1. What are the common carbon fiber composite molding processes?
Hand lay-up - wet lay-up forming
Coat the mold working surface with release agent and gel coat, lay the cut carbon fiber prepreg cloth on the mold working surface, brush or spray the resin system glue, and after reaching the required thickness, the molding, solidification, and demoulding. Today, with the highly developed preparation technology, the hand lay-up process is still widely used in many fields such as petrochemical containers, storage tanks, automobile shells, etc., with the advantages of simple process, low investment and wide application. Its disadvantages are loose texture, low density, low product strength, and mainly rely on labor, unstable quality, and low production efficiency.
Injection molding process
It belongs to the type of low-pressure molding of the hand lay-up process, which uses chopped fibers and resins to be mixed with a spray gun, sprayed with compressed air on the mold, and then pressed by hand with rubber to achieve a predetermined thickness, and then cured into shape. A semi-mechanized molding process created to improve the lay-up molding has improved the work efficiency to a certain extent, but it still cannot meet the mass production requirements for manufacturing the transition layer of automobile body, ship hull, bathtub and storage tank.
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Compression molding
The carbon fiber prepreg is placed between the upper and lower molds, and the mold clamping puts the mold on the hydroforming table, and after a certain period of high temperature and high pressure to solidify the resin, the carbon fiber products are removed. This molding technology has the advantages of high efficiency, good quality, high dimensional accuracy, and low environmental impact, and is suitable for the molding of composite parts with mass production and high strength. However, the mold manufacturing in the early stage is complex, the investment is high, and the size of the workpiece is limited by the size of the press.
Pultrusion
Continuous carbon fiber tows, tapes or cloths impregnated with resin glue are formed and cured through extrusion molds under the action of traction, and profiles of unlimited lengths are continuously produced. Pultrusion is a special process in the composite molding process, and its advantage is that the production process can be fully automated and controlled, and the production efficiency is high.
Second, the advantages of the mold after coating
- Enhance the release property of the mold county, reduce the adhesion between the product and the mold county, improve the product quality, and avoid the use of release agents to contaminate the product
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2. Improve the hardness of the mold surface, reduce the damage of the forming surface, and the mold surface after coating has extremely high hardness, and it is difficult to cause damage to the high-pressure brush and particles of the material, so as to prolong the life of the mold
3. Protect the high mirror mold The processing cost of the mirror mold is extremely high, and the suitable high-gloss and high-hardness coating not only ensures that the surface finish is not affected, but also reduces the high repair cost
4。 Protect the special processing surface (precision Edm processing surface) A large number of products require surface roughness due to function, which greatly improves the processing cost of the molding surface of the injection mold, and the coating with high hardness and super adhesion force can effectively protect the time-consuming and labor-consuming special working surface of the mold
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5。 The mold core accessories can achieve oil-free lubrication of the injection mold's ejector pins can achieve oil-free lubrication after coating, which not only improves the life of the mold, but also eliminates the need for secondary cleaning of the product
6。 For materials with abrasives and glass fibers, the injection molding production of the above hard materials is greatly improved, because the erosion of different materials and sports wear accelerates the scrapping of the mold, and the extremely high hardness coating applied to the mold surface can completely solve the problem