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CN113601876B - Continuous dry fiber additive manufacturing method - Google Patents

Continuous dry fiber additive manufacturing method Download PDF

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Publication number
CN113601876B
CN113601876B CN202110901117.7A CN202110901117A CN113601876B CN 113601876 B CN113601876 B CN 113601876B CN 202110901117 A CN202110901117 A CN 202110901117A CN 113601876 B CN113601876 B CN 113601876B
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Prior art keywords
fiber
dry fiber
dry
continuous
additive manufacturing
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CN202110901117.7A
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CN113601876A (en
Inventor
吕明迪
关昊辰
杨朝坤
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Shandong Zhongheng Jingxin Carbon Fiber Science & Technology Development Co ltd
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Shandong Zhongheng Jingxin Carbon Fiber Science & Technology Development Co ltd
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Publication of CN113601876A publication Critical patent/CN113601876A/en
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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
    • B29C70/342Shaping 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 isostatic pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00Making preforms
    • B29B11/04Making preforms by assembling preformed material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00Making preforms
    • B29B11/06Making preforms by moulding the material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • 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
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
    • 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
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The invention discloses a continuous dry fiber additive manufacturing method, which comprises the steps of puffing continuous dry fibers, respectively inputting the combined fibers formed by the bulked yarn dry fibers and the dry fibers to an output end, carrying out laminated laying and licker-in needling to enable the dry fibers to be intertwined to form a three-dimensional dry fiber blank, carrying out deposition or dipping and hot pressing processes to obtain a three-dimensional fiber preform, and carrying out machining and coating treatment to the three-dimensional fiber preform to finally obtain a continuous fiber reinforced resin matrix composite finished product with the porosity less than or equal to 1.5%. The invention provides a reliable method for rapid forming of continuous dry fiber preform, provides a rapid and low-cost manufacturing means for forming of three-dimensional fiber preform, opens up a new fiber preform processing method for additive manufacturing of composite materials, and lays a new technical support for development of high-performance composite materials.

Description

Continuous dry fiber additive manufacturing method
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a continuous dry fiber additive manufacturing method.
Background
With the wider and wider application of fiber composite materials and the rapid development of 3D output technology, the 3D output of continuous fibers of composite materials is in a new stage of thick and thin development, and has an explosive growth situation in the fields of new product development, mold manufacturing and machining.
The method of in-situ impregnation, tow coextrusion, tow extrusion, in-situ combination, prepreg and the like is adopted to solve some problems of continuous fiber additive manufacturing, but simultaneously brings new problems, such as reduced comprehensive properties of fibers, high-quality resin or prepreg requirements, output end cleaning problems and the like, does not exert the advantages of the existing fiber resources, changes fiber properties for adapting to additive manufacturing, and is unfavorable for manufacturing high-performance composite materials.
However, in the existing additive manufacturing process of continuous dry fibers, a male mold and a female mold are needed for manufacturing the thermosetting resin composite material, resin glue solution is singly impregnated for compounding, and the composite material is separated in the heating curing and compounding process, so that the composite material cannot be continuously processed, the processing cost is high, and the processing efficiency is low.
Disclosure of Invention
The invention aims to provide a continuous dry fiber additive manufacturing method, which solves the problems in the prior art, ensures that the dry fiber additive manufacturing is quick and low in cost, and can prepare a composite material with excellent performance and a product thereof.
In order to achieve the above object, the present invention provides the following solutions:
the invention provides a continuous dry fiber additive manufacturing method, which comprises the following steps,
step one, puffing continuous dry fibers to obtain continuous dry fiber bulked yarns, and forming bulked yarn rolls;
inputting the dry fiber bulked yarns and the dry fibers into an output end in a dust-free space in a one-to-one correspondence manner, continuously outputting the combined fibers formed by the dry fiber bulked yarns and the dry fibers by the output end according to a set track, and carrying out laminated tiling on the combined fibers to form a fiber molding blank;
thirdly, after the laminated and laid combined fibers reach a set thickness, carrying out a licker-in needling operation on the side surface and the top surface of the fiber molding blank body for one time, thereby molding a three-dimensional dry fiber blank body;
and fourthly, depositing or dipping the three-dimensional dry fiber blank to obtain a high-temperature composite material product, carrying out hot pressing treatment on the high-temperature composite material product to obtain a three-dimensional fiber preform, and carrying out machining and coating treatment on the three-dimensional fiber preform to finally obtain a continuous fiber reinforced thermosetting resin matrix composite material finished product with the porosity less than or equal to 1.5%.
Preferably, the monofilaments in the dry fiber bulked yarn in the first step are in a separated state, the tows of the dry fiber bulked yarn are in a corrugated shape and/or a spiral shape, and the dry fibers are made of a thermosetting resin composite material.
Preferably, after the merged fiber tiled each time in the third step reaches a set length, the merged fiber is cut once through a cutting device, and the cutting device is arranged at the lower end of the output end.
Preferably, the set thickness in the third step is 8-24 layers of the combined fibers.
Preferably, the needling operation of the licker-in the third step is completed through three forming licker-in, and the needling reciprocation frequency of the forming licker-in is 1-5 times that of the output end.
Preferably, the output head end and the forming licker-in are arranged on the same bracket, and the three forming licker-in are respectively positioned on two side surfaces and the top surface of the fiber forming blank.
Preferably, a plurality of prickers are uniformly distributed on the cylindrical surface of the forming licker-in, and barbs are arranged at the tips of the prickers.
Preferably, a conveying device, a tension control clamping roller and a guide roller are arranged on a channel where the dry fiber bulked yarn and the dry fiber form a combined fiber, and the tension control clamping roller can respectively regulate and control the prestress of the dry fiber bulked yarn and the dry fiber.
Preferably, the dry fibers are glass fibers, carbon fibers, ultra-high molecular weight polyethylene fibers or aramid fibers.
Preferably, the hot pressing process of the high-temperature composite material product in the fourth step is a process of autoclave and/or bag pressure vacuumizing.
Compared with the prior art, the invention has the following technical effects:
the invention provides a reliable method for rapid forming of continuous dry fiber composite material, provides a rapid and low-cost manufacturing means for forming of three-dimensional fiber preform, opens up a new fiber preform processing method for additive manufacturing of composite material, and lays a new technical support for development of high-performance composite material.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view of a three-dimensional fiber preform according to the present invention;
FIG. 2 is a schematic diagram showing a second structure of the three-dimensional fiber preform according to the present invention;
FIG. 3 is a schematic diagram of a three-dimensional fiber preform manufacturing structure according to the present invention;
FIG. 4 is a schematic illustration of the structure of a dry fiber bulked yarn of the present invention;
FIG. 5 is a schematic view of the lancet of the present invention;
wherein: 50-barbs, 100-needles, 200-flat-pressing licker-in, 300-left licker-in, 310-right licker-in, 400-fiber forming blanks, 500-dry fiber bulked yarns, 600-bulked yarn packages, 700-dry fiber packages, 800-output ends, 900-guide rollers and 910-shearing devices.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by a person skilled in the art based on the embodiments of the invention without any inventive effort, are intended to fall within the scope of the invention.
The invention aims to provide a continuous dry fiber additive manufacturing method, which solves the problems in the prior art, ensures that the dry fiber additive manufacturing is quick and low in cost, and can prepare a composite material with excellent performance and a product thereof.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
As shown in fig. 1 to 5: the embodiment provides a continuous dry fiber additive manufacturing method, which comprises the following steps,
step one, puffing continuous dry fibers (monofilament entangled bundles) by using a licker-in needling operation, so that an adhesive film among the fibers can be destroyed to obtain continuous dry fiber bulked yarns 500, and a bulked yarn roll is formed; the filaments in the dry fiber bulked yarn 500 are in a separated state, the tows of the dry fiber bulked yarn 500 are in a corrugated shape and/or a spiral shape, the dry fibers are thermosetting resin composite materials, and are tows formed by single fibers with diameters of 4-9 mu m, and the dry fibers and the dry fiber bulked yarn 500 which are not subjected to bulking treatment are respectively manufactured into packages. The bulked yarn package 600 and the dry fiber package 700 are symmetrically and rotatably arranged on the shaft brackets at two sides outside the dust-free box body. The conveying device, the tension control clamping roller and the guide roller 900 are arranged on a channel where the dry fiber bulked yarn 500 and the dry fiber form a combined fiber, and the tension control clamping roller can respectively regulate and control the prestress of the dry fiber bulked yarn 500 and the dry fiber.
In the dust-free space, the dry fiber bulked yarn 500 and the dry fibers are input into the output end 800 in a one-to-one correspondence (equal width), the output end 800 continuously outputs the combined fibers formed by the dry fiber bulked yarn 500 and the dry fibers according to a set track, and the combined fibers are laminated and tiled to form the fiber molding blank 400.
Step three, after the bonded fibers laid in a laminated manner each time reach a set thickness, performing a licker-in needling operation on the side surface and the top surface of the fiber forming embryo 400, thereby forming a three-dimensional dry fiber embryo; after each laid combined fiber reaches a set length, the combined fiber needs to be cut once by a cutting device 910, and the cutting device 910 is arranged at the lower end of the output end 800. The thickness of the combined fiber is set to 8-24 layers. The spike roller needling operation is accomplished by three forming spike rollers with needling reciprocation frequency of the forming spike rollers being 1-5 times the reciprocation frequency of the output tip 800. The output end and the forming licker-in are arranged on the same bracket, and the three forming licker-in are respectively positioned on two side surfaces and the top surface of the fiber forming blank 400, namely a left licker-in 300, a right licker-in 310 and a flat licker-in 200. The forming licker-in on two sides can roll simultaneously or independently, and the forming licker-in on the other side can be lifted. A plurality of prickers 100 are uniformly distributed on the cylindrical surface of the forming licker-in, barbs 50 are arranged at the tips of the prickers 100, and partial dry fiber monofilaments are mutually entangled along the depth direction of the prickers 100 under the action of the prickers, so that a three-dimensional dry fiber blank with a certain thickness is formed.
And fourthly, depositing or impregnating the three-dimensional dry fiber blank to obtain a high-temperature composite material product, carrying out hot pressing treatment on the high-temperature composite material product to obtain a three-dimensional fiber preform, and carrying out machining and coating treatment on the three-dimensional fiber preform to finally obtain a continuous fiber reinforced resin matrix composite material finished product with the porosity less than or equal to 1.5%.
And step four, the hot pressing process treatment of the high-temperature composite material product is the process treatment of autoclave and or bag pressure vacuumizing.
Wherein the dry fiber is glass fiber, carbon fiber, ultra-high molecular weight polyethylene fiber or aramid fiber. When the raw material is 12K continuous dry carbon fiber, and when the combined fiber layering operation reaches the design thickness of 20mm of the laminated and tiled, a licker-in needling operation is performed once, and the needling frequency=the reciprocation frequency of the output end 800. When the raw material is 6K continuous dry carbon fiber, and when the layering operation of the combined fiber reaches the design thickness of 30mm of laminated and tiled, the operation of needling by a licker-in is carried out once, and the reciprocating frequency of needling is=2 times of the reciprocating frequency of the output end 800. When the raw material is 12K continuous dry carbon fiber, and when the layering operation of the combined fiber reaches the design thickness of 40mm of laminated and tiled, the operation of needling by a licker-in is carried out once, and the reciprocating frequency of needling is=2 times of the reciprocating frequency of the output end 800. When the raw material is 2400tex continuous dry glass fiber, and when the combined fiber layering operation reaches the design thickness of 20mm of the laminated and laid layers, a licker-in needling operation is performed once, and the needling frequency=2 times of the reciprocation frequency of the output end 800. When the raw material is 24K continuous dry carbon fiber, and when the layering operation of the combined fiber reaches the design thickness of 60mm of the laminated and laid layer, the operation of needling by a licker-in is carried out once, and the reciprocating frequency of needling is=2 times of the reciprocating frequency of the output end 800. When the raw material is a mixed fiber (mixed between two fiber layers) of 12K dry carbon fiber and 2400tex glass fiber dry fiber, when the combined fiber layering operation reaches the design thickness of 100mm of the laminated tiling, a licker-in needling operation is performed once, and the reciprocating frequency of needling = 2 times of the reciprocating frequency of the output end 800.
The principles and embodiments of the present invention have been described in this specification with reference to specific examples, the description of which is only for the purpose of aiding in understanding the method of the present invention and its core ideas; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.

Claims (9)

1. A continuous dry fiber additive manufacturing method, characterized in that: comprises the following steps of the method,
step one, puffing continuous dry fibers to obtain continuous dry fiber bulked yarns, and forming bulked yarn rolls;
inputting the dry fiber bulked yarns and the dry fibers into an output end in a dust-free space in a one-to-one correspondence manner, continuously outputting the combined fibers formed by the dry fiber bulked yarns and the dry fibers by the output end according to a set track, and carrying out laminated tiling on the combined fibers to form a fiber molding blank;
thirdly, after the laminated and laid combined fibers reach a set thickness, carrying out a licker-in needling operation on the side surface and the top surface of the fiber molding blank body for one time, thereby molding a three-dimensional dry fiber blank body; the needling operation of the licker-in is completed through three forming licker-in, and the needling reciprocation frequency of the forming licker-in is 1-5 times of the reciprocation frequency of the output end;
and fourthly, depositing or dipping the three-dimensional dry fiber blank to obtain a high-temperature composite material product, carrying out hot pressing treatment on the high-temperature composite material product to obtain a three-dimensional fiber preform, and carrying out machining and coating treatment on the three-dimensional fiber preform to finally obtain a continuous fiber reinforced resin matrix composite material finished product with the porosity less than or equal to 1.5%.
2. The continuous dry fiber additive manufacturing method of claim 1 wherein: the monofilaments in the dry fiber bulked yarn in the first step are in a separated state, and the tows of the dry fiber bulked yarn are in a corrugated shape and/or a spiral shape.
3. The continuous dry fiber additive manufacturing method of claim 1 wherein: and thirdly, after the combined fibers tiled each time reach a set length, cutting the combined fibers once through a cutting device, wherein the cutting device is arranged at the lower end of the output end.
4. The continuous dry fiber additive manufacturing method of claim 1 wherein: and in the third step, the set thickness is 8-24 layers of the combined fibers.
5. The continuous dry fiber additive manufacturing method of claim 1 wherein: the output head end and the forming licker-in are arranged on the same bracket, and the three forming licker-in are respectively positioned on two side surfaces and the top surface of the fiber forming embryo body.
6. The continuous dry fiber additive manufacturing method of claim 1 wherein: the cylindrical surface of the forming licker-in is uniformly provided with a plurality of prickers, and the tips of the prickers are provided with barbs.
7. The continuous dry fiber additive manufacturing method of claim 1 wherein: the device is characterized in that a conveying device, a tension control clamping roller and a guide roller are arranged on a channel for forming the combined fiber by the dry fiber bulked yarn and the dry fiber, and the tension control clamping roller can respectively regulate and control the prestress of the dry fiber bulked yarn and the dry fiber.
8. The continuous dry fiber additive manufacturing method of claim 1 wherein: the dry fiber is glass fiber, carbon fiber, ultra-high molecular weight polyethylene fiber or aramid fiber.
9. The continuous dry fiber additive manufacturing method of claim 1 wherein: and the hot pressing process treatment of the high-temperature composite material product in the step four is the process treatment of vacuumizing an autoclave and/or a bag pressure.
CN202110901117.7A 2021-08-06 2021-08-06 Continuous dry fiber additive manufacturing method Active CN113601876B (en)

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CN109094055B (en) * 2018-09-29 2020-06-19 西安交通大学 Combined type multi-channel continuous dry fiber 3D printing composite material forming device
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