Carbon fiber coil forming process and application

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Carbon fiber coil forming process is a kind of composite material product forming method using carbon fiber prepreprepreprepreprepreprepreprepreform in hot coiling machine.

Carbon fiber (CF) is a fibrous carbon material with a carbon content of more than 90%. It is made by carbonization of various organic fibers in inert gas and at high temperature. It has excellent mechanical properties. Especially in the more than 2000 ℃ high temperature inert environment, is the only material strength is not falling. As a new material in the 21st century, carbon fiber and carbon fiber reinforced composite (CFRP), with its high strength, high elastic modulus and low specific weight, have been widely used in automobiles. Carbon fiber can be seen in vehicles' appearance plates, engine cabin gas tanks, indoor door panels and decorative panels. Experts say carbon fiber could revolutionize the car industry in the next five years.


Carbon fiber coil forming process is a kind of composite material product forming method using carbon fiber prepreprepreprepreprepreprepreprepreform in hot coiling machine.
The principle is to use the hot roll on the pipe coiling machine, so that the pre - dip material softens, melting the resin adhesive on the pre - dip material. Under certain tension, during the roll rotation operation, the preprepretreatment material is continuously rolled on the core of the pipe by friction between the roller and the spindle until the required thickness is reached. Then, the pretreatment material is cooled and shaped by the cold roll, removed from the winding machine and solidified in the curing furnace. After the pipe is solidified, the core model can be removed. According to the method of preloading in the forming process, it can be divided into manual feeding method and continuous mechanical method. The basic process is: first, clean the drum, then heat the hot roller to the set temperature, and adjust the prepreg tension. Without applying pressure on the drum, wrap the primer around the tube core coated with demoulding agent for 1 turn, then put down the press roller, put the print head cloth on the hot roller, and pull out the presoaking material at the same time, stick it on the heating part of the head cloth, and connect it with the primer cloth. The length of the primer cloth is about 800 ~ 1200mm, depending on the pipe diameter. The lap length of the primer cloth and the adhesive cloth is generally 150 ~ 250mm. When the thick wall pipe is rolled, the rotation speed of the core die will be appropriately accelerated in normal operation, and the design speed will be slowed down near the wall thickness to reach the design thickness and cut off the adhesive cloth. Then, the core die is rotated 1 ~ 2 times while the pressure of the roller is maintained. Finally, the press roller is hoisted to measure the outer diameter of the billet. After passing the test, it is removed from the coiling machine and sent to the curing furnace for solidification and forming.
1. Seat heating pad
Carbon fiber car seat heating pad is a breakthrough in the application of carbon fiber heating in the automobile industry. Carbon fiber heating element technology is becoming more and more popular in the automobile supporting market. It will completely replace the traditional seat heating system. Almost all of the world's top and luxury car manufacturers now have these seat heating devices, such as Mercedes, BMW, audi, Volkswagen, Honda and nissan. Carbon fiber thermal load carbon fiber (CFRP) is a kind of heat conducting material with high efficiency, with a thermal efficiency of up to 96%, both in the heating pad
The heat is evenly distributed in the heating area of the seat, and the carbon fiber wire and temperature are evenly distributed. The heating pad can be used for a long time to keep the leather surface of the seat smooth and intact. No trace of lines, no local discoloration. If the temperature exceeds the set range, the power will be cut off automatically. If the temperature cannot meet the temperature requirement, the temperature will be adjusted automatically. Carbon fiber is suitable for absorbing infrared wavelengths of human body, which can promote health, reduce driving fatigue and increase comfort.
2. Car body and chassis
Because carbon fiber reinforced polymer matrix composites have sufficient strength and stiffness, they are suitable for making the lightest materials of automobile body, chassis and other major structural components. The application of carbon fiber composite materials is expected to reduce the weight of automobile body and chassis by 40% ~ 60%, equivalent to 1/3 ~ 1/6 of the weight of steel structure. The British materials systems laboratory has studied the weight loss effect of carbon fiber composite materials. The results show that the body weight of carbon fiber reinforced polymer materials is only 172kg, while the body weight of steel is 368kg, and the weight loss is about 50%. And when the production capacity is less than 20,000 vehicles, the cost of using RTM process to produce composite material body is lower than that of steel body. Toray has developed a technology that USES carbon fiber reinforced plastic (CFRP) to shape a car chassis (front floor) in 10 minutes. But due to the high cost of carbon fiber, carbon fiber composite material application in automobile co., LTD., only in F1, limousines, small batch, model application, such as company B M W Z - 9, Z - 22 of the body, M3 series roof canopy and body, G M Ultralite body, ford's body in original GT40, porsche 911 GT3 monocoque body, etc.
3, the wheel hub
W H E L S A N D M O R E, A well-known expert in wheel hub manufacturing in Germany, has launched the "megalight-forged Series" wheel hub Series, which adopts two-chip design. The outer ring is made of carbon fiber, and the inner hub is lightweight alloy. Taking the 20-inch wheel hub as an example, the megalight-forged Series wheel ring is only 6kg, which is a lot lighter than the average weight of about 18kg. A set of wheels for a 20-inch megalight-forged Series were priced at 20,000 euros, about 218,600 yuan. There are 18 to 23 inches available. The weight of the R X - X car wheel made by CFRP is only 6kg, which can drive at high speed and reduce the radial inertia force of the wheel to the maximum extent. The world's lightest carbon fiber/magnesium wheel, developed by British company madyg, consists of two parts, carbon fiber wheel net and magnesium brake disc, and is connected with special titanium plated hardware.
4. Fuel tank
The use of CFRP can achieve the lightweight of pressure vessel under the condition of meeting this requirement. With the development of eco-car, it is accepted that hydrogen-fueled fuel cell cars use CFRP materials to make fuel tanks. According to the Japan energy agency's fuel cell symposium, 5 million cars will use fuel cells in Japan by 2020. The Hummer H2H suv is also starting to use hydrogen fuel cells and is expected to reach a certain market size in 2015.
5. Brake pad
Carbon fiber is also used in brake pads for its environmental protection and wear-resisting characteristics, but products containing carbon fiber composite materials are especially expensive, so the brake pads are still mainly used in high-end cars. Carbon fiber brake pads are widely used in racing cars, such as F1 cars. It can within 50 m distance to the speed of the car down from 300 km/h to 50 km/h, at this time of the brake disc temperature rises to above 900 ℃, brake disc will turn red because of the large amounts of heat energy. Carbon brake disc capable of withstanding the high temperature of 2500 ℃, and with very good braking stability. Although carbon brake disc has the excellent performance of deceleration performance, but currently in production cars use carbon fiber brake disc is not practical, because the performance of the carbon fiber brake disc when the temperature is above 800 ℃ can achieve the best. In other words, the braking device of a car must be driven for several kilometers before it can enter the optimal working state, which is not applicable to most vehicles that are only driving for short distances. In addition, the carbon fiber brake disc wear speed is very high and the manufacturing cost is very high.