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CN111186147B - Forming method for preparing lightweight automobile parts by using continuous fiber mixed chopped fibers - Google Patents

Forming method for preparing lightweight automobile parts by using continuous fiber mixed chopped fibers Download PDF

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Publication number
CN111186147B
CN111186147B CN202010112600.2A CN202010112600A CN111186147B CN 111186147 B CN111186147 B CN 111186147B CN 202010112600 A CN202010112600 A CN 202010112600A CN 111186147 B CN111186147 B CN 111186147B
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Prior art keywords
honeycomb structure
chopped fibers
continuous fiber
metal insert
fabric prepreg
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CN202010112600.2A
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CN111186147A (en
Inventor
顾勇涛
李宁
李熠杰
王定
岳海亮
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Jiangsu Hengrui Carbon Fiber Technology Co ltd
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Jiangsu Hengrui Carbon Fiber Technology Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/54Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005Body finishings

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

The invention discloses a forming method for preparing a lightweight automobile part by using continuous fiber mixed chopped fibers, wherein the automobile part structurally comprises the following steps: the honeycomb structure layer comprises an appearance layer, a honeycomb structure layer and a metal insert for installation, wherein the metal insert is embedded in the honeycomb structure layer, the appearance layer is combined on the surface of the honeycomb structure layer, and the appearance layer, the honeycomb structure layer and the metal insert are solidified and molded together; the molding method comprises the following specific steps: (1) selecting materials; (2) feeding; (3) closing the mold, curing and ejecting; (4) and performing edge microprocessing. The forming method for preparing the lightweight automobile parts by using the continuous fiber mixed chopped fibers has the advantages that the mechanical property and the appearance shape of the parts are remarkably enhanced in comparison with the traditional carbon fiber SMC parts from the radial direction or the axial direction. The method can be applied to parts with complex shapes on the market of automobiles and sports equipment in a large scale, and is suitable for producing semi-structural members with high repeatability and complex structures in a large scale.

Description

Forming method for preparing lightweight automobile parts by using continuous fiber mixed chopped fibers
Technical Field
The invention relates to the field of carbon fiber automobile part forming, in particular to a forming method for preparing light automobile parts by using continuous fiber mixed chopped fibers.
Background
At present, the light weight of automobiles is a hot topic, and how to prepare light automobile parts under the condition of ensuring the performance becomes an issue to be overcome by experts and scholars in the industry. A large number of practices prove that: the purpose of reducing weight can be effectively achieved by using the fiber reinforced resin matrix composite material. Therefore, the common glass fiber reinforced resin based prepreg, glass fiber SMC material, carbon fiber reinforced resin based prepreg and carbon fiber SMC material are now the main raw materials of new energy automobile parts. However, the application range and the application process of the new material are inseparable, but due to the limited material performance and the limited forming process, the defects of the existing material are mainly reflected in the following aspects:
1. mechanical properties: both the glass fiber reinforced resin matrix composite material and the chopped glass fiber SMC material cannot completely meet the load bearing requirement of automobile parts, and thus, the large-range application of the composite material is limited.
2. The complexity of the shape of the workpiece is as follows: the continuous fiber prepreg cannot be used for preparing a part with a complex shape; but the pure glass fiber or carbon fiber sheet cannot meet the force bearing requirement of the part;
in order to solve the above two problems, a molding method for preparing a lightweight automobile part from continuous fiber mixed chopped fiber is urgently needed in the market.
Disclosure of Invention
The invention mainly solves the technical problem of providing a forming method for preparing light automobile parts by using continuous fiber mixed chopped fibers, which can fully utilize the advantages of excellent mechanical property of the continuous fibers and easy preparation of complex shapes by using the chopped fibers.
In order to solve the technical problems, the invention adopts a technical scheme that: the forming method for preparing the lightweight automobile part by using the continuous fiber and the chopped fiber is provided, and the automobile part structure comprises the following steps: the honeycomb structure layer comprises an appearance layer, a honeycomb structure layer and a metal insert for installation, wherein the metal insert is embedded in the honeycomb structure layer, the appearance layer is combined on the surface of the honeycomb structure layer, and the appearance layer, the honeycomb structure layer and the metal insert are solidified and molded together;
the molding method comprises the following specific steps:
(1) and material selection: the main material of the appearance layer is fabric prepreg selected according to design requirements; the main material of the honeycomb structure layer comprises chopped carbon fiber sheets; the metal insert selects an embedded nut according to design requirements;
(2) feeding: the method comprises the steps of inserting a metal insert and laying materials;
(2.1) metal insert insertion: embedding a metal insert on a male die with an ejection mechanism in advance according to the molding design requirement of a workpiece, and co-curing and molding the metal insert with continuous fibers and chopped fibers;
(2.2) material placement: calculating the input amount of the chopped fibers according to the volume of the die cavity and the density of the chopped fiber material; stacking together fabric prepreg and chopped fiber material; the feeding area of the chopped fibers accounts for 70 to 90 percent of the fabric prepreg; placing the finished material on the male die;
(3) closing the mold, curing and ejecting: according to a preset program, paying attention to the mold closing speed; after the solidification process is finished, the ejection mechanism moves, and a workpiece is taken out;
(4) and edge microprocessing: and (5) polishing off the rich resin and carbon fiber burrs at the edges to obtain a finished piece with a net size.
In a preferred embodiment of the invention, the fabric prepreg is a unidirectional or textured fabric prepreg.
In a preferred embodiment of the present invention, the fabric prepreg is a carbon fiber, an aramid fiber or a hybrid woven fabric prepreg.
In a preferred embodiment of the present invention, the resin matrix of the chopped carbon fiber sheet is loaded with a colorant to meet design requirements.
In a preferred embodiment of the present invention, the wall thickness of the honeycomb layer ranges from 1mm to 3 mm.
In a preferred embodiment of the invention, both the fabric prepreg and the carbon fiber sheet are made of materials of the same resin system that cure rapidly.
In a preferred embodiment of the invention, the appearance layer uses carbon fiber fabric prepreg of vinyl, and the honeycomb structure layer uses carbon fiber SMC of unsaturated polyester.
In a preferred embodiment of the present invention, in the step (2.2), the volume is calculated by subtracting the thickness of the cured continuous fiber fabric prepreg from the height of the mold cavity.
In a preferred embodiment of the invention, in the step (2.2), the continuous fiber fabric prepreg is cut according to the ratio of 1:1 of the area of the die cavity.
In a preferred embodiment of the invention, in step (2.2), the fed area of chopped fibres is 80% of the fabric prepreg.
The invention has the beneficial effects that: the forming method for preparing the lightweight automobile parts by using the continuous fiber mixed chopped fibers has the advantages that the mechanical property and the appearance shape of the parts are remarkably enhanced in comparison with the traditional carbon fiber SMC parts from the radial direction or the axial direction. The technology can be applied to parts with complex shapes on the market of automobiles and sports equipment in large scale in the future, and is suitable for producing semi-junction components with high repeatability and complex structures in large scale.
Drawings
FIG. 1 is a schematic structural view of a preferred embodiment of a metal-embedded honeycomb structure layer according to the present invention;
FIG. 2 is a schematic structural view of an appearance layer;
the parts in the drawings are numbered as follows: 1-appearance layer, 2-metal embedded honeycomb structure layer and 3-embedded metal.
Detailed Description
The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, will make the advantages and features of the invention easier to understand by those skilled in the art, and thus will clearly and clearly define the scope of the invention.
Referring to fig. 1 and 2, an embodiment of the present invention includes:
a molding method for preparing a lightweight automobile part from continuous fiber hybrid chopped fibers, wherein the automobile part structure comprises the following steps: appearance layer 1, honeycomb structure layer 2 and the metal insert 3 that is used for the installation, metal insert 3 embedded in honeycomb structure layer 2, appearance layer 1 combine in honeycomb structure layer 2's surface, appearance layer 1 honeycomb structure layer 2 with the metal insert 3 solidification shaping jointly.
To explain the method in detail, the 3D model design shown in fig. 1 is completed by optimizing the design of the front bumper model of the left side decorative part of the automobile, and adding a honeycomb structure with the wall thickness of 2mm and a metal insert for installation as follows:
the preparation method of the product comprises the following steps:
(1) and material selection: as shown in fig. 1, in order to meet the molding requirement of the honeycomb structure, the chopped carbon fiber sheet is used for realizing the post-molding of the honeycomb section; the resin matrix of the carbon fiber sheet can be added with pigments to meet aesthetic requirements; the appearance layer is selected more, if certain mechanical property requirements exist, carbon fiber, aramid fiber or some mixed woven fabric prepreg can be used as the appearance layer, so that the mechanical property requirements are met, and appearance lines are enriched; note that: both fabric prepregs and carbon fiber sheets are typically selected from materials of the same resin system that cure rapidly.
Metal inserts: according to the design requirements, a metal insert meeting the requirements is used, such as an M6 × 12 insert nut.
(2) Feeding: the CF-SMC material is used in an amount calculated on the volume of the mould cavity and then dosed over an area of 70% to 90% (preferably 80%) of the article. For example, the appearance layer uses a vinyl carbon fiber fabric prepreg, and the honeycomb structure uses an unsaturated polyester carbon fiber SMC.
(2.1) metal insert insertion: according to the design requirement of the product modeling, a metal insert (such as an M6 nut) is embedded in a male die with an ejection mechanism in advance, and is co-cured and molded with continuous fibers and chopped fibers.
(2.2) material placement: cutting the continuous fiber fabric prepreg according to the ratio of 1:1 of the area of the die cavity; calculating the input amount of chopped fibers according to the volume of the die cavity (the height of the die cavity is required to be subtracted by the thickness of the cured continuous fiber fabric prepreg during volume calculation) and the density of the chopped fiber material; stacking together fabric prepreg and chopped fiber material; note that the fabric prepreg must be flat, wrinkle free, and the staple fibers are fed in an amount of 70% to 90% (preferably 80%) of the fabric prepreg. The finished material is quickly placed over the male mold.
(3) Closing the mold, curing and ejecting: according to a preset program, paying attention to the mold closing speed; and after the curing procedure is finished, the ejection mechanism moves, and the workpiece is taken out.
(4) And edge microprocessing: as the CF-SMC has some glue overflow phenomena in the preparation process, the resin-rich and carbon fiber burrs at the edge are simply polished off by using a hand polishing tool, and a finished piece with a net size can be obtained.
The forming method for preparing the lightweight automobile part by using the continuous fiber mixed chopped fiber has the following advantages:
(1) flexible hybrid form: the continuous fibers can be selected from unidirectional or textured fabric prepregs according to the appearance requirement of the product; the sheet-shaped carbon fiber prepreg can also be made into materials with colors or patterns according to the market requirements;
(2) the mechanical property of the hybrid process is superior to that of the traditional chopped fiber prepreg forming technology: due to the local reinforcement of the continuous fibers, the parts prepared by the continuous fiber reinforced carbon fiber SMC hybrid process technology are far superior to the traditional SMC preparation technology in terms of mechanical properties.
(3) And the metal insert required by the product can be co-cured and molded.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes performed by the present specification and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.

Claims (10)

1. A forming method for preparing a lightweight automobile part by using continuous fiber hybrid chopped fibers is characterized in that the automobile part structure comprises the following steps: the honeycomb structure layer comprises an appearance layer, a honeycomb structure layer and a metal insert for installation, wherein the metal insert is embedded in the honeycomb structure layer, the appearance layer is combined on the surface of the honeycomb structure layer, and the appearance layer, the honeycomb structure layer and the metal insert are solidified and molded together;
the molding method comprises the following specific steps:
(1) and material selection: the main material of the appearance layer is a continuous fiber fabric prepreg selected according to design requirements; the main material of the honeycomb structure layer comprises chopped carbon fiber sheets; the metal insert selects an embedded nut according to design requirements;
(2) feeding: the method comprises the steps of inserting a metal insert and laying materials;
(2.1) metal insert insertion: embedding a metal insert on a male die with an ejection mechanism in advance according to the molding design requirement of a workpiece, and co-curing and molding the metal insert with continuous fibers and chopped fibers;
(2.2) material placement: calculating the input amount of the chopped fibers according to the volume of the die cavity and the density of the chopped fiber material; stacking together fabric prepreg and chopped fiber material; the feeding area of the chopped fibers accounts for 70 to 90 percent of the fabric prepreg; placing the finished material on the male die;
(3) closing the mold, curing and ejecting: according to a preset program, paying attention to the mold closing speed; after the solidification process is finished, the ejection mechanism moves, and a workpiece is taken out;
(4) and edge microprocessing: and (5) polishing off the rich resin and carbon fiber burrs at the edges to obtain a finished piece with a net size.
2. The molding method for manufacturing a light-weight automobile part from continuous fiber hybrid chopped fibers according to claim 1, wherein the fabric prepreg is unidirectional or textured fabric prepreg.
3. The molding method for manufacturing a light-weight automobile part from continuous fiber hybrid chopped fiber according to claim 1, wherein the fabric prepreg is carbon fiber, aramid fiber or hybrid fabric prepreg.
4. The molding method for manufacturing a lightweight automobile part from continuous fiber hybrid chopped fibers according to claim 1, wherein a colorant is added to a resin matrix of the chopped carbon fiber sheet to meet design requirements.
5. The molding method for preparing a lightweight automobile part from continuous fiber hybrid chopped fibers according to claim 1, wherein the wall thickness of the honeycomb layer ranges from 1mm to 3 mm.
6. The method of claim 1, wherein a fast curing, same resin system material is used for both the fabric prepreg and the carbon fiber sheet.
7. The molding method for manufacturing a lightweight automobile part using continuous fiber hybrid chopped fibers according to claim 1, wherein the appearance layer uses a vinyl carbon fiber fabric prepreg, and the honeycomb structure layer uses an unsaturated polyester carbon fiber SMC.
8. The molding method for preparing light-weight automobile parts from continuous fiber hybrid chopped fibers according to claim 1, wherein in the step (2.2), the thickness of the cured continuous fiber fabric prepreg is subtracted from the height of the mold cavity in volume calculation.
9. The molding method for manufacturing a light-weight automobile part from continuous fiber hybrid chopped fibers according to claim 1, wherein in the step (2.2), the continuous fiber fabric prepreg is cut according to a ratio of 1:1 of the area of the mold cavity.
10. The molding method for preparing light-weight automobile parts from continuous fiber hybrid chopped fibers according to claim 1, wherein in the step (2.2), the feeding area of the chopped fibers accounts for 80% of the fabric prepreg.
CN202010112600.2A 2020-02-24 2020-02-24 Forming method for preparing lightweight automobile parts by using continuous fiber mixed chopped fibers Active CN111186147B (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1211947A (en) * 1996-01-11 1999-03-24 波音公司 Composite honeycomb sandwich structure
CN1902046A (en) * 2004-01-19 2007-01-24 伊兰科有限公司 High impact strength, elastic, composite, fibre, metal laminate
CN105538816A (en) * 2016-02-03 2016-05-04 北京博简复才技术咨询有限公司 Flaky molded material-prepreg mixed composite material and manufacturing method thereof
CN107512057A (en) * 2016-06-17 2017-12-26 科思创聚合物(中国)有限公司 Layer of polyurethane pressure moulding article and preparation method thereof
CN107187078B (en) * 2017-06-28 2020-01-31 江苏兆鋆新材料股份有限公司 carbon fiber prepreg rapid compression molding process

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1736298A1 (en) * 2005-06-17 2006-12-27 Rieter Technologies AG Method of manufacturing of a sound insulating body and sound insulating body
JP2007301865A (en) * 2006-05-12 2007-11-22 Kawakami Sangyo Co Ltd Method of manufacturing sheet for formation of honeycomb core and mold
CA2889501C (en) * 2012-12-26 2017-05-23 Toray Industries, Inc. Molded product having hollow structure and process for producing same
GB2539228B (en) * 2015-06-10 2017-07-26 Fergusson's Advanced Composite Tech Ltd A method of making a composite structure

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1211947A (en) * 1996-01-11 1999-03-24 波音公司 Composite honeycomb sandwich structure
CN1902046A (en) * 2004-01-19 2007-01-24 伊兰科有限公司 High impact strength, elastic, composite, fibre, metal laminate
CN105538816A (en) * 2016-02-03 2016-05-04 北京博简复才技术咨询有限公司 Flaky molded material-prepreg mixed composite material and manufacturing method thereof
CN107512057A (en) * 2016-06-17 2017-12-26 科思创聚合物(中国)有限公司 Layer of polyurethane pressure moulding article and preparation method thereof
CN107187078B (en) * 2017-06-28 2020-01-31 江苏兆鋆新材料股份有限公司 carbon fiber prepreg rapid compression molding process

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Denomination of invention: Forming method for preparing lightweight automobile parts with continuous fiber hybrid chopped fiber

Effective date of registration: 20211116

Granted publication date: 20211008

Pledgee: Industrial Commercial Bank of China Ltd. Changshu branch

Pledgor: JIANGSU HENGRUI CARBON FIBER TECHNOLOGY Co.,Ltd.

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