CN110239175A - 轻质纤维增强聚合物夹层结构 - Google Patents

轻质纤维增强聚合物夹层结构 Download PDF

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Publication number
CN110239175A
CN110239175A CN201910162073.3A CN201910162073A CN110239175A CN 110239175 A CN110239175 A CN 110239175A CN 201910162073 A CN201910162073 A CN 201910162073A CN 110239175 A CN110239175 A CN 110239175A
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layer
polymer matrix
composite sandwich
fibre reinforced
sandwich
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CN110239175B (zh
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H·G·起亚
S·X·赵
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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Abstract

提出了一种纤维增强聚合物(FRP)夹层结构、制造/使用这种FRP夹层结构的方法，以及具有由压缩模塑的热固性或热塑性FRP夹层结构制成的车辆部件的机动车辆。多维复合夹层结构包括由热固性或热塑性聚合物基质(例如树脂或尼龙)的形成的第一(表)层和第二(表)层，其填充有纤维增强材料、例如短切碳纤维。封装在第一表层和第二表层之间的第三(芯)层由填充有纤维增强材料和填料材料(例如中空玻璃微球)的热固性/热塑性聚合物基质形成。第一层、第二层和第三层具有基本相似的相应的流变流动性质，使得所有三个层在预定的压缩模塑压力下一致地流动。这些层可以由相同的热固性/热塑性聚合物材料形成，并且包括相同的纤维增强材料。

Description

轻质纤维增强聚合物夹层结构
引言
本发明一般涉及复合材料夹层结构的制造。更具体地，本发明的各方面涉及压缩模塑纤维增强聚合物夹层结构，以及用于构造纤维增强聚合物夹层结构的系统、方法和装置。
复合材料用于制造大量现代产品。例如，许多目前生产的汽车、船只和飞机与承载车身板、美学装饰板、支撑框架构件以及由复合材料全部或部分制造的各种其他部件组装在一起。纤维增强塑料(FRP)是一种示例性复合材料，该复合材料有利于其高强度重量比、增加弹性、耐腐蚀性和轻质性质而用于大规模生产制造应用。FRP通常通过将高拉伸强度纤维材料(例如玻璃、碳、芳族聚酰胺或玄武岩纤维)悬浮在固化聚合物(例如热固性环氧树脂基质或热塑性聚酯或尼龙)内而形成。
有许多可用于大规模生产热固性和热塑性FRP复合构造的技术，其中一个示例包括压缩模塑。压缩模塑是一种高容量、高压力的制造工艺，其中基础材料放置在气动或液压模压机的开口模具空腔中。施加预热或原位加热以使基础材料处于塑化或其它柔韧状态。顶部塞子然后关闭模具的开口面；将匹配的模具部件夹在一起，以便压缩塞子和模具之间的基础材料。模内压力急剧增加，例如达到2000-4000磅/平方英寸(psi)，以迫使基础材料填充内部模具空腔。在组分热固性/热塑性材料固化的同时保持模具的热量和压力。固化后，可以手动、机械地或通过与模压机一体的起模杆将部件脱模。
发明内容
本文公开了一种轻质纤维增强聚合物夹层结构，其制造方法和使用这种FRP夹层结构的方法，以及配备有一个或多个车辆部件的机动车辆，每个车辆部件由压缩模塑的热固性或热塑性FRP夹层结构制成。举例来说，提出了一种轻质FRP夹层结构，其具有填充有玻璃微球的热固性环氧树脂芯板，该热固性环氧树脂芯板被封装在例如具有[0/90/90/0]纤维取向的、穿孔的环氧树脂浸渍的碳纤维板(“预浸料”)之间，，并压缩模塑为所需的部件几何形状。在该示例中，[0/90/90/0]预浸料框架板可以插入两个外部预浸料层之间，并且制造有窗口，该窗口在其中容纳热固性环氧树脂芯板。本文还提供了一种轻质FRP夹层结构，其具有填充有玻璃微球的碳纤维增强热塑性聚合物(CFRTP)芯板，其被封装在CFRTP表层之间并压缩模塑成所需的部件几何形状。在该示例中，芯板可以由原始和回收CFRTP材料的组合挤出而成。对于前述FRP夹层结构中的任一种而言，玻璃-微球填料可以补充有或用木材颗粒、粘土薄片、碳酸钙碎片或任何其它合适的填料材料代替。作为另一种选择，外表层可以用玻璃纤维、芳族聚酰胺纤维、玄武岩纤维或任何其它合适的纤维材料代替或补充碳增强纤维。
对于至少一些所公开的概念的附带益处包括低质量、高强度FRP夹层结构，其可以在不破坏或分层中间芯层的情况下被压缩模塑。穿孔的碳纤维预浸料层在压缩模塑力下提供流变流动性。在压缩模塑之前，芯层可以部分固化，以匹配预浸料层的流变性质。此外，将回收的CFRTP与中空微球结合使用有助于形成可流动的芯。芯层和表层的可比较的流变性质允许夹层结构在压缩模塑下一致地流动。当与传统的对应FRP夹层结构相比时，其他附带的益处可包括增加的强度、减小的质量、降低的部件成本、降低的生产成本和改进的燃料经济性(例如，在用于机动车辆应用时)。
本发明的方面涉及一种轻质纤维增强聚合物夹层结构。例如，提出了一种多维FRP复合夹层结构，其包括(或基本上由其组成)第一和第二(最外部表皮)层和第三(中心芯)层，所述第三(中心芯)层被封装在第一和第二层夹中间或以其他方式夹在第一和第二层之间。第一层由第一热固性或热塑性聚合物基质形成，在其中嵌入有第一基于纤维的增强材料。同样地，第二层由第二热固性或热塑性聚合物基质形成，在其中嵌入有第二基于纤维的增强材料。对于至少一些应用，第一和第二层由嵌有相同增强纤维的相同聚合物材料制成。第三层由第三聚合物基质、例如热塑性尼龙或热固性环氧树脂形成。第三基于纤维的增强材料、例如短切碳纤维或碳纤维板嵌入第三聚合物基质中，并且填料材料、例如中空玻璃微球散布在第三聚合物基质中。第一、第二和第三层具有基本相似的相应的流变流动性质，使得所有三个层在预定的压缩模塑压力的作用下一致地流动。
本发明的其他方面涉及配备有由压缩模塑的FRP夹层结构制成的车辆部件(例如，电池组支撑盘、底板或外部车身面板)的机动车辆。如本文所使用的那样，术语“机动车辆”可以包括任何相关的交通工具平台，例如乘用车辆(内燃机、混合动力、全电动、燃料电池、完全或部分自主等)、商用车辆、工业车辆、履带式车辆、越野和全地形车辆(ATV)、农场设备、船、飞机等。作为示例，提出了一种机动车辆，其包括具有刚性车架的车身，例如制造成一体式车身、车身车架分离式车身结构或其他车辆底盘结构。由FRP夹层结构整体或部分制造的车辆部件安装在刚性车架上。在该示例中，FRP夹层结构包括一对(外)表层，每层表层由嵌有纤维增强材料的热固性或热塑性聚合物基质形成。设置在两个表层之间并附着到两个表层的芯层由与表层相同的热固性或热塑性聚合物基质形成，并且可以嵌入与表层相同的纤维增强材料。合适的FRP填料材料散布在芯层的热固性/热塑性聚合物基质中。表层和芯层具有相似的流变流动性质，使得三个层在压缩模塑期间通常一致地流动(例如，在校准的模塑温度和压力下)。
本发明的其他方面涉及其制造方法和用于使用高强度、低质量的FRP夹层结构的方法。在一个示例中，提出了一种用于形成多维复合夹层结构的方法。该代表性方法包括，以任何顺序并与上文或下文公开的任何特征和选项的任何组合：由第一聚合物基质形成第一层，所述第一聚合物基质包括嵌入该第一聚合物基质内的第一纤维增强材料；由第二聚合物基质形成第二层，所述第二聚合物基质包括嵌入该第二聚合物基质内的第二纤维增强材料；由第三聚合物基质形成第三层，第三层包括嵌入该第三聚合物基质内的第三纤维增强材料，以及散布在该第三聚合物基质内的填料材料；将第三层定位在第一层和第二层之间；将第一、第二和第三层压缩模塑为弯曲的、阶梯状或其他形状的多维复合夹层结构。第一、第二和第三层分别具有基本上相似的第一、第二和第三流变流动性质，使得第一、第二和第三层通常在预定的压缩模塑压力和/或温度下一致地流动。
以上发明内容不旨在表示本发明的每个实施例或每个方面。相反，前述发明内容仅提供了本文阐述的一些新颖概念和特征的示例。本发明的上述特征和优点以及其他特征和伴随的优点将从以下结合附图和所附权利要求的用于实施本发明的示例性示例和代表性模式的详细描述中变得显而易见。此外，本发明明确地包括以上和以下呈现的元件和特征的任何和所有组合和子组合。
附图说明
图1是示意性说明根据本发明的方面的、用于制造多维热塑性或热固性纤维增强聚合物夹层结构的代表性压缩模塑系统和方法的工作流程图。
本发明可以进行各种修改和替换形式，并且已经通过附图中的示例示出了一些代表性实施例，并且将在本文中对其进行详细描述。然而，应该理解，本发明的新颖方面不限于以上列举的附图中所示的特定形式。而是，本发明内容将涵盖落入所附权利要求所涵盖的本发明范围内的所有修改、等同物、组合、子组合、置换、分组和替代。
具体实施方式
本发明可以有许多不同的形式的实施例。在附图中示出并且将在本文中详细描述本发明的代表性实施例，应理解这些示出的示例是作为所公开的原理的示例而不是对本发明的广泛方面的限制而提供的。就此而言，例如在摘要、引言、发明内容和具体实施方式部分中描述但未在权利要求中明确阐述的元件和限制不应单独或共同地通过暗示、推论或以其他方式并入权利要求中。出于本详细描述的目的，除非明确声明：单数包括复数，并且反之亦然；“和”和“或”这两个词应该表示合取范式和析取范式；“任何”和“所有”都应表示“任何和所有”；并且词语“包括”和“包含”和“具有”各自表示“包括但不限于”。此外，近似词，例如“约”、“几乎”、“基本上”、“近似”等等例如可以在本文中以“在、接近或接近于”或“在0-5％之内”或“在可接受的制造公差范围内”或其任何逻辑组合的意义上使用。
现在参考附图，其中相同的附图标记表示相同的特征，图1所示是通常用10表示的代表性的控制器-自动压缩模塑系统，其用于制造轻质、高强度纤维增强塑料(FRP)夹层结构。图示的压缩模塑制造系统10(在此也称为“制造系统”或“压缩模塑系统”)仅仅是示例性应用，利用该应用可以实践本发明的新颖方面和特征。同样，用于制造机动车辆部件的本发明构思的实施方式也应当被理解为本文公开的新颖方面和特征的代表性应用。这样，应当理解，本发明的方面和特征可以被实施用于制造其他基于FRP的产品，并且可以被集成到任何逻辑相关类型的压缩模塑架构中。此外，在附图中仅通过示例的方式示出了制造系统10的选择部件，并且将在本文中详细描述。然而，在不脱离本发明的预期范围的情况下，图1的制造系统10可包括许多附加和替代特征，以及其他可用和以下开发的外围组件。最后，图1中呈现的特征不一定按比例绘制并且纯粹出于指导性目的而提供。因此，图1中所示的特定尺寸和相对尺寸不应被解释为限制性的。
图1的压缩模塑制造系统10采用代表性的高流动压缩模压机12，以用于制造通常由至少三层组成的各种热塑性或热固性FRP夹层结构14中的任何一种：第一(外表)层16、第二(外表)层18，以及介于第一和第二层16、18之间的第三(中心芯)层20。根据所示的示例，第一、第二和第三层16、18、20基本上跨越整个并且因此彼此共同延伸。此外，第一和第二层16、18示出为直接附接到第三层20的相应的相对表面。虽然描绘为三部分结构，但预期FRP夹层结构14包括多于图1中呈现的三个层16、18、20。例如，FRP夹层结构14可包括一个或多个粘合剂层、附加增强层和/或可选的层压层或表面涂层(例如，耐腐蚀喷雾、镀铝、涂料、增强纤维素材料或其任何组合)。相比之下，预期FRP夹层结构14基本上或仅由三个所示的层16、18、20组成，并且因此仅包括两个FRP外表层，其在其间夹在单个纤维增强的和填料改性的热固性或热塑性聚合物芯之间。如本文所用，术语“层”包括但不一定要求复合构造的特定区段跨越所有剩余层的整体(即，与其共同延伸)。
继续参考图1的代表性架构，压缩模压机12包括限定凹入的模具空腔21的下半模(或“工具”)22，预加热的夹层堆叠14A被引入该模具空腔中。压力机座24带有下模加热板26，该下模加热板在其上表面上支撑下半模22。与模塑工具22并置的是液压或气动致动的冲头28，其在其下表面上承载上模加热板30，该上模加热板支撑上半模(或“模具”)32。在压缩模压机12的操作期间，在引入夹层堆叠14A之前或同时，下半模和上半模22、32通过它们各自的加热板26、30预热。然后，上半模32通过冲头28的控制器调节运动向下过渡到与下半模22匹配接合。在将模塑工具22夹紧或以其他方式密封到模模具32之后，夹层堆叠14A在模具空腔21内受到热和压力，这导致堆叠14A中的层16、18、20的、熔化或塑化的聚合物-和-纤维混合物的伴随流速。压缩模压机12内的夹层堆叠14A的压缩和加热使得可流动树脂/纤维混合物流过内模具空腔21的所有区段。在模具空腔21中保持温度和压力，直到熔化的热塑性/热固性聚合物结晶或以其他方式固化并变得完全固结。可以使用压缩气体、冷却流体或其他可用技术来执行对模塑工具22和/或模具32的冷却。
为了形成用于形成最终FRP夹层结构14的夹层堆叠14A，可以将计量量的热塑性或热固性聚合物基质34与预定量的短切纤维混合或浸渍到纤维粗纱或垫(通俗地说被称为“预浸料”)中，纤维和预浸料在图1中共同表示为纤维增强材料36。填料材料38，例如由各种玻璃、陶瓷或其他直径为约10至约100微米的碳材料制成的中空微球(或“微气球”)，散布在整个热塑性或热固性聚合物基质34中。为了形成芯板20A，聚合物34和填料材料38的混合物可以通过挤出机40、例如在热塑性FRP夹层结构应用中。替代地，聚合物34、纤维增强材料36和填料材料38的混合物可以通过预浸料浇铸和切割线42，例如在热固性树脂FRP夹层结构应用中，以形成芯板20A。对于至少一些实施方式，第三层20可以基本上由芯板20A组成，或者可选地，可以包括插入互补框架板20B的通孔或窗23中的芯板20A。
第三层20-无论是单独的芯板20A还是与框架板20B组合的芯板20A-都插入第一和第二层16和18之间以形成未加热的夹层堆叠14B。然后将该未加热的夹层堆叠14B放入烘箱44中并加热至软化温度以形成预热的夹层堆叠14A，随后将其送入模压机12中进行压缩模塑。芯层20的热固性或热塑性元件可以与表层16、18的热固性或热塑性相容，使得它们聚结并在它们之间形成牢固的粘合。对于任选或替代配置，在开始最终热压缩模塑工艺之前，每个表层16、18可以粘附到芯层20的相应表面上。可以对第一和/或第二表层16、18的外表面施加真空，足以防止在堆叠冷却期间的凹陷并且有助于改善外表层16、18的外表面外观。
根据所示的示例，图1的FRP夹层结构14被压缩模塑成弯曲的、阶梯状的或其他非平面的多维部件、例如用于电动机驱动汽车的可充电锂离子牵引电池组的电池组支撑盘。如上所述，FRP夹层结构14可以采用三部分整体结构的形式，其中第三(芯)层20设置在第一和第二(外表)层16、18之间。第一层16是由第一聚合物基质形成的纤维增强聚合物组合物，所述第一聚合物基质嵌有第一基于纤维的增强材料。同样，第二层18是由第二聚合物基质形成的纤维增强聚合物组合物，所述第二聚合物基质嵌有第二基于纤维的增强材料。虽然第一层16和第二层18可以在结构上不同，但是对于至少一些实施方式，可能期望这两个层16、18的形状、尺寸和/或组成基本相同。作为非限制性示例，两个外表层16、18可以由预浸料有热固性树脂基质的纤维粗纱或垫制成。热固性树脂组合物可以是不饱和聚酯树脂、可浇铸尼龙树脂、乙烯基酯树脂或任何其它合适的整体模塑复合料(BMC)。
该纤维粗纱/垫可以采用具有约30％至50％重量含量的或者在更具体的示例中约40％重量含量的热固性树脂基质的、穿孔的单向或双向[0/90/90/0]碳纤维预浸料的形式。可以改变这些穿孔的特征，包括改变它们的尺寸、形状、分布模式和/或密度(每单位面积的穿孔数)，以实现所需的功能。在代表性和非限制性配置中，穿孔可具有约10至100微米的平均宽度或直径，其中平均密度约为每平方米100-1000个穿孔。可以利用重量百分比(wt％)为约90±2wt％的、长度为约85±2mm的嵌入纤维，以及重量百分比为约10±2wt％的、长度为约10±2mm的嵌入纤维来实现期望的穿孔浓度。虽然一些应用可受益于使用基于碳纤维的增强材料，但预浸料可由高拉伸强度玻璃纤维、石墨纤维、芳族聚酰胺纤维、玄武岩纤维或其组合制成。预浸料可以由被组装成多层组件的、若干层纤维形成，例如具有不同但特别设计的纤维取向的纤维。可选地，可以堆叠若干多层组件以组成具有特定纤维取向的叠层，以便增强构造中的部件的结构完整性。
继续上述示例，外表层16、18可以由尼龙树脂或其他热塑性聚合物制成，其嵌入有约25％至45％体积份的，或者对于至少一些实施例而言约35％体积份的连续-长度或不连续长度的增强纤维。在一个更具体的示例中，热塑性聚合物是呈由加热的己内酰胺聚合的半结晶聚酰胺形式的单个单体尼龙。嵌入的增强纤维材料可包括涂覆或未涂覆的、平均长度为约0.5英寸至1.5英寸的短切碳纤维。替代地，增强纤维可以是各种高强度纤维中的任何一种，例如但不限于玻璃、金属和/或陶瓷纤维或本文讨论的任何其他纤维材料。还可以设想，在每层或所有层中使用的纤维增强材料具有相似或不同的尺寸以及由相似或不同的材料组成。大约0.03英寸至0.05英寸的短纤维可用于某些应用，而长度至少为0.5英寸，并且延伸至约2.0英寸和更长的长纤维可适当地用于压缩模塑操作。同样，热塑性树脂基质可以采用其他可用形式，所述形式包括聚苯硫醚(PPS)、聚醚醚酮(PEEK)、聚醚酰亚胺(PEI)、聚醚酮酮(PEKK)、聚醚砜(PES)。和/或聚醚酮酮-cc(PEKK-FC)，仅举几个示例。填料、添加剂和/或改性剂根据需要掺入任何层中，以实现特定的机械性能、各向异性或各向同性特性、尺寸稳定性等。
夹在其间的和刚性粘合到外表层16、18的是由第三聚合物基质形成的FRP芯层20，所述第三聚合物基质嵌有第三纤维增强材料并且至少部分地填充有散布在整个第三聚合物基质中的填料材料。虽然芯层20可以在结构上不同于外表层16、18，但是对于至少一些实施方式而言，可能希望芯层20的聚合物组合物和基于纤维的增强材料基本上与外表层16、18的那些相同。在热固性聚合物应用中，例如，芯层20(例如，框架板20B)可包括穿孔的单向或双向的、具有约30-50％重量含量的a热固性树脂基质的[0/90/90/0]碳纤维预浸料。相反，在热塑性聚合物应用中，芯层20(例如，框架板20B)可包括嵌入有约25-45％体积份的短切碳纤维的尼龙树脂。在这方面，以上关于外表层16、18描述的任何特征、选项和替代方案可以类似地应用于芯层20。作为非限制性示例，用于形成芯层20的聚合物基质可包括呈由己内酰胺聚合的半结晶聚酰胺形式的热塑性尼龙。
作为另一种选择，第三聚合物基质可包括有机双酚A二缩水甘油醚(DEBAG)液体环氧树脂，其是表氯醇和双酚A的反应产物，其中任选的甲基四氢邻苯二甲酸酐(MTPHA)固化剂补充有任选的无硅氧烷的、基于聚合物的空气释放添加剂。芯层20的聚合物基质材料可包含前述组成部分的、比例为100：85：1(树脂：试剂：添加剂)的混合物。用于芯板20A的填料材料可以基本上由散布的、例如约50％体积份的、具有约20μm的尺寸和约0.46g/cc的中空玻璃微球组成。对于至少一些实施例而言，填料材料可包括固体或中空玻璃微球、木材颗粒、粘土薄片、碳酸钙碎片或其任何组合。如上所述，芯层20可以采用互补框架板20B，该互补框架板20B由与相应的表层16、18相似的FRP组合物形成，并且制造有通孔或窗23，在所述通孔或窗2中嵌套有芯板20A。在充分混合并浇铸上述材料之后，但在模塑之前，芯板20A可以进入B阶段条件，例如，通过在约100℃的烘箱加热约25分钟以达到约700PaS至1000PaS的粘度范围，并且然后在放置在表层和压缩模塑(例如，在约50吨(1000psi)下)之前在冷却器中淬火。
在热塑性FRP夹层结构应用中，芯层20可包括原始热塑性聚合物材料和补充有合适填料材料的再循环CFRTP材料的组合。例如，芯板20A可由约30％的回收CFRTP和约20％的、具有50％体积份的中空玻璃微球的原始聚合物(例如尼龙6)形成。再循环的CFRTP组合物可具有短的短切碳纤维(例如，约1或2mm)。在挤出和浇铸之后，可以将炉料加热至约250℃，然后放入内部温度约为150℃的模具中。然后将堆叠在约2000psi的压力下压缩模塑，并且然后在移除之前将其保持在模具中约30-45秒。
为了帮助确保所得的FRP夹层结构14将适当地模塑而不破坏或分层芯层20，芯层20的化学和结构组成被协同配制以匹配相邻的表层16、18的整体流变特性，使得夹层堆叠14A的多个层通常彼此一致地流动。特别地，制造第一、第二和第三层16、18、20以帮助确保它们基本相似的各自的流变流动性质，使得当经历预定的压缩模塑压力和/或温度时，夹层堆叠14A的层16、18、20一致地流动，其示例如上所述。作为一些非限制性示例，这些流变性质可单独或组合地包括各自的软化点、延展性、粘度和动态剪切流变仪(DSR)。芯层20的流变响应(粘度)应与表层16、18大致相同，以使夹层堆叠14A层一致地移动。在上面提供的热固性示例中，b阶段FRP芯与预先测量的微球填料组合将具有通常等于或略高于周围碳纤维预浸料表层的粘度。另外，这些碳纤维预浸料板可以被穿孔以使它们在压缩模塑条件下可流动。同样地，在碳纤维夹层装料中加入装有中空微球的再生和原始聚合物芯板将有助于确保芯层的粘度通常等于或略高于原始CFRTP表层的粘度。这些CFRTP表层可以用短切纤维制成，其尺寸被如此确切以确保该层在压缩模塑条件下是可流动的。
已经参考所示实施例详细描述了本发明的各方面；然而，本领域技术人员将认识到，在不脱离本发明的范围的情况下，可以对其进行许多修改。本发明不限于本文公开的精确构造和组合物；从前面的描述中显而易见的任何和所有修改、改变和变化都在由所附权利要求限定的本发明的范围内。此外，本文的构思明确地包括前述元件和特征的任何和所有组合和子组合。

Claims (10)

1.一种多维复合夹层结构，包括：
第一层，其由第一聚合物基质形成并包括嵌入所述第一聚合物基质中的第一纤维增强材料；
第二层，其由第二聚合物基质形成并包括嵌入所述第二聚合物基质中的第二纤维增强材料；和
第三层，其设置在所述第一层和第二层之间，所述第三层由第三聚合物基质形成，并包括嵌入所述第三聚合物基质内的第三纤维增强材料和散布在所述第三聚合物基质内的填料材料，
其中所述第一层、第二层和第三层分别具有基本上相似的第一流变流动性质、第二流变流动性质和第三流变流动性质，使得所述第一层、第二层和第三层通常在预定的压缩模塑压力下一致地流动。
2.根据权利要求1所述的复合夹层结构，其中所述第一聚合物基质和第二聚合物基质各自包括热固性树脂基质，并且所述第一纤维增强材料和第二纤维增强材料各自包括预浸料有所述热固性树脂基质的纤维板。
3.根据权利要求2所述的复合夹层结构，其中所述纤维板是穿孔的单向预浸料，其具有40％重量含量的所述热固性树脂基质。
4.根据权利要求3所述的复合夹层结构，其中所述填料材料包括中空玻璃微球，并且所述第三聚合物基质包括50％体积份的所述中空玻璃微球。
5.根据权利要求4所述的复合夹层结构，其中所述第三聚合物基质包括液体环氧树脂，所述液体环氧树脂是表氯醇和双酚A与甲基四氢邻苯二甲酸酐固化剂的反应产物。
6.根据权利要求6所述的复合夹层结构，其中所述第三层还包括由预浸料有所述热固性树脂基质的纤维板形成的框架板，芯板包括通孔，所述通孔内嵌有带有嵌入的第三纤维增强材料和所述散布的填料材料的所述第三聚合物基质。
7.根据权利要求1所述的复合夹层结构，其中所述第一纤维增强材料和第二纤维增强材料各自包括短切纤维，并且所述第一聚合物基质和第二聚合物基质各自包括具有35％体积份的短切纤维的热塑性尼龙。
8.根据权利要求7所述的复合夹层结构，其中所述热塑性尼龙是由己内酰胺聚合的半结晶聚酰胺，并且所述第一纤维增强材料和第二纤维增强材料各自包括短切碳纤维。
9.根据权利要求8所述的复合夹层结构，其中所述填料材料包括中空玻璃微球，并且所述第三聚合物基质包括50％体积份的所述中空玻璃微球。
10.根据权利要求9所述的复合夹层结构，其中所述第三聚合物基质包括热塑性尼龙，并且所述热塑性尼龙是由己内酰胺聚合的半结晶聚酰胺。
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