Apparatus and method for efficiently preparing multi-directional continuous fiber-reinforced composite material

Patent metadata

Field	Value
Publication number	US-11529772-B2
Application number	US-202117477452-A
Country	US
Kind code	B2
Filing date	Sep 16, 2021
Priority date	Sep 30, 2020
Publication date	Dec 20, 2022
Grant date	Dec 20, 2022

Abstract

An apparatus and a method for preparing a multi-directional continuous fiber-reinforced composite material. The apparatus includes an electrostatic fiber-splitting device configured to controllably split a fiber bundle, a powder spreading device configured to spread a powder, and a pre-press molding device configured to cut the fiber and compact the powder. The electrostatic fiber-splitting device includes a rotatable fiber-splitting table. The pressing plate is controlled by an electromagnet, and the pressing plate is energized to generate a high-voltage electrostatic field to disperse the continuous fiber bundle into monofilament fibers.

First claim

What is claimed is:

1. An apparatus for preparing a multi-directional continuous fiber-reinforced composite material, comprising:
an electrostatic fiber bundle-splitting device;
a powder spreading device; and
a pre-press molding device;
wherein the electrostatic fiber bundle-splitting device is configured to controllably split a fiber; the powder spreading device is configured to spread a powder; and the pre-press molding device is configured to cut the fiber and compact the powder;
the electrostatic fiber bundle-splitting device comprises a hollow shaft, a fiber-splitting table and a rotating table; the hollow shaft, the fiber-splitting table and the rotating table are arranged coaxially; the rotating table is fixedly arranged on the hollow shaft; the fiber-splitting table is fixedly provided on a first support plate; an upper end of the hollow shaft is connected to the first support plate through a first mounted bearing; and a lower end of the hollow shaft is connected to a second supporting plate through a second mounted bearing;
the rotating table is provided with a pre-pressing hole; and two sides of the pre-pressing hole are respectively provided with a pressing device configured to press a fiber bundle;
the fiber-splitting table is fixedly provided with a first rack and a second rack; a first pressing plate is arranged on the first rack through a first spring; and a second pressing plate is arranged on the second rack through a second spring;
a first conductive block is arranged below the first rack; a second conductive block is arranged below the second rack; two sides of the first conductive block are respectively provided with a first electromagnet; and two sides of the second conductive block are respectively provided with a second electromagnet;
the pre-press molding device comprises an eccentric wheel, an eccentric wheel shaft, a push rod and a quick-change forming mold; the eccentric wheel is sleeved on the eccentric wheel shaft; the eccentric wheel shaft is configured to be driven by a power device; and the push rod is connected to a quick-change male die of the quick-change forming mold through a pin;
the quick-change forming mold comprises the quick-change male die, a first sleeve barrel, a backing plate and a female die cavity; the first sleeve barrel, the backing plate and the female die cavity are all arranged in the hollow shaft; the female die cavity is a hollow cylinder; the backing plate is in a shape of boss, and comprises a cylinder at an upper portion and a base plate at a lower portion; an outer diameter of the base plate is smaller than an inner diameter of the hollow shaft; an outer diameter of the cylinder of the backing plate is the same as an inner diameter of the female die cavity; an inner cavity formed between the cylinder of the backing plate and the female die cavity is configured to accommodate a preform of the multi-directional continuous fiber-reinforced composite material; the backing plate is arranged in a groove on an upper end of the first sleeve barrel through transition fit; the female die cavity is arranged on a boss located in an inner cavity of the hollow shaft; and the inner cavity of the hollow shaft is in clearance fit with an outer wall of the first sleeve barrel; and
the powder spreading device comprises a powder storage box and a ball screw module; the powder storage box is arranged on the ball screw module; a lower end of the powder storage box is provided with a powder outlet; a gear is arranged at the powder outlet; a gear shaft is arranged in the powder storage box; the gear is provided on the gear shaft; an addendum circle of the gear is in transition fit with an inner wall of the powder storage box; two sides of the gear closely fit the inner wall of the powder storage box; and a scraper is fixedly arranged on a rear side of the powder storage box.

2. The apparatus of claim 1 , wherein the pressing device comprises a third rack; the third rack is threadedly connected to a screw rod; and a lower end of the screw rod is provided with a pressing block.

3. The apparatus of claim 1 , wherein one end of the eccentric wheel shaft is arranged on a third rack through a first bearing, and the other end of the eccentric wheel shaft is arranged on a fourth rack through a second bearing; a lower end of the third rack is connected to a first guide pillar, and a lower end of the fourth rack is connected to a second guide pillar; a first guide sleeve is sleeved on the first guide pillar and is configured to slide on the first guide pillar; and a second guide sleeve is sleeved on the second guide pillar and is configured to slide on the second guide pillar; and
an upper part of the first guide sleeve and an upper part the second guide sleeve are both connected to a connecting plate; one side of the connecting plate is provided with a first ring-shaped hook, and the other side of the connecting plate is provided with a second ring-shaped hook; an outer side of the third rack is provided with a third ring-shaped hook; an outer side of the fourth rack is provided with a fourth ring-shaped hook; a first tension spring is connected between the first ring-shaped hook and the third ring-shaped hook; and a second tension spring is connected between the second ring-shaped hook and the fourth ring-shaped hook.

4. The apparatus of claim 1 , wherein the electrostatic fiber bundle-splitting device is arranged on a support component; and the support component is arranged on a guide rail.

5. A method for preparing a multi-directional continuous fiber-reinforced composite material using the apparatus of claim 1 , comprising:
(1) feeding powder into the powder storage box of the powder spreading device;
(2) moving the backing plate of the pre-press molding device such that an upper surface of the backing plate is located below an upper surface of the rotating table, and a distance between the upper surface of the backing plate and the upper surface of the rotating table is equal to a thickness of a single layer of the powder;
(3) moving the powder storage box of the powder spreading device to a side of the backing plate such that a distance between a lower end of the gear of the powder storage box and the upper surface of the rotating table is 1-2 cm;
(4) discharging the powder from the powder storage box; and simultaneously, horizontally moving the powder storage box to uniformly spread the powder into an inner cavity formed by the backing plate and the female die cavity of the pre-press molding device;
(5) placing a first end of a first fiber bundle horizontally in a groove of the first conductive block, and placing a second end of the first fiber bundle in a groove of the second conductive block; powering on the first electromagnet such that the first pressing plate is attracted by the first electromagnet, and at this time, a first spring assembly is stretched and the first pressing plate closely fits the first conductive block to fix the first end of the first fiber bundle;
(6) powering on the first conductive block and the first pressing plate such that an electrostatic field is formed between the first conductive block and the first pressing plate to disperse the second end of the first fiber bundle;
(7) powering on the second electromagnet such that the second pressing plate is attracted by the second electromagnet to stretch a second spring assembly such that the second pressing plate closely fits the second conductive block to fix the second end of the first fiber bundle; and powering off the first conductive block and the first pressing plate;
(8) powering off the first electromagnet, and powering on the second conductive block and the second pressing plate such that an electrostatic field is formed between the second conductive block and the second pressing plate to dispers

Assignees

• Shaanxi Univ Of Science & Technology

Inventors

• Zhao Xueni
• Liu Mingyue
• Gui Zhenzhen
• Liu Ao
• Zheng Jiamei
• Wei Sensen
• Chen Xueyan

Classifications

• B29C70/34 Primary

  and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} · CPC title

• B29C70/54

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• C04B35/645 Primary

  Pressure sintering · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• B28B13/022

  Feeding several successive layers, optionally of different materials · CPC title