，弧形多孔口模一内的树脂熔体经孔进入浸渍辊浅腔，随着浸渍辊的转动，树脂熔体均匀地涂覆在浸渍辊的凹槽的表面；步骤二中加热后的具有一定预张力的纤维带以一定包角通过浸渍辊，在纤维束的预张力作用下，浸渍辊的凹槽表面的树脂熔体被挤入纤维带内，成型预成型预浸带；Step 3: The extruder extrudes the resin melt into the second arc-shaped porous die. With the increase of the amount of resin melt extruded, the resin melt in the second arc-shaped porous die enters the second arc-shaped porous die through the hole. Inside, the resin melt in the arc-shaped porous die 1 enters the shallow cavity of the impregnating roller through the hole, and as the impregnating roller rotates, the resin melt is uniformly coated on the surface of the groove of the impregnating roller; The fiber tape with a certain pretension passes through the impregnating roller with a certain wrap angle, and under the pretension of the fiber bundle, the resin melt on the surface of the groove of the impregnating roller is extruded into the fiber tape, and the preformed prepreg tape is formed;

步骤四、预成型预浸带继续被牵拉系统以一定的包角通过若干均化辊，使纤维束与树脂熔体均匀分布；经过若干均化辊后的预成型预浸带进一步被牵拉通过上光辊，预浸带成型；通过牵拉系统牵拉、收卷成型连续纤维增强热塑性预浸带。Step 4. The preformed prepreg tape is continuously drawn by the system to pass through several homogenizing rollers at a certain wrapping angle, so that the fiber bundles and the resin melt are evenly distributed; the preformed prepreg tape after passing through several homogenizing rollers is further drawn. The prepreg tape is formed by the glazing roller; the continuous fiber reinforced thermoplastic prepreg tape is drawn and wound by the drawing system.

进一步的，所述步骤一中，经分丝系统分散后的纤维带的宽度与浸渍辊凹槽宽度一致，分纱后纤维带厚度控制在0.02mm-1mm，单根纤维束的预张力在0.1N至50N。Further, in thestep 1, the width of the fiber tape dispersed by the spinning system is consistent with the groove width of the dipping roll, the thickness of the fiber tape after spinning is controlled at 0.02mm-1mm, and the pretension of a single fiber bundle is 0.1 mm. N to 50N.

进一步的，所述步骤二中，纤维带通过加热系统温度升至360℃-450℃后进入浸渍系统。Further, in the second step, the temperature of the fiber tape is raised to 360°C-450°C through the heating system and then enters the impregnation system.

相对于现有技术，本发明所述的连续纤维增强热塑性预浸带的熔融浸渍装置具有以下优势：Compared with the prior art, the melt impregnation device of the continuous fiber reinforced thermoplastic prepreg tape of the present invention has the following advantages:

1)高粘度聚醚醚酮类树脂熔体或聚亚苯基硫醚类树脂熔体均匀涂覆在动力浸渍辊表面，一定预张力的纤维束以一定包角缠绕其上，并随着浸渍辊的转动通过浸渍辊，纤维被树脂熔体的浸渍力来自于纤维带与浸渍辊间形成的压力。本发明避免纤维束与高粘度树脂熔体在牵拉方向的较高的相对剪切力，避免纤维的损伤，以及由此带来的浸渍过程的不连续性。1) The high viscosity polyether ether ketone resin melt or polyphenylene sulfide resin melt is uniformly coated on the surface of the dynamic impregnating roller, and the fiber bundle with a certain pretension is wound on it at a certain wrapping angle, and is impregnated with the impregnation. The rotation of the roll passes through the impregnation roll, and the impregnation force of the fiber by the resin melt comes from the pressure formed between the fiber belt and the impregnation roll. The invention avoids the relatively high relative shearing force between the fiber bundle and the high-viscosity resin melt in the drawing direction, and avoids the damage of the fiber and the discontinuity of the impregnation process caused thereby.

2)在浸渍辊表面的高粘度树脂熔体膜全部浸渍入纤维带内，其厚度可以通过牵拉速度与挤出速度准确控制，从而实现了对预浸带纤维含量的准确控制，同时避免树脂的浪费，以及避免未浸渍纤维树脂在高温下的降解，影响预浸带质量及浸渍过程的连续性。2) The high-viscosity resin melt film on the surface of the impregnating roller is completely impregnated into the fiber tape, and its thickness can be accurately controlled by the pulling speed and extrusion speed, so as to achieve accurate control of the fiber content of the prepreg tape, while avoiding resin waste, and to avoid the degradation of the unimpregnated fiber resin at high temperature, which affects the quality of the prepreg tape and the continuity of the impregnation process.

3)本申请实现高粘度聚醚醚酮类树脂熔体或聚亚苯基硫醚类树脂熔体对连续纤维束的浸渍，同时保证浸渍带的纤维浸渍程度与制备的连续性。3) The present application realizes the impregnation of continuous fiber bundles by high-viscosity polyetheretherketone resin melt or polyphenylene sulfide resin melt, while ensuring the degree of fiber impregnation of the impregnating tape and the continuity of preparation.

附图说明Description of drawings

构成本发明的一部分的附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。在附图中：The accompanying drawings constituting a part of the present invention are used to provide further understanding of the present invention, and the exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the attached image:

图1为本发明实施例所述的一种连续纤维增强热塑性预浸带的熔融浸渍装置的结构示意图；1 is a schematic structural diagram of a melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape according to an embodiment of the present invention;

图2为本发明实施例所述的一种连续纤维增强热塑性预浸带的熔融浸渍装置的工作原理图；Fig. 2 is the working principle diagram of a melt impregnation device of a continuous fiber reinforced thermoplastic prepreg tape according to an embodiment of the present invention;

图3为本发明的电吹风加热系统的结构示意图；3 is a schematic structural diagram of the hair dryer heating system of the present invention;

图4为本发明中浸渍系统的结构示意图；Fig. 4 is the structural representation of the impregnation system in the present invention;

图5为图4的A-A向剖视图；Fig. 5 is A-A sectional view of Fig. 4;

图6为本发明中上光棍的结构示意图。FIG. 6 is a schematic structural diagram of an upper bachelor in the present invention.

附图标记说明：Description of reference numbers:

1-纱架，2-分丝系统，3-加热系统，31-电热吹风机，32-升温通道，33-热电偶，4-浸渍系统，41-浸渍辊，411-传动轴，42-挤出多孔口模，421-弧形多孔口模一，422-弧形多孔口模二，423-加热套，43-挤出机，431-挤出机连接管，44-浅腔，45-树脂熔体，46-传动轴，5-均化辊，6-上光辊，61-凹辊，62-凸辊，63-弹簧，7-牵拉系统，8-保温系统，9-预浸带，10-树脂熔体。1- Creel, 2- Spinning system, 3- Heating system, 31- Electric blower, 32- Heating channel, 33- Thermocouple, 4- Dip system, 41- Dip roller, 411- Drive shaft, 42- Extrusion Porous Die, 421-Arc Porous Die 1, 422-Arc Porous Die 2, 423- Heating Jacket, 43- Extruder, 431- Extruder Connecting Pipe, 44- Shallow Cavity, 45- Resin Melt body, 46-drive shaft, 5-homogenizing roll, 6-glazing roll, 61-concave roll, 62-convex roll, 63-spring, 7-pulling system, 8-insulation system, 9-prepreg belt, 10 - Resin melt.

具体实施方式Detailed ways

需要说明的是，在不冲突的情况下，本发明中的实施例及实施例中的特征可以相互组合。It should be noted that the embodiments of the present invention and the features of the embodiments may be combined with each other under the condition of no conflict.

下面将参考附图并结合实施例来详细说明本发明。The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

如图1-图6所示，一种连续纤维增强热塑性预浸带的熔融浸渍装置，包括依次设置的纱架1、分丝系统2、加热系统3、浸渍系统4、若干均化辊5、上光辊6和牵拉系统7，在所述纱架1前端设有对纤维束提供预张力的预张力装置，能够控制纤维束退纱后的张力；所述的分丝系统2，通过分丝辊或吹风等方法能够将多束纤维均匀分散成厚度均一的纤维带，分丝后的纤维带厚度可以控制在0.02–1mm；As shown in Fig. 1-Fig. 6, a melt impregnation device for continuous fiber reinforced thermoplastic prepreg tape includes acreel 1, aspinning system 2, aheating system 3, animpregnation system 4, a plurality of homogenizing rollers 5, Theglazing roller 6 and the drawing system 7 are provided with a pre-tensioning device that provides pre-tensioning to the fiber bundles at the front end of thecreel 1, which can control the tension after the fiber bundles are withdrawn; Multi-strand fibers can be uniformly dispersed into fiber ribbons of uniform thickness by methods such as silk rollers or air blowing.

所述的加热系统3包括升温通道32和若干电热吹风机31，若干电热吹风机31均匀分布在升温通道32的上下方，在升温通道32内对应每一电热吹风机31处设有一热电偶33，所述热电偶33检测升温通道32内的风温；利用电热吹风机31在升温通道32内对分散好的连续纤维带上下面进行加热，风温通过热电偶33测试，并通过调整风速大小调控纤维束加热温度，对通过的纤维带加热至360℃-450℃，控温精度为±1℃；Theheating system 3 includes aheating channel 32 and a plurality ofelectric heating blowers 31. The plurality of electricheating hair dryers 31 are evenly distributed above and below theheating channel 32. Athermocouple 33 is provided in theheating channel 32 corresponding to eachelectric heating blower 31. Thethermocouple 33 detects the air temperature in theheating channel 32; theelectric heating blower 31 is used to heat the upper and lower surfaces of the dispersed continuous fiber belt in theheating channel 32, the wind temperature is tested by thethermocouple 33, and the heating of the fiber bundle is regulated by adjusting the wind speed. Temperature, heating the passing fiber tape to 360℃-450℃, the temperature control accuracy is ±1℃;

所述的浸渍系统4包括浸渍辊41、挤出多孔口模42和与连接挤出多孔口模的挤出机43，所述的挤出多孔口模42设置在浸渍辊41的下方，浸渍辊41表面设有凹槽，浸渍辊41通过传动轴411与电机连接，所述的挤出多孔口模42包括一体成型的且上下布置的弧形多孔口模一421和弧形多孔口模二422，所述的弧形多孔口模一421与浸渍辊41的凹槽之间形成浅腔44，浅腔44的深度0.05mm至1mm，通过调整挤出多孔口模42高度来调节浅腔的深度，也即控制了浸渍辊表面涂覆树脂熔体的厚度，所述的挤出机43经由挤出机连接管431与弧形多孔口模二422连通；在弧形多孔口模2的底部包裹有加热套423；Thedipping system 4 includes a dippingroll 41, an extrusion perforated die 42 and anextruder 43 connected with the extrusion perforated die. The extrusion perforated die 42 is arranged below the dippingroll 41. The dipping roll The surface of 41 is provided with grooves, the dippingroller 41 is connected to the motor through thetransmission shaft 411, and the extrusionporous die 42 includes an arc-shapedporous die 1 421 and an arc-shapedporous die 2 422 that are integrally formed and arranged up and down. , ashallow cavity 44 is formed between the arc-shapedporous die 1 421 and the groove of the dippingroller 41, the depth of theshallow cavity 44 is 0.05mm to 1mm, and the depth of the shallow cavity is adjusted by adjusting the height of the extrusionporous die 42 , that is, the thickness of the resin melt coated on the surface of the dipping roll is controlled, and theextruder 43 communicates with the arc-shapedporous die 2 422 via the extruder connecting pipe 431; wrapping at the bottom of the arc-shapedporous die 2 Withheating jacket 423;

若干均化辊5等高平行布置，所述均化辊5低于浸渍辊41的中心布置，所述上光辊6为动力对辊，包括上下布置且配合使用的凹辊61和凸辊62，凹辊61上设有容纳预浸带的凹槽，凹辊61的凹槽与凸辊62的凸起配合，动力对辊的两端通过弹簧63提供辊间压力；Several homogenizing rollers 5 are arranged in parallel at the same height, the homogenizing roller 5 is arranged below the center of the dippingroller 41, theglazing roller 6 is a power pair of rollers, including aconcave roller 61 and aconvex roller 62 arranged up and down and used together , theconcave roller 61 is provided with a groove for accommodating the prepreg tape, the groove of theconcave roller 61 is matched with the protrusion of theconvex roller 62, and the power provides the pressure between the rollers through the spring 63 at both ends of the roller;

牵拉系统7牵拉自纱架1退纱进入分丝系统5后的纤维带在穿过升温通道32后自浸渍辊41的上方绕过，绕过浸渍辊41的纤维带以S型绕制方式经过两个均化辊5后伸入动力对辊之间成型预浸带9。The fiber tape drawn by the pulling system 7 after unwinding from thecreel 1 and entering the spinning system 5 passes through theheating channel 32 and bypasses the top of the dippingroll 41, and the fiber tape that passes around the dippingroll 41 is wound in an S shape After passing through the two homogenizing rollers 5, theprepreg tape 9 is formed between the pair of powered rollers.

所述弧形多孔口模二422与弧形多孔口模一421由多孔钢板隔开，且弧形多孔口模一421的上表面也为多孔钢板，弧形多孔口模的孔隙直径为0.01mm-1mm，密度为1个-100个/mm²，两个弧形多孔口模确保挤出的聚醚醚酮类树脂熔体或聚亚苯基硫醚类树脂熔体在沿着浸渍辊表面均匀挤出，并涂覆在浸渍辊凹槽表面，通过调节挤出速率与浸渍辊转速，调控树脂涂层在浸渍辊凹槽表面的厚度在0.02-1mm。挤出多孔口模42是由从上到下布置的三块弧形钢板围成，且三块弧形钢板的边侧通过水平连接板连接密封，从上到下的第一块弧形钢板上和第二块弧形钢板上都均匀开设多个孔，用于挤出树脂熔体。The arc-shapedporous die 2 422 and the arc-shaped porous die-1 421 are separated by a porous steel plate, and the upper surface of the arc-shapedporous die 1 421 is also a porous steel plate, and the pore diameter of the arc-shaped porous die is 0.01mm. -1mm, the density is 1-100/mm² , two arc-shaped perforated dies ensure that the extruded polyether ether ketone resin melt or polyphenylene sulfide resin melt is along the surface of the dipping roll It is uniformly extruded and coated on the surface of the groove of the dipping roll. By adjusting the extrusion rate and the speed of the dipping roll, the thickness of the resin coating on the surface of the groove of the dipping roll is adjusted to 0.02-1mm. The extrusion perforated die 42 is surrounded by three arc-shaped steel plates arranged from top to bottom, and the sides of the three arc-shaped steel plates are connected and sealed by horizontal connecting plates. And a plurality of holes are evenly opened on the second arc-shaped steel plate for extruding the resin melt.

所述浸渍辊41和所有均化辊5均为能调速、控温的动力辊，浸渍辊41和均化辊5均为电加热方式进行加热；浸渍辊41的速度控制在转速0.2转/分钟-20转/分钟；同时浸渍辊41表面温度控制在360℃-450℃，温度变化小于1℃；均化辊5设置两个或多个，所述均化辊5表面进行抛光镀铬镜面处理，处理后的表面硬度在800-1200HV之间；均化辊5的转速控制为0.2转/分钟-20转/分钟，温度控制为360℃-450℃，控制精度±1℃；通过调整均化辊5的纵向位置，改变预浸带对浸渍辊41与均化辊5的包角。The dippingroll 41 and all the homogenizing rolls 5 are power rolls capable of speed regulation and temperature control. The dippingroll 41 and the homogenizing roll 5 are heated by electric heating; the speed of the dippingroll 41 is controlled at a speed of 0.2 rpm/ min-20 r/min; at the same time, the surface temperature of the dippingroller 41 is controlled at 360°C-450°C, and the temperature change is less than 1°C; two or more homogenizing rollers 5 are provided, and the surface of the homogenizing roller 5 is polished and chrome-plated and mirrored , the surface hardness after treatment is between 800-1200HV; the rotation speed of the homogenizing roller 5 is controlled at 0.2 r/min-20 r/min, the temperature is controlled at 360°C-450°C, and the control accuracy is ±1°C; by adjusting the homogenization The longitudinal position of the roll 5 changes the wrapping angle of the prepreg tape to the dippingroll 41 and the homogenizing roll 5 .

在浸渍辊41和均化辊5的外围设有保温系统8，所述保温系统8为由陶瓷纤维毯制成的保温箱，将浸渍辊4、均化辊5整体封闭，降低高温浸渍辊4与均化辊5的散热，外层保温材料的温度低于50℃。Aninsulation system 8 is provided on the periphery of the dippingroll 41 and the homogenizing roll 5. Theinsulation system 8 is a thermal insulation box made of ceramic fiber blankets. With the heat dissipation of the homogenizing roller 5, the temperature of the outer layer of thermal insulation material is lower than 50°C.

上光辊6的辊表面经电镀硬化与镜面处理，处理后的表面硬度在800-1200HV之间；对辊间压力通过两端弹簧张力控制，张力大小10N-1000N；均化辊的转速控制为0.2转/分钟-20转/分钟，所述上光辊6上设有水冷冷却结构，具体为：动力对辊内通水冷却，控制温度小于100℃。The surface of theglazing roller 6 is electroplated and hardened and mirror-treated, and the surface hardness after treatment is between 800-1200HV; the pressure between the rollers is controlled by the spring tension at both ends, and the tension is 10N-1000N; the speed of the homogenizing roller is controlled as 0.2 r/min-20 r/min, theglazing roller 6 is provided with a water-cooling cooling structure, specifically: water cooling in the power pair of rollers, and the control temperature is less than 100°C.

牵引系统7以0.1-5m/min速度稳定将成型的预浸带牵拉出来。The pulling system 7 stably pulls the formed prepreg tape out at a speed of 0.1-5 m/min.

一种利用上述熔融浸渍装置制备连续纤维增强热塑性预浸带的方法，具体包括以下步骤：A method for preparing a continuous fiber reinforced thermoplastic prepreg tape utilizing the above-mentioned melt impregnation device, specifically comprising the following steps:

步骤一、多束纤维束以一定预张力下从纱架1退纱后进入分丝系统2，分丝系统2将纤维束分丝成厚度均一宽度恒定的纤维带；经分丝系统2分散后的纤维带的宽度与浸渍辊41的凹槽宽度一致，分纱后纤维带厚度控制在0.02mm-1mm，单根纤维束的预张力在0.1N至50N；Step 1. The multi-strand fiber bundles enter theyarn splitting system 2 after unwinding from thecreel 1 under a certain pretension. The width of the fiber belt is consistent with the groove width of the dippingroller 41, the thickness of the fiber belt after yarn separation is controlled at 0.02mm-1mm, and the pretension of a single fiber bundle is 0.1N to 50N;

步骤二、纤维带进入加热系统3，纤维带通过加热系统3温度升至360℃-450℃后由牵拉系统7牵拉进入浸渍系统4；Instep 2, the fiber tape enters theheating system 3, and the fiber tape passes through theheating system 3 and the temperature rises to 360°C-450°C and then is pulled by the pulling system 7 into theimpregnation system 4;

步骤三、挤出机43将聚醚醚酮类树脂熔体挤入弧形多孔口模二422，随着挤入聚醚醚酮类树脂熔体量的增多，弧形多孔口模二422内的树脂熔体经孔进入弧形多孔口模一421内，弧形多孔口模一421内的树脂熔体经孔进入浸渍辊浅腔44，随着浸渍辊41的转动，树脂熔体43均匀地涂覆在浸渍辊41的凹槽的表面；步骤二中加热后的具有一定预张力的纤维带以一定包角通过浸渍辊41，一定张力的纤维带与表面涂覆一定厚度聚醚醚酮类树脂膜的浸渍辊间形成垂直于纤维束的径向压力，在该压力作用下，浸渍辊41的凹槽表面的树脂熔体43被挤入纤维带内，成型预成型预浸带；Step 3: Theextruder 43 extrudes the polyether ether ketone resin melt into the second arc-shapedporous die 422. The resin melt enters into the arc-shapedporous die 1 421 through the hole, and the resin melt in the arc-shapedporous die 1 421 enters the impregnating rollershallow cavity 44 through the hole. With the rotation of the impregnatingroller 41, theresin melt 43 is uniform It is coated on the surface of the groove of the dippingroller 41; instep 2, the heated fiber tape with a certain pretension passes through the dippingroller 41 at a certain wrapping angle, and the fiber tape with a certain tension is coated with a certain thickness of polyether ether ketone on the surface. A radial pressure perpendicular to the fiber bundle is formed between the impregnating rolls of the resin-like film. Under the action of this pressure, theresin melt 43 on the surface of the groove of the impregnatingroll 41 is extruded into the fiber tape to form a preformed prepreg tape;

步骤四、预成型预浸带继续被牵拉系统以一定的包角通过若干均化辊5，实现纤维束与树脂熔体10均匀分布；经过若干均化辊5后的预成型预浸带进一步被牵拉通过两个反向低温压辊，预浸带成型；通过牵拉系统7牵拉、收卷成型连续纤维增强热塑性预浸带。Step 4. The preformed prepreg tape is continuously drawn by the pulling system to pass through several homogenizing rollers 5 at a certain wrapping angle, so that the fiber bundles and theresin melt 10 are evenly distributed; It is drawn through two reverse low temperature pressing rolls, and the prepreg tape is formed; the continuous fiber reinforced thermoplastic prepreg tape is drawn and wound by the drawing system 7 to form.

高粘度聚醚醚酮类熔体通过特殊设计的挤出口模挤出均匀涂覆到动力高温浸渍辊表面；具有一定预应力、分散成一定厚度的预热连续纤维束，以高于或等于浸渍辊表面线速度的以一定的包角牵引通过表面涂覆树脂熔体膜的高温浸渍辊；在这个过程中，具有一定预张力的纤维束对浸渍辊表面形成径向力，该径向力将浸渍辊表面的树脂挤入纤维束内，实现纤维束的浸渍；树脂初步浸渍的纤维束继续以一定包角通过多个高温均化辊，进一步提升纤维与树脂在预浸带的分布均匀性；然后，预浸带被牵引通过两个反向的低温压辊，成型表面光洁的连续纤维增强聚醚醚酮类热塑性预浸带。The high-viscosity polyetheretherketone melt is extruded and uniformly coated on the surface of the dynamic high-temperature impregnating roller through a specially designed extrusion die; preheated continuous fiber bundles with a certain prestress and dispersed into a certain thickness are higher than or equal to the impregnation rate. The surface line speed of the roller is drawn at a certain wrap angle through the high-temperature impregnating roller coated with the resin melt film; The resin on the surface of the impregnating roller is squeezed into the fiber bundle to realize the impregnation of the fiber bundle; the fiber bundle preliminarily impregnated with the resin continues to pass through multiple high-temperature homogenizing rollers at a certain wrap angle to further improve the distribution uniformity of fibers and resin in the prepreg tape; The prepreg tape is then drawn through two opposing low temperature press rolls to form a smooth surface continuous fiber reinforced polyether ether ketone thermoplastic prepreg tape.

本发明中纤维束、高粘度树脂熔体与浸渍辊在牵引方向不产生明显的相对运动，从而避免纤维在高剪切力作用下损伤、断裂以及过大牵引力导致生产不连续等问题；同时，该发明方法，可以使得挤出机挤出的树脂熔体全部浸渍纤维，避免树脂浪费，同时避免利用胶槽技术中某些部位的树脂不能被纤维带出发生降解，影响预浸带质量及不能连续生产等问题。In the present invention, the fiber bundle, the high-viscosity resin melt and the impregnating roller do not produce obvious relative motion in the pulling direction, so as to avoid problems such as fiber damage, breakage and discontinuous production caused by excessive pulling force under the action of high shear force; at the same time, The inventive method can make the resin melt extruded by the extruder fully impregnated with fibers, avoid resin waste, and avoid resin in some parts of the glue tank technology that cannot be taken out by fibers and degrade, which affects the quality of prepreg tape and can not be degraded. Continuous production, etc.

以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。The above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the scope of the present invention. within the scope of protection.

Claims (10)

1. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape, characterized by: comprises a creel (1), a yarn dividing system (2), a heating system (3), an impregnation system (4), a plurality of homogenizing rollers (5), a glazing roller (6) and a traction system (7) which are arranged in sequence,

the heating system (3) comprises a heating channel (32) and a plurality of electric heating blowers (31), the electric heating blowers (31) are uniformly distributed above and below the heating channel (32), a thermocouple (33) is arranged in the heating channel (32) corresponding to each electric heating blower (31), and the thermocouple (33) detects the wind temperature in the heating channel (32);

The dipping system (4) comprises a dipping roller (41), an extrusion porous mouth mold (42) and an extruder (43) connected with the extrusion porous mouth mold, the extrusion porous mouth mold (42) is arranged below the dipping roller (41), a groove is formed in the surface of the dipping roller (41), the dipping roller (41) is connected with a motor through a transmission shaft (411), the extrusion porous mouth mold (42) comprises a first arc-shaped porous mouth mold (421) and a second arc-shaped porous mouth mold (422) which are integrally formed and arranged up and down, a shallow cavity (44) is formed by matching the first arc-shaped porous mouth mold (421) and the groove of the dipping roller (41), and the extruder (43) is communicated with the second arc-shaped porous mouth mold (422) through an extruder connecting pipe (431);

the device comprises a plurality of homogenizing rollers (5), wherein the homogenizing rollers (5) are arranged in parallel, the homogenizing rollers (5) are lower than the center of a soaking roller (41), the polishing rollers (6) are power roller pairs and comprise concave rollers (61) and convex rollers (62) which are arranged up and down and used in a matched mode, grooves for containing prepreg tapes are formed in the concave rollers (61), the grooves of the concave rollers (61) are matched with the protrusions of the convex rollers (62), and pressure between the rollers is provided at two ends of each power roller pair through springs (63);

the fiber belt drawn by the drawing system (7) and drawn by the yarn withdrawing of the creel (1) and entering the yarn separating system (5) bypasses from the upper part of the impregnation roller (41) after passing through the temperature rising channel (32), and the fiber belt bypassing the impregnation roller (41) enters the space between the power roller pairs after passing through the plurality of homogenizing rollers (5) to form the prepreg belt (9).

2. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the second arc-shaped porous mouth mold (422) and the first arc-shaped porous mouth mold (421) are separated by a porous steel plate, and the upper surface of the first arc-shaped porous mouth mold (421) is also provided with the porous steel plate.

3. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the dipping roller (41) and all the homogenizing rollers (5) are power rollers capable of regulating speed and controlling temperature.

4. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: and a heat insulation system (8) for reducing the heat dissipation of the impregnation roller and the homogenizing roller is arranged at the peripheries of the impregnation roller (41) and the homogenizing roller (5), and the heat insulation system (8) is a heat insulation box made of a ceramic fiber blanket.

5. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the front end of the creel (1) is provided with a pre-tension device for providing pre-tension for the fiber bundle.

6. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the surface of the homogenizing roller (5) is subjected to mirror surface polishing and chromium plating, and the polishing roller (6) is provided with a cooling structure.

7. A melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape as claimed in claim 1, characterized in that: the bottom of the arc-shaped porous die (2) is wrapped with a heating sleeve (423).

8. A method of making a continuous fiber reinforced thermoplastic prepreg tape using the melt impregnation device for a continuous fiber reinforced thermoplastic prepreg tape according to any one of claims 1 to 7, characterized by: the method specifically comprises the following steps:

step one, a plurality of fiber bundles are withdrawn from a creel (1) under certain pretension and then enter a fiber dividing system (2), and the fiber bundles are divided into fiber belts with uniform thickness and constant width by the fiber dividing system (2);

step two, the fiber belt enters a heating system (3), the temperature of the fiber belt is raised to the impregnation temperature, and the fiber belt is pulled by a pulling system (7) to enter an impregnation system (4);

extruding the resin melt (10) into an arc-shaped porous opening die II (422) by an extruder (43), wherein the resin melt in the arc-shaped porous opening die II (422) enters an arc-shaped porous opening die I (421) through holes along with the increase of the amount of the extruded resin melt (10), the resin melt in the arc-shaped porous opening die I (421) enters a shallow cavity (44) of the impregnation roller through the holes, and the resin melt (43) is uniformly coated on the surface of the groove of the impregnation roller (41) along with the rotation of the impregnation roller (41); the fiber belt with certain pretension after being heated in the second step passes through an impregnation roller (41) at a certain wrap angle, and under the pretension action of a fiber bundle, the resin melt (43) on the surface of the groove of the impregnation roller (41) is extruded into the fiber belt to form a preformed prepreg belt;

Step four, continuously drawing the preformed prepreg tape by a drawing system to pass through a plurality of homogenizing rollers (5) at a certain wrap angle, so that the fiber bundles and the resin melt (10) are uniformly distributed; the preformed prepreg tape passing through the plurality of homogenizing rollers (5) is further pulled to pass through a polishing roller (6) to be formed; and (3) drawing and rolling the continuous fiber reinforced thermoplastic prepreg tape by a drawing system (7).

9. The method of making a continuous fiber reinforced thermoplastic prepreg tape according to claim 8, characterized in that: in the first step, the width of the fiber band dispersed by the yarn separating system (2) is consistent with the width of the groove of the impregnation roller (41), the thickness of the fiber band after yarn separation is controlled to be 0.02mm-1mm, and the pretension of a single fiber bundle is 0.1N-50N.

10. The method of making a continuous fiber reinforced thermoplastic prepreg tape according to claim 8, characterized in that: in the second step, the fiber band is heated to 360-450 ℃ through the heating system (3) and then enters the impregnation system (4).

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