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碳纤维缠绕管
Carbon Fiber Filament-Wound Tubes

      碳纤维复合材料缠绕技术是通过将浸渍树脂的碳纤维按特定角度、张力规则缠绕在芯模上,经固化成型获得高强度、高刚度制品的关键工艺。由碳纤维缠绕技术生产的产品应用广泛。其技术的核心优势在于能充分发挥碳纤维的轴向强度(可达3000MPa以上),且制品纤维体积含量高(通常60%-70%)、结构整体性强,是高端复合材料制品的主流成型方式之一。


      一、技术原理与核心要素


      碳纤维缠绕技术的本质是“定向纤维增强”,通过精准控制纤维缠绕的角度、张力和路径,使制品在受力方向上实现纤维的最优排布,从而匹配使用场景的力学需求(如内压容器的环向 / 轴向强度平衡)。所以其关键参数主要有,第一、决定制品力学性能的核心参数缠绕角度(环向角度、轴向角度和螺旋角度);第二、决定产品质量的增强纤维的高精度张力控制;第三、决定产品细观性能的纤维浸渍方法。


      二、核心工艺和技术流程


      碳纤维缠绕技术的全流程可分为“设计 - 制备 - 成型 - 检测”四大阶段,各环节技术细节直接影响制品性能。

      第一、前期设计与仿真:基于产品受力需求(如内压、拉伸、弯曲),通过 CAD/CAE 软件(如 CATIA、ANSYS)设计缠绕路径,模拟纤维排布、张力分布及固化后的应力状态。

      第二、基于产品的芯模设计:根据制品形状定制(金属、复合材料或可溶芯模),要求表面光滑(粗糙度 Ra≤0.8μm)以保证制品内壁质量。

      第三、原材料选择与匹配:碳纤维(常用 T700、T800 级(高强度型)或 M40J、M55J 级(高模量型),根据产品需求选择丝束规格(12K、24K 等))以及树脂体系(环氧、酚醛、双马来酰亚胺(BMI)等,需匹配固化工艺)。

      第四、缠绕成型设备与工艺:设备类型只要包括数控缠绕机(多轴联动可实现复杂路径缠绕,定位精度达 ±0.1mm)和机器人缠绕系统(柔性更高,适用于大型异形件)。缠绕方式主要包括干法缠绕和湿法缠绕。

      第五、固化与后处理以:根据树脂类型选择固化方式,如热压罐(高压环境,适用于航空级制品)、烘箱(常压,适用于民用产品)或微波固化(高效节能,固化时间缩短 50%)。后处理主要是脱模后去除飞边、钻孔,必要时进行表面喷涂(如防腐蚀涂层)或机加工(精度要求 ±0.05mm)。

      第六、质量检测:无损检测:超声探伤(检测分层、气泡)、X 射线(检测纤维排布缺陷)、CT 扫描(三维结构分析);力学性能测试:拉伸强度(≥2000MPa)、爆破压力(如 45MPa 氢能瓶需通过 1.5 倍工作压力爆破测试)、疲劳寿命(≥10 万次循环)。


      三、慧通缠绕技术的典型产品


      1、标准碳纤维轻量化结构管:主要有圆管、方管、花纹管等。

      2、各种碳纤维轻量化异型管:主要有异型截面管(六角管、八角管、‌椭圆管‌)、变径管(锥形管)、弯曲管等。

      3、先进碳纤维高强度缠绕轴:主要有气胀轴、传动轴、连轴器等。

      4、先进碳纤维轻量化液压缸:主要有活塞杆、液压缸等。

      5、先进碳纤维轻量化储气罐:主要有储氢瓶、氧气瓶、液化油气罐等。


The winding technology of carbon fiber composite materials is a key process of obtaining high-strength and high stiffness products by winding carbon fibers impregnated with resin on a core mold at a specific angle and tension rule, and then curing and forming them. Products produced by carbon fiber winding technology are widely used. The core advantage of its technology lies in the ability to fully utilize the axial strength of carbon fiber (up to 3000MPa or more), and the high fiber volume content (typically 60% -70%) and strong structural integrity of the product, making it one of the mainstream forming methods for high-end composite material products.
1、 Technical principles and core elements
The essence of carbon fiber winding technology is "directional fiber reinforcement", which precisely controls the angle, tension, and path of fiber winding to achieve the optimal arrangement of fibers in the direction of force, thereby matching the mechanical requirements of the usage scenario (such as the circumferential/axial strength balance of internal pressure vessels). So its key parameters mainly include, firstly, the core parameter that determines the mechanical properties of the product, the winding angle (circumferential angle, axial angle, and helical angle); Secondly, high-precision tension control of reinforcing fibers that determine product quality; Thirdly, the fiber impregnation method that determines the microscopic performance of the product.
2、 Core techniques and technical procedures
The entire process of carbon fiber winding technology can be divided into four stages: "design preparation molding testing", and the technical details of each stage directly affect the performance of the product.
1.Preliminary design and simulation: Based on the product's stress requirements (such as internal pressure, tension, and bending), the winding path is designed using CAD/CAE software (such as CATIA, ANSYS) to simulate fiber arrangement, tension distribution, and stress state after curing.
2.Product based core mold design: customized according to the shape of the product (metal, composite material, or soluble core mold), requiring a smooth surface (roughness Ra ≤ 0.8 μ m) to ensure the quality of the inner wall of the product.
3.Raw material selection and matching: carbon fiber (commonly T700, T800 grade (high-strength type) or M40J, M55J grade (high modulus type), choose fiber bundle specifications (12K, 24K, etc.) according to product requirements) and resin system (epoxy, phenolic, bismaleimide (BMI), etc., need to be matched with curing process)
4.Winding forming equipment and process: Equipment types only need to include CNC winding machines (multi axis linkage can achieve complex path winding, with positioning accuracy of ± 0.1mm) and robot winding systems (more flexible, suitable for large shaped parts). The winding methods mainly include dry winding and wet winding.
5.Curing and post-treatment: Choose the curing method according to the resin type, such as hot press tank (high-pressure environment, suitable for aviation grade products), oven (atmospheric pressure, suitable for civilian products), or microwave curing (high-efficiency and energy-saving, reducing curing time by 50%). Post treatment mainly involves removing burrs and drilling holes after demolding, and if necessary, surface spraying (such as anti-corrosion coating) or machining (accuracy requirement ± 0.05mm).
6.Quality inspection: Non destructive testing: ultrasonic testing (detecting delamination and bubbles), X-ray (detecting fiber arrangement defects), CT scanning (three-dimensional structural analysis); Mechanical performance testing: tensile strength (≥ 2000MPa), burst pressure (e.g. 45MPa hydrogen cylinder needs to pass 1.5 times the working pressure burst test), fatigue life (≥ 100000 cycles)
3、 Typical products of WUT winding technology
1. Standard carbon fiber lightweight structural pipes: mainly including round pipes, square pipes, patterned pipes, etc.
2. Various lightweight carbon fiber shaped pipes: mainly including irregular cross-section pipes (hexagonal, octagonal, elliptical), variable diameter pipes (conical), curved pipes, etc.
3. Advanced carbon fiber high-strength winding shaft: mainly includes inflatable shaft, transmission shaft, coupling, etc.
4. Advanced carbon fiber lightweight hydraulic cylinders: mainly including piston rods, hydraulic cylinders, etc.
5. Advanced carbon fiber lightweight gas storage tanks: mainly including hydrogen storage cylinders, oxygen cylinders, liquefied oil and gas cylinders, etc.
碳纤维异形管
Carbon Fiber Filament-Wound Rolls
碳纤维缠绕辊
Carbon Fiber Filament-Wound Roller Shafts
碳纤维缠绕轴
Carbon Fiber Filament-Wound Roller Shafts
碳纤维液压缸
Carbon Fiber Hydraulic Cylinders
碳纤维储气罐
Carbon Fiber Gas Storage Tanks
碳纤维工业品
Carbon Fiber Industrial Products
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