CN109808204A - 热塑性连续-非连续纤维复合板的制造方法 - Google Patents

热塑性连续-非连续纤维复合板的制造方法 Download PDF

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Publication number
CN109808204A
CN109808204A CN201810093127.0A CN201810093127A CN109808204A CN 109808204 A CN109808204 A CN 109808204A CN 201810093127 A CN201810093127 A CN 201810093127A CN 109808204 A CN109808204 A CN 109808204A
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China
Prior art keywords
thermoplasticity
discontinuous fiber
continuous
thermoplastic
layer
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CN201810093127.0A
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English (en)
Inventor
曾宇璨
吴礼竹
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Shangwei International Investment Holding Co Ltd
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Swancor Industrial Co Ltd
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Publication of CN109808204A publication Critical patent/CN109808204A/zh
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    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
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Abstract

本发明提供一种热塑性连续‑非连续纤维复合板的制造方法，包括提供包括连续纤维与第一热塑性树脂的热塑性复合材。机械处理热塑性复合材，以形成多个碎片，使其中的连续纤维成为非连续纤维。使用多个碎片作为原料形成至少一热塑性非连续纤维聚集体层。热压合至少一热塑性非连续纤维聚集体层与至少一热塑性连续纤维层。本发明的热塑性连续‑非连续纤维复合板具有良好的弯曲特性以及成型性。

Description

热塑性连续-非连续纤维复合板的制造方法
技术领域
本发明涉及一种多层复合板制造方法，尤其涉及一种热塑性连续-非连续纤维复合板的制造方法。
背景技术
由基质树脂和增强纤维(reinforcing fibers)所构成的纤维增强板材由于具有良好的机械特性、轻质性以及耐腐蚀性，因此被广泛利用在例如飞机、汽车、运动用具等用途的部件的材料。
现有热塑性连续纤维板材多由数层连续纤维布及热塑高分子进行热压合(lamination)而成，相对于传统热固连续纤维材料来说，有快速成型及可回收的特性，然而在实际使用上仍有重大缺点。
在回收方面，目前含热塑性连续纤维材料的回收，大多采用热裂解法，必须透过高温炉调控适合温度，选择性热裂解高分子，留下纤维，如此法虽然可最大程度保留纤维长度，但处理能秏高，且在热分解过程中，原来在纤维表面的上浆剂(sizing)也一同被分解掉，影响后续纤维再利用在树脂含浸性。另外还有使用溶剂将高分子与纤维分离，不仅秏费溶剂，最后还是要秏费能源把溶剂与高分子分离，制造更多环保问题。
另外一种回收再利用方式是将回收的连续纤维基材(例如连续纤维基材的边材)与热塑性树脂进行混料造粒，并将上述粒子作为射出处理使用的原料。此法技术门槛低且成熟，具有方便使用性。然而，在直接进行注射成型的情况下，边料的纤维在热塑性树脂中无法充分分散。此外，经过螺杆混料造粒以及射出机的螺杆熔融，接着高压剪切力推进，经流道注塑模具后，材料内纤维长度大幅降低，所能提升的力学增强性能有限。因此，日本专利公开号JP 2006-218793公开了可将碳纤维增强热塑性树脂成形品粉碎、粒化后，混合新品的碳纤维增强热塑性树脂颗粒并进行注射射型。然而如此这样一来则将提高制作成本。
此外，世界专利公开号WO 2012086682 A1(中国对应案CN 103119209 A、欧洲对应案EP 2642007 A1以及美国对应案US 20130192434)公开一种制造碳纤维增强塑料的方法。此方法是将含有碳纤维的碳纤维基材的边材切断，将所得到的切断片在进行梳棉(carding)处理过程中加入热塑性树脂纤维，以得到含热塑性树脂纤维的碳纤维聚集体。之后，将含热塑性树脂纤维的碳纤维聚集体含浸基质树脂并成型，以得到碳纤维增强塑料。然而，上述的方法所得到的碳纤维聚集体仍需进行含浸处理，且所花费的时间长，再利用性以及绿能环保性不佳。
此外，对比热固连续纤维材料，传统连续纤维热塑材料成形性非常差，无法成形几何结构复杂的部件，尤其对于高厚度的板材，在曲率较高的部位成形性非常差，且容易发生皱折。由于热塑碳纤维板材受限于成形复杂度低，使其应用普及率相对较低。
然而，现今要达到高厚度的多层碳纤维复合板，表层为连续碳纤维，中间芯层多为蜂巢结构、发泡材料，但此方式无法二次成形、材料利用率低、材料成本也无法有效的降低。
发明内容
本发明提供一种热塑性连续-非连续纤维复合板的制造方法，可达成具有良好的弯曲特性以及成型性的热塑性连续-非连续纤维复合板。
本发明的热塑性连续-非连续纤维复合板的制造方法，包括提供热塑性复合材，所述热塑性复合材包括连续纤维与第一热塑性树脂；机械处理所述热塑性复合材，以形成多个碎片，使其中的所述连续纤维成为非连续纤维；使用所述多个碎片作为原料形成至少一热塑性非连续纤维聚集体层；以及热压合所述至少一热塑性非连续纤维聚集体层与至少一热塑性连续纤维层。
在本发明的一实施例中，上述的热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤可包括：重叠所述热塑性非连续纤维聚集体层与两层的所述热塑性连续纤维层，并进行热压合，使所述热塑性非连续纤维聚集体层夹在两层的所述热塑性连续纤维层之间。
在本发明的一实施例中，上述的热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤可包括：重叠所述热塑性连续纤维层与两层的所述热塑性非连续纤维聚集体层，并进行热压合，使所述热塑性连续纤维层夹在两层的所述热塑性非连续纤维聚集体层之间。
在本发明的一实施例中，上述的热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤包括：交替地重叠所述热塑性连续纤维层与所述热塑性非连续纤维聚集体层，并进行热压合。
在本发明的一实施例中，在热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层之前，可更包括于所述热塑性非连续纤维聚集体层的至少一表面上形成强化层，其中所述强化层至少位于所述热塑性非连续纤维聚集体层与所述热塑性连续纤维层之间。
在本发明的一实施例中，上述的强化层例如是单一膜层或由粉体所构成。
在本发明的一实施例中，上述形成所述热塑性非连续纤维聚集体层的方法可包括：热压合所述多个碎片。
在本发明的一实施例中，上述热压合所述多个碎片的方法例如是模压或冲压。
在本发明的一实施例中，上述形成所述热塑性非连续纤维聚集体层的方法可包括：对所述多个碎片进行混练造粒，以形成多个粒子；以及使用所述多个粒子进行射出成型。
在本发明的一实施例中，上述热压合所述热塑性非连续纤维聚集体层与所述热塑性连续纤维层的方法包括：使用平板膜或平面钢板来进行压合。
在本发明的一实施例中，上述的热塑复合材中的所述连续纤维例如是碳纤维、玻璃纤维、玄武岩纤维、金属纤维、陶瓷纤维或化学纤维。
在本发明的一实施例中，上述的热塑复合材中的所述第一热塑性树脂例如是聚碳酸酯(polycarbonate，PC)、聚丙烯(polypropylene，PP)、聚砜(polysulfone，PS)、热塑性聚胺基甲酸酯(thermoplastic polyurethane，TPU)、丙烯腈-丁二烯-苯乙烯树脂(Acrylonitrile Butadiene Styrene，ABS)、聚乙烯(polyethylene，PE)、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。
在本发明的一实施例中，上述的强化层包括第二热塑性树脂。
在本发明的一实施例中，上述的第二热塑性树脂包括聚碳酸酯、聚丙烯、聚砜、热塑性聚胺基甲酸酯、丙烯腈-丁二烯-苯乙烯树脂、聚乙烯、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。
在本发明的一实施例中，上述的第一热塑性树脂不同于所述第二热塑性树脂。
在本发明的一实施例中，上述的非连续纤维的长度为3mm至20mm。
在本发明的一实施例中，上述的非连续纤维的长度小于3mm。
在本发明的一实施例中，上述的非连续纤维的长度为20mm至50mm。
在本发明的一实施例中，上述的热塑性复合材为回收的热塑性复合材。
基于上述，本发明的热塑性连续-非连续纤维复合板具有由热塑性连续纤维层以及热塑性非连续纤维聚集体层所堆叠而成的结构，因此具有良好的弯曲特性以及成型性。
为让本发明的上述特征和优点能更明显易懂，下文特举实施例，并配合附图作详细说明如下。
附图说明
图1为本发明第一实施例的热塑性连续-非连续纤维复合板的剖面示意图；
图2为本发明第二实施例的热塑性连续-非连续纤维复合板的剖面示意图；
图3为本发明第三实施例的热塑性连续-非连续纤维复合板的剖面示意图；
图4为本发明第四实施例的热塑性连续-非连续纤维复合板的剖面示意图；
图5为本发明第五实施例的热塑性连续-非连续纤维复合板的剖面示意图；
图6为本发明第六实施例的热塑性连续-非连续纤维复合板的剖面示意图；
图7是依照本发明的第一实施例的一种热塑性连续-非连续纤维复合板的制造流程步骤图；
图8A是第一实施例的一种热塑性非连续纤维聚集体层的剖面示意图；
图8B是所述第一实施例的另一种热塑性非连续纤维聚集体层的剖面示意图；
图9为本发明一实施例的热塑性连续-非连续纤维复合板的剖面示意图。
附图标号说明：
S100、S102、S104、S106：步骤
100、200、300、400、500、600、700：热塑性连续-非连续纤维复合板
102、112、122、132：热塑性非连续纤维聚集体层
102a：第一表面
102b：第二表面
103、113、123、133：强化层
104、114、124、134：热塑性连续纤维层
105：粒子
107：碎片
具体实施方式
下文列举一些实施例并配合附图来进行详细地说明，但所提供的实施例并非用以限制本发明所涵盖的范围。此外，附图仅以说明为目的，并未依照原尺寸作图。为了方便理解，下述说明中相同的元件将以相同的符号标示来说明。另外，关于文中所使用“包含”、“包括”、“具有”等等用语，均为开放性的用语；也就是指包含但不限于。而且，文中所提到的方向性用语，例如：“上”、“下”等，仅是用以参考附图的方向。因此，使用的方向性用语是用来说明，而并非用来限制本发明。
图1为本发明第一实施例的热塑性连续-非连续纤维复合板的剖面示意图。
请参照图1，热塑性连续-非连续纤维复合板100包括交互堆叠的热塑性非连续纤维聚集体层102以及热塑性连续纤维层104。热塑性非连续纤维聚集体层102包括非连续纤维以及第一热塑性树脂。在一实施例中，热塑性非连续纤维聚集体层102中的非连续纤维例如是碳纤维、玻璃纤维、玄武岩纤维、金属纤维、陶瓷纤维或化学纤维；热塑性非连续纤维聚集体层102中的第一热塑性树脂例如是聚碳酸酯(polycarbonate，PC)、聚丙烯(polypropylene，PP)、聚砜(polysulfone，PS)、热塑性聚胺基甲酸酯(thermoplasticpolyurethane，TPU)、丙烯腈-丁二烯-苯乙烯树脂(Acrylonitrile Butadiene Styrene，ABS)、聚乙烯(polyethylene，PE)、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。在一实施例中，热塑性非连续纤维聚集体层102的原料例如是回收的热塑性复合材的碎片，其中所述热塑性复合材包括连续纤维与热塑性树脂。具体来说，可对回收热塑性复合材进行机械处理，以形成碎片，并使回收热塑性复合材中的连续纤维成为非连续纤维。
在一实施例中，热塑性非连续纤维聚集体层102中的非连续纤维的长度为3mm至20mm。在另一实施例中，热塑性非连续纤维聚集体层102中的非连续纤维的长度小于3mm。在又一实施例中，热塑性非连续纤维聚集体层102中的非连续纤维的长度为20mm至50mm。
热塑性连续纤维层104包括连续纤维以及第二热塑性树脂。在一实施例中，热塑性连续纤维层104中的连续纤维例如是碳纤维、玻璃纤维、玄武岩纤维、金属纤维、陶瓷纤维或其他化学纤维等材料；热塑性连续纤维层102中的第二热塑性树脂例如是聚碳酸酯、聚丙烯、聚砜、热塑性聚胺基甲酸酯、丙烯腈-丁二烯-苯乙烯树脂、聚乙烯、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。在一实施例中，热塑性连续纤维层104例如是由热塑性树脂所预浸的连续纤维布。
热塑性连续-非连续纤维复合板100具有由热塑性连续纤维层以及热塑性非连续纤维聚集体层所堆叠而成的结构，因此具有良好的弯曲特性以及成型性。
图2为本发明第二实施例的热塑性连续-非连续纤维复合板的剖面示意图。在本实施例中，热塑性连续-非连续纤维复合板200更包括强化层103。强化层103分别配置于热塑性非连续纤维聚集体层102的相对的第一表面102a与第二表面102b上。在一实施例中，强化层103例如是单一膜层或由粉体所构成。在一实施例中，强化层103的材料包括第三热塑性树脂。第三热塑性树脂例如是聚碳酸酯、聚丙烯、聚砜、热塑性聚胺基甲酸酯、丙烯腈-丁二烯-苯乙烯树脂、聚乙烯、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。在本实施例中，强化层103配置于热塑性非连续纤维聚集体层102的相对表面(即第一表面102a以及第一表面102b)上，但本发明不限于此。在另一实施例中，强化层103可仅配置于热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间。
一般来说，纤维与纤维之间互相堆叠可能会产生空隙，因此会造成力学强度下降。在本实施例中，由于在热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间形成有强化层103，强化层103可填平热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间的空隙，进而强化未来成品的整体机械性质。此外，若是热塑性非连续纤维聚集体层102表面为光滑表面，也可利用不同于热塑性非连续纤维聚集体层102中的热塑性树脂，对其改质增加热塑性非连续纤维聚集体层与后续结构层之间的接着力。此外，热塑性纤维层通常会与一般工程塑料(异种材料)进行结合，然而热塑性纤维层并无法满足所有异种材料的贴合。在本实施例中，由于热塑性非连续纤维聚集体层102的表面上形成有强化层103，因此可通过强化层103来对热塑性非连续纤维聚集体层102的表面进行界面改质，以提升与异种材料的结合性。
图3为本发明第三实施例的热塑性连续-非连续纤维复合板的剖面示意图。在本实施例中，热塑性连续-非连续纤维复合板300包括一热塑性非连续纤维聚集体层112以及两个热塑性连续纤维层114，其中两个热塑性连续纤维层114分别配置于热塑性非连续纤维聚集体层112的相对表面上。此外，在本实施例中，热塑性非连续纤维聚集体层112的相对表面上形成有强化层113，且强化层113配置于热塑性非连续纤维聚集体层112与热塑性连续纤维层114之间。
图4为本发明第四实施例的热塑性连续-非连续纤维复合板的剖面示意图。在本实施例中，热塑性连续-非连续纤维复合板400包括两个热塑性非连续纤维聚集体层122以及一热塑性连续纤维层124，其中两个非连续纤维聚集体层122分别配置于热塑性连续纤维层124的相对表面上。此外，在本实施例中，每一个热塑性非连续纤维聚集体层122的相对表面上形成有强化层123，但本发明不限于此。在另一实施例中，强化层123可仅配置于热塑性非连续纤维聚集体层122的面对热塑性连续纤维层124的表面上。
图5为本发明第五实施例的热塑性连续-非连续纤维复合板的剖面示意图。在本实施例中，热塑性连续-非连续纤维复合板500包括多个热塑性非连续纤维聚集体层以及多个热塑性连续纤维层。具体来说，热塑性连续-非连续纤维复合板500包括两个热塑性非连续纤维聚集体层132以及两个热塑性连续纤维层134，其中热塑性非连续纤维聚集体层132与热塑性连续纤维层134交互堆叠。在本实施例中，每一个热塑性非连续纤维聚集体层132的相对表面皆形成有强化层133，但本发明不限于此。在另一实施例中，强化层133可仅配置于每一个热塑性非连续纤维聚集体层132的面对热塑性连续纤维层134的表面上。
图6为本发明第六实施例的热塑性连续-非连续纤维复合板的剖面示意图。在本实施例中，最外层均为热塑性连续纤维层134，以组成强度较佳的板材。以上热塑性非连续纤维聚集体层与热塑性连续纤维层的数量与尺寸均可依照需求作变化，并不限于上述实施例所述。此外，在上述该些实施例的热塑性非连续纤维聚集体层的表面上皆形成有强化层，但本发明不限于此，亦可以不形成有强化层。
图7是依照本发明的第一实施例的一种热塑性连续-非连续纤维复合板的制造流程步骤图。请参照图1以及图7，下文将参考图1的热塑性连续-非连续纤维复合板来说明本实施例的热塑性连续-非连续纤维复合板的制造方法。
请参照图7，在步骤S100中，提供热塑性复合材，所述热塑性复合材包括连续纤维与热塑性树脂。在一实施例中，热塑性复合材为回收热塑性复合材。由于热塑性复合材在成型时会产生许多大小不一的边料及处理废料，因此本发明的热塑性非连续纤维聚集体层使用上述的回收边料及处理废料作为原料并进行二次成型，进而大幅降低成本并提高材料利用率以及绿能环保性佳。此外，由于回收热固性复合材作为原料需要高能燃烧或酸洗，因此相较于使用热固性复合材作为原料，本实施例使用热塑性复合材作为原料有节能减碳的优点。此外，相较于使用含浸前的干纱作为原料，本实施例使用已含浸的热塑性复合材作为原料，因此所制得的成品含浸性佳。
接着，在步骤S102中，机械处理所述热塑性复合材，以形成多个碎片，使其中的连续纤维成为非连续纤维。在一实施例中，所述机械处理包括将纤维长度小于20mm的回收热塑性复合材粉碎。在另一实施例中，所述机械处理包括将纤维长度在20mm以上的回收热塑性复合材以撕碎机撕碎。经过机械处理后的碎片可包括短纤、长纤或超长纤；举例来说，经粉碎得到的碎片例如是纤维长度小于5mm的短纤或者纤维长度在5mm～20mm的长纤；经撕碎得到的碎片例如是纤维长度超过20mm的超长纤。
然后，在步骤S104中，直接使用上述碎片作为原料形成至少一热塑性非连续纤维聚集体层102。在一实施例中，形成热塑性非连续纤维聚集体层102的方法可先对碎片进行混练造粒，以形成多个粒子，并使用所述粒子进行射出成型，如图8A所示。在另一实施例中，形成上述热塑性非连续纤维聚集体层102的方法包括热压合碎片，如模压或冲压，如图8B所示。
之后，在步骤S106中，热压合至少一热塑性非连续纤维聚集体层102与至少一热塑性连续纤维层104。热压合热塑性非连续纤维聚集体层102与热塑性连续纤维层104的方法例如是使用平板膜或平面钢板来进行压合(lamination)。至此，即完成本发明的热塑性连续-非连续纤维复合板100。
由于热塑性连续-非连续纤维复合板100具有由热塑性连续纤维层以及热塑性非连续纤维聚集体层所堆叠而成的结构，因此具有良好的弯曲特性以及成型性。
在图8A中，热塑性非连续纤维聚集体层102是由粒子105组成，此热塑性非连续纤维聚集体层102的表面放大会观察到一些空隙且表面因此不大平整。在图8B中，热塑性非连续纤维聚集体层102是由碎片107堆叠而成，热塑性非连续纤维聚集体层102表面放大也会有表面不大平整的情形。
因此，在一实施例中，可在进行步骤S106之前，于热塑性非连续纤维聚集体层102的至少一表面上形成强化层103。接着再进行热压合，使强化层103至少位于热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间。由于在热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间形成有强化层103，强化层103可填平热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间的空隙，进而强化未来成品的整体机械性质。此外，在本实施例中，强化层103形成于热塑性非连续纤维聚集体层102的相对表面(即第一表面102a以及第一表面102b)上，如图2所示，但本发明不限于此。在另一实施例中，强化层103可仅形成于热塑性非连续纤维聚集体层122的面对热塑性连续纤维层124的表面上，即强化层103可仅形成形成于热塑性非连续纤维聚集体层102与热塑性连续纤维层104之间。
在一实施例中，热压合至少一热塑性非连续纤维聚集体层与至少一热塑性连续纤维层的步骤可先重叠热塑性非连续纤维聚集体层与两层的热塑性连续纤维层，并进行热压合，使热塑性连续-非连续纤维复合板300的热塑性非连续纤维聚集体层112夹在两层热塑性连续纤维层114之间，如图3所示。
在一实施例中，热压合至少一热塑性非连续纤维聚集体层与至少一热塑性连续纤维层的步骤可先重叠热塑性连续纤维层与两层的热塑性非连续纤维聚集体层，并进行热压合，使热塑性连续-非连续纤维复合板400的热塑性连续纤维层124夹在两层热塑性非连续纤维聚集体层122之间，如图4所示。
在一实施例中，热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤包括：交替地重叠热塑性连续纤维层与热塑性非连续纤维聚集体层，并进行热压合，以得到如图5或图6所示的热塑性连续-非连续纤维复合板。
此外，在其他实施例中，可通过选用不同尺寸的热塑性非连续纤维聚集体层102与热塑性连续纤维层104而热压合形成如图9的复杂结构的热塑性连续-非连续纤维复合板700。以上热塑性非连续纤维聚集体层与热塑性连续纤维层的数量与尺寸均可依照需求作变化，并不限于上述实施例所述。
以下列举一些实验例来验证本发明的功效，但本发明并不局限于以下的内容。
实验例1
首先，将具有纤维长度小于20mm的碳纤维的热塑性复合材进行粉碎，以得到纤维长度为3mm～20mm的碎片(即粉碎料)。接着，对粉碎料进行混练造粒，即添加新鲜塑料进行混炼并制作出粒子(纤维长度小于3mm)，再使用所述粒子进行射出成型，以得到热塑性非连续纤维聚集体层。然后，热压合上述热塑性非连续纤维聚集体层与两层3K预浸布(即热塑性连续纤维层)，其中3K预浸布是指由3K碳纱依经纬各半编成的布所制成的预浸布。上述所得到的结构为以热塑性连续纤维层作为上下外皮层的热塑性连续纤维层/热塑性非连续纤维聚集体层/热塑性连续纤维层的三明治结构。
实验例2
首先，将具有纤维长度小于20mm的碳纤维的热塑性复合材进行粉碎，以得到纤维长度为3mm～20mm的碎片(即粉碎料)。接着，将粉碎料进行热压合以形成热塑性非连续纤维聚集体层。
实验例3
首先，将具有纤维长度20mm以上的碳纤维的热塑性复合材以撕碎机撕碎，以得到纤维长度为20mm～50mm的碎片(粉碎料)。接着，将粉碎料进行热压合以形成热塑性非连续纤维聚集体层。
对照组
将三层单方向预浸布与两层3K预浸布进行热压合，其中单方向预浸布与3K预浸布皆为热塑性连续纤维层。
然后对上述实验例1～3与对照组分别进行机械强度测试与力学和成本的降幅估算，结果显示于下表一。要特别说明的是，所有的量测数据皆是控制在相同的厚度，且所使用的3K预浸布皆相同。
表一
从表一可得到，实验例1～3可达到降低32％～35％成本且维持不同程度的力学强度，材料利用率提高至99％的功效。
虽然本发明已以实施例揭示如上，然其并非用以限定本发明，任何所属技术领域中技术人员，在不脱离本发明的精神和范围内，当可作些许的更改与润饰，故本发明的保护范围当视权利要求所界定的为准。

Claims (19)

1.一种热塑性连续-非连续纤维复合板的制造方法，其特征在于，包括：
提供热塑性复合材，所述热塑性复合材包括连续纤维与第一热塑性树脂；
机械处理所述热塑性复合材，以形成多个碎片，使其中的所述连续纤维成为非连续纤维；
使用所述多个碎片作为原料形成至少一热塑性非连续纤维聚集体层；以及
热压合所述至少一热塑性非连续纤维聚集体层与至少一热塑性连续纤维层。
2.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤包括：重叠所述热塑性非连续纤维聚集体层与两层的所述热塑性连续纤维层，并进行热压合，使所述热塑性非连续纤维聚集体层夹在两层的所述热塑性连续纤维层之间。
3.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤包括：重叠所述热塑性连续纤维层与两层的所述热塑性非连续纤维聚集体层，并进行热压合，使所述热塑性连续纤维层夹在两层的所述热塑性非连续纤维聚集体层之间。
4.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层的步骤包括：交替地重叠所述热塑性连续纤维层与所述热塑性非连续纤维聚集体层，并进行热压合。
5.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，在热压合所述至少一热塑性非连续纤维聚集体层与所述至少一热塑性连续纤维层之前，还包括于所述热塑性非连续纤维聚集体层的至少一表面上形成强化层，其中所述强化层至少位于所述热塑性非连续纤维聚集体层与所述热塑性连续纤维层之间。
6.根据权利要求5所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述强化层包括单一膜层或由粉体所构成。
7.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，形成所述热塑性非连续纤维聚集体层的方法包括：热压合所述多个碎片。
8.根据权利要求7所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，热压合所述多个碎片的方法包括模压或冲压。
9.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，形成所述热塑性非连续纤维聚集体层的方法包括：对所述多个碎片进行混练造粒，以形成多个粒子；以及使用所述多个粒子进行射出成型。
10.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，热压合所述热塑性非连续纤维聚集体层与所述热塑性连续纤维层的方法包括：使用平板膜或平面钢板来进行压合。
11.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述热塑复合材中的所述连续纤维包括碳纤维、玻璃纤维、玄武岩纤维、金属纤维、陶瓷纤维或化学纤维。
12.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述热塑复合材中的所述第一热塑性树脂包括聚碳酸酯、聚丙烯、聚砜、热塑性聚胺基甲酸酯、丙烯腈-丁二烯-苯乙烯树脂、聚乙烯、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。
13.根据权利要求5所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述强化层包括第二热塑性树脂。
14.根据权利要求13所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述第二热塑性树脂包括聚碳酸酯、聚丙烯、聚砜、热塑性聚胺基甲酸酯、丙烯腈-丁二烯-苯乙烯树脂、聚乙烯、热塑性环氧树脂、聚氨酯树脂、聚脲树脂或其组合。
15.根据权利要求13所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述第一热塑性树脂不同于所述第二热塑性树脂。
16.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述非连续纤维的长度为3mm至20mm。
17.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述非连续纤维的长度小于3mm。
18.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述非连续纤维的长度为20mm至50mm。
19.根据权利要求1所述的热塑性连续-非连续纤维复合板的制造方法，其特征在于，所述热塑性复合材为回收的热塑性复合材。
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