CN111890654A - Composite board manufacturing method, composite board manufacturing equipment and composite board - Google Patents
Composite board manufacturing method, composite board manufacturing equipment and composite board Download PDFInfo
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- CN111890654A CN111890654A CN201910369169.7A CN201910369169A CN111890654A CN 111890654 A CN111890654 A CN 111890654A CN 201910369169 A CN201910369169 A CN 201910369169A CN 111890654 A CN111890654 A CN 111890654A
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- composite
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
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Abstract
The invention discloses a composite board manufacturing method, composite board manufacturing equipment and a composite board. The composite board comprises a core layer and a surface layer arranged on the core layer, wherein the core layer is made of discontinuous fiber reinforced thermoplastic composite materials, the surface layer is made of at least one of continuous fiber reinforced thermoplastic composite materials, discontinuous fiber reinforced thermoplastic composite materials, inorganic filler filled thermoplastic composite materials, organic filler filled thermoplastic composite materials and metal sheets, and the manufacturing method of the composite board comprises the following steps: A) melt-plasticizing a mixture including discontinuous fibers and a thermoplastic resin, and providing the melt-plasticized mixture into a mold; and B) providing the facing into a mold, wherein the melt-plasticized mixture is combined with the facing in the mold to obtain the composite panel. The composite board manufacturing method provided by the embodiment of the invention has the advantages of high manufacturing efficiency, low implementation cost, low energy consumption and the like.
Description
Technical Field
The invention relates to a composite board manufacturing method and a composite board manufacturing device, and also relates to a composite board.
Background
At present, light weight has become a great demand in the fields of aerospace, railway freight cars, wind power generation, automobile industry, chemical industry and the like, and novel materials with light weight and high strength have become important development trends in the material industry. The fiber reinforced thermoplastic composite material is widely applied to the fields of railway freight cars, truck freight cars, containers and the like because of the advantages of light weight, high strength, nearly unlimited storage period of impregnating compounds, high impact toughness, recyclability and the like.
Disclosure of Invention
The invention aims to overcome the problems in the prior art and provides a composite board manufacturing method, a composite board manufacturing device and a composite board.
In order to achieve the above object, a first aspect of the present invention provides a method for manufacturing a composite panel, the composite panel including a core layer made of a discontinuous fiber-reinforced thermoplastic composite material and a face layer provided on the core layer, the face layer being made of at least one of a continuous fiber-reinforced thermoplastic composite material, a discontinuous fiber-reinforced thermoplastic composite material, an inorganic filler-filled thermoplastic composite material, an organic filler-filled thermoplastic composite material, and a metal sheet, the method comprising the steps of: A) melt plasticizing a mixture including discontinuous fibers and a thermoplastic resin, providing the melt plasticized mixture into a mold; and B) providing the facing into the mould, wherein the melt-plasticized mixture is combined with the facing in the mould so as to obtain the composite panel.
The composite board manufacturing method provided by the embodiment of the invention has the advantages of high manufacturing efficiency, low implementation cost and low energy consumption.
Preferably, the mixture is melt plasticized using a screw extruder.
Preferably, the step B) includes: b-1) providing the facing into the mould; b-2) bonding the melt-plasticized mixture to the face layer so as to form the core layer; and B-3) before the core layer is cooled and set, allowing the surface layer and the core layer to leave the mold, and then carrying out vacuum adsorption on the surface layer and the core layer so as to obtain the composite plate.
Preferably, the composite plate manufacturing method further includes: cooling and/or slitting the composite panel.
A second aspect of the present invention provides a composite board manufacturing apparatus for implementing the composite board manufacturing method according to the first aspect of the present invention, the composite board manufacturing apparatus including: a screw extruder; and a die located downstream of the screw extruder.
The composite board manufacturing equipment provided by the embodiment of the invention has the advantages of high manufacturing efficiency, low operation cost and low energy consumption.
Preferably, the composite board manufacturing apparatus further comprises: a vacuum suction device located downstream of the mold; a cooling device located downstream of the vacuum adsorption device; and a cutting device located downstream of the cooling device.
A third aspect of the present invention provides a composite panel comprising: a first facing, preferably made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet; and a core layer comprising: the vertical plate is connected with the first surface layer and is vertical to the first surface layer; and the inclined plate group comprises a first inclined plate and a second inclined plate which are arranged in a crossed mode, each of the first inclined plate and the second inclined plate is connected with the core layer, and preferably, the core layer is made of a discontinuous fiber reinforced thermoplastic composite material.
Preferably, the number of the vertical plates is multiple, the number of the inclined plate groups is multiple, the multiple vertical plates and the multiple inclined plate groups are alternately arranged along the width direction of the first face layer, preferably, the first inclined plate of each inclined plate group is connected with the adjacent vertical plate, the second inclined plate of each inclined plate group is connected with the adjacent vertical plate, more preferably, the end part of the first inclined plate of each inclined plate group, which is adjacent to the first face layer, is connected with one of the two adjacent vertical plates, the end part of the first inclined plate of each inclined plate group, which is far away from the first face layer, is connected with the other of the two adjacent vertical plates, the end part of the second inclined plate of each inclined plate group, which is adjacent to the first face layer, is connected with the other of the two adjacent vertical plates, and the end part of the second inclined plate of each inclined plate group, which is far away from the first face layer, is connected with the one of the two adjacent vertical plates.
Preferably, the composite plate further includes a second surface layer, the first end of the riser is connected to the first surface layer, the second end of the riser is connected to the second surface layer, the first end of the first inclined plate is connected to the first surface layer, the second end of the first inclined plate is connected to the second surface layer, the first end of the second inclined plate is connected to the first surface layer, and the second end of the second inclined plate is connected to the second surface layer, and preferably, the second surface layer is made of at least one of a continuous fiber reinforced thermoplastic composite material, a discontinuous fiber reinforced thermoplastic composite material, an inorganic filler filled thermoplastic composite material, an organic filler filled thermoplastic composite material, and a metal sheet.
Preferably, the core layer is a plurality of core layers disposed between the first facing layer and the second facing layer, wherein an intermediate layer is disposed between two adjacent core layers, the intermediate layer being connected to each of the riser, the first sloping plate and the second sloping plate of the adjacent core layer, preferably the intermediate layer is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite and a metal sheet.
A fourth aspect of the present invention provides a composite panel comprising: a first facing made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet; and the core layer is connected with the first surface layer and is made of a discontinuous fiber reinforced thermoplastic composite material.
The composite board according to the embodiment of the invention has both excellent processability and excellent mechanical properties.
Drawings
FIG. 1 is a schematic structural diagram of a composite panel according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a composite panel according to an embodiment of the present invention;
FIG. 3 is a schematic structural diagram of a composite panel according to an embodiment of the present invention;
fig. 4 is a schematic structural view of a composite board manufacturing apparatus according to an embodiment of the present invention.
Detailed Description
The following detailed description of embodiments of the invention is intended to be illustrative, and is not to be construed as limiting the invention.
The invention provides a composite board manufacturing method. The composite board comprises a core layer and a surface layer arranged on the core layer, wherein the core layer is made of a discontinuous fiber reinforced thermoplastic composite material, and the surface layer is made of at least one of a continuous fiber reinforced thermoplastic composite material, a discontinuous fiber reinforced thermoplastic composite material, an inorganic filler filled thermoplastic composite material, an organic filler filled thermoplastic composite material and a metal sheet. The manufacturing method of the composite board comprises the following steps:
A) melt-plasticizing a mixture including discontinuous fibers and a thermoplastic resin, and providing the melt-plasticized mixture into a mold; and
B) the facing is provided into the mould and the melt-plasticized mixture is combined with the facing in the mould to obtain the composite panel.
The facing layer may be obtained by known methods, such as a hot pressing process or a winding process. The method of manufacturing a composite panel according to embodiments of the present invention does not require the order in which the facing and the molten and plasticized mixture are provided into the mold.
And cooling the melted and plasticized mixture to obtain the discontinuous fiber reinforced thermoplastic composite material. Due to the discontinuous fiber reinforced thermoplastic composite material, the discontinuous fiber reinforced thermoplastic composite material not only has good processability, such as being formed by injection molding, extrusion molding, and hot pressing, but also has a complex structure of a part made of the discontinuous fiber reinforced thermoplastic composite material.
However, since the fibers in the discontinuous fiber-reinforced thermoplastic composite material are discontinuous, the mechanical properties of the parts made of the discontinuous fiber-reinforced thermoplastic composite material are poor.
Because the fibers in the continuous fiber reinforced thermoplastic composite material are in a continuous state, the mechanical properties of the parts made of the continuous fiber reinforced thermoplastic composite material are excellent. However, since the fibers are brittle materials and have low elongation at break, the processability of the continuous fiber reinforced thermoplastic composite material is poor, and the continuous fiber reinforced thermoplastic composite material can be formed only by a hot pressing process or a winding process, so that the shape of a part made of the continuous fiber reinforced thermoplastic composite material is single.
The method for manufacturing a composite panel according to an embodiment of the present invention may obtain the composite panel by thermally compounding the face sheet and the melt-plasticized mixture (the discontinuous fiber reinforced thermoplastic composite) in the mold using a co-extrusion process. Thereby improving the manufacturing efficiency of the composite panel.
In the prior art, a core layer is manufactured through injection molding or extrusion molding, and then the core layer and a surface layer are combined together through a hot pressing process so as to obtain a composite board. That is, the conventional manufacturing method requires two processes to obtain the composite board.
The composite board manufacturing method according to the embodiment of the invention simultaneously completes the molding of the core layer and the combination of the surface layer and the core layer by utilizing a co-extrusion process. In other words, the composite board manufacturing method according to the embodiment of the present invention requires only one process to obtain the composite board.
Because each process is carried out, a certain amount of waste products are generated, namely, each process has a certain rejection rate. Therefore, the method for manufacturing the composite board according to the embodiment of the invention can reduce the rejection rate by reducing the number of processes, thereby reducing the manufacturing cost of the composite board.
Moreover, each process needs corresponding equipment and operators to complete, so that the process is reduced, the equipment investment can be reduced, the number of operators is reduced, and the manufacturing cost of the composite board can be reduced.
In prior manufacturing methods, the core layer, which has been cooled, needs to be heated in order to bond the core layer and the facings together. In the method of manufacturing a composite panel according to an embodiment of the present invention, energy consumption can be reduced by combining the mixture, which is melt-plasticized, with the facing layer, thereby eliminating the need to reheat the core layer, which has been cooled.
Therefore, the composite board manufacturing method has the advantages of high manufacturing efficiency, low implementation cost, low energy consumption and the like.
By using the composite board manufacturing method according to the embodiment of the present invention, a (fiber reinforced thermoplastic) composite board having both excellent workability and excellent mechanical properties can be manufactured. In particular, the core layer can be made relatively complex in shape but not mechanically demanding, taking advantage of the excellent processability of the discontinuous fiber reinforced thermoplastic composite. The surface layer with strict requirement on mechanical property and relatively simple structure can be prepared by utilizing the excellent mechanical property of the continuous fiber reinforced thermoplastic composite material.
Preferably, the mixture is melt plasticized using a screw extruder.
In some embodiments of the invention, said step B) comprises:
b-1) providing a facing layer into the mold.
B-2) the melt-plasticized mixture is bonded to the face layer so as to form the core layer.
B-3) before the core layer is cooled and set, the surface layer and the core layer are made to leave the mould, and then the surface layer and the core layer are subjected to vacuum adsorption so as to obtain the composite plate. Through carrying out vacuum adsorption to this surface course and this sandwich layer to can make the surface of this sandwich layer smoother.
Preferably, the composite board manufacturing method further comprises cooling and/or slitting the composite board. By cooling the composite board, the shaping of the composite board can be accelerated. The composite board is cut, so that the composite board with a preset size can be obtained.
A composite board manufacturing apparatus 20 according to an embodiment of the present invention is described below with reference to the accompanying drawings. The composite panel manufacturing apparatus 20 according to the embodiment of the present invention is used to implement the composite panel manufacturing method according to the above-described embodiment of the present invention.
As shown in fig. 4, the composite panel manufacturing apparatus 20 according to the embodiment of the present invention includes a screw extruder 210 and a die 220, and the die 220 is located downstream of the screw extruder 210.
Wherein the screw extruder 210 may melt plasticize the mixture including the discontinuous fibers and the thermoplastic resin. The facing for manufacturing the composite panel may be delivered into the mold 220 by a delivery device or may be manually delivered into the mold 220. Under downstream forces, the facing and the molten and plasticized mixture are able to enter the mold 220 continuously, so that the composite panel can be continuously manufactured. The mold 220 may provide the core layer and the composite panel with a predetermined structure.
Therefore, the composite board manufacturing apparatus 20 according to the embodiment of the present invention has the advantages of high manufacturing efficiency, low operation cost, low energy consumption, and the like.
As shown in fig. 4, the composite panel manufacturing apparatus 20 may further include a vacuum adsorption device 230, a cooling device 240, and a cutting device 250. The vacuum suction device 230 is located downstream of the mold 220, the cooling device 240 is located downstream of the vacuum suction device 230, and the cutting device 250 is located downstream of the cooling device 240.
Before the core layer is cooled to set, the face layer and the core layer may be moved out of the mold 220 and into a vacuum suction apparatus 230 to vacuum-suck the face layer and the core layer. Whereby the surface of the core layer can be made smoother.
A composite panel 10 according to an embodiment of the present invention is described below with reference to the drawings. As shown in fig. 1-3, a composite plate 10 according to an embodiment of the present invention includes a first face layer 110 and a core layer 120. The core layer 120 includes a vertical plate 121 and a ramp group 122.
The vertical plate 121 is connected to the first surface layer 110, and the vertical plate 121 is perpendicular to the first surface layer 110. The inclined plate group 122 includes a first inclined plate 1221 and a second inclined plate 1222 that are arranged in a crossing manner, i.e., the first inclined plate 1221 intersects with the second inclined plate 1222. Each of the first sloping plate 1221 and the second sloping plate 1222 is connected to the core layer 120.
Preferably, the core layer 120 is made of a non-continuous fiber reinforced thermoplastic composite. The first facing 110 is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet.
Therefore, the core layer 120 with a relatively complex shape but low requirement on mechanical properties can be manufactured by utilizing the excellent processability of the discontinuous fiber reinforced thermoplastic composite material, and the first surface layer 110 with a strict requirement on mechanical properties but a relatively simple structure can be manufactured by utilizing the excellent mechanical properties of the continuous fiber reinforced thermoplastic composite material, so that the composite plate 10 has both excellent processability and excellent mechanical properties.
As shown in fig. 1 to 3, there are a plurality of vertical plates 121 and a plurality of inclined plate groups 122, and the vertical plates 121 and the inclined plate groups 122 are alternately arranged along the width direction of the first surface layer 110. The width direction of the first face layer 110 is shown by an arrow a in fig. 1. Thereby further increasing the moment of inertia of the composite panel 10.
Preferably, as shown in fig. 1 to 3, the first sloping plate 1221 of each sloping plate group 122 is connected to the adjacent vertical plate 121, and the second sloping plate 1222 of each sloping plate group 122 is connected to the adjacent vertical plate 121. Thereby further increasing the moment of inertia of the composite panel 10.
As shown in fig. 1 to 3, more preferably, an end of the first inclined plate 1221 of each inclined plate group 122 adjacent to the first surface layer 110 is connected to one of the two adjacent vertical plates 121, and an end of the first inclined plate 1221 of each inclined plate group 122 away from the first surface layer 110 is connected to the other of the two adjacent vertical plates 121. The end of the second sloping plate 1222 of each sloping plate group 122 adjacent to the first surface layer 110 is connected to the other of the two adjacent vertical plates 121, and the end of the second sloping plate 1222 of each sloping plate group 122 away from the first surface layer 110 is connected to the one of the two adjacent vertical plates 121. Thereby further increasing the moment of inertia of the composite panel 10.
In order to make the technical solution of the present application easier to understand, the technical solution of the present application will be further described by taking the vertical plate 121 as an example, which extends in the vertical direction. The up-down direction is shown by arrow B in fig. 1.
When the inclined plate group 122 is adjacent to only one vertical plate 121, one of the upper end portion and the lower end portion of the first inclined plate 1221 of the inclined plate group 122 is connected to the adjacent vertical plate 121, and the other of the upper end portion and the lower end portion of the second inclined plate 1222 of the inclined plate group 122 is connected to the adjacent vertical plate 121.
When the inclined plate group 122 is adjacent to the two vertical plates 121, an upper end portion of the first inclined plate 1221 of the inclined plate group 122 is connected to one of the two adjacent vertical plates 121, a lower end portion of the first inclined plate 1221 of the inclined plate group 122 is connected to another one of the two adjacent vertical plates 121, an upper end portion of the second inclined plate 1222 of the inclined plate group 122 is connected to the another one of the two adjacent vertical plates 121, and a lower end portion of the second inclined plate 1222 of the inclined plate group 122 is connected to the one of the two adjacent vertical plates 121.
As shown in fig. 1-3, in one example of the present invention, composite plate 10 further includes a second facing 130, a first end of riser 121 is coupled to first facing 110, and a second end of riser 121 is coupled to second facing 130. The first sloping plate 1221 is connected at a first end to the first facing 110 and the second sloping plate 1221 is connected at a second end to the second facing 130. The first end of the second sloping panel 1222 is connected to the first facing 110 and the second end of the second sloping panel 1222 is connected to the second facing 130. By providing the second surface layer 130, the mechanical properties of the composite panel 10 can be further improved.
For example, the upper end of the vertical plate 121 is connected to the first facing 110, and the lower end of the vertical plate 121 is connected to the second facing 130. The upper end portion of the first inclined plate 1221 is connected to the first facing 110, and the lower end portion of the first inclined plate 1221 is connected to the second facing 130. The upper end portion of the second sloping plate 1222 is connected to the first panel 110, and the lower end portion of the second sloping plate 1222 is connected to the second panel 130.
As shown in fig. 1 to 3, for the first sloping plate 1221 and the second sloping plate 1222 of any one sloping plate group 122 and the two vertical plates 121 adjacent to the sloping plate group 122: the upper end portion of the first sloping plate 1221, the first face layer 110, and the upper end portion of one of the two standing plates 121 are connected to each other, the lower end portion of the first sloping plate 1221, and the lower end portion of the other of the two standing plates 121, the second sloping plate 1222, the upper end portion of the first face layer 110, and the upper end portion of the other of the two standing plates 121 are connected to each other, and the lower end portion of the second sloping plate 1222, the second face layer 130, and the lower end portion of the one of the two standing plates 121 are connected to each other.
The second face layer 130 may be made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet. The mechanical properties of the composite plate 10 can thereby be further improved.
In manufacturing the composite panel 10 including the first facing 110, the second facing 130, and the core layer 120, the first facing 110 and the second facing 130 may be provided into the mold, and the melt-plasticized mixture (non-continuous fiber reinforced thermoplastic composite) is combined with the first facing 110 and the second facing 130 in the mold to obtain the composite panel 10.
As shown in fig. 3, in a specific example of the present invention, the core layer 120 is plural, and the plural core layers 120 are disposed between the first surface layer 110 and the second surface layer 130. Wherein, an intermediate layer 140 is disposed between two adjacent core layers 120, and the intermediate layer 140 is connected to each of the vertical plate 121, the first sloping plate 1221 and the second sloping plate 1222 of the adjacent core layer 120.
That is, the core layer 120 may be disposed between the first facing 110 and the intermediate layer 140, or may be disposed between the intermediate layer 140 and the second facing 130, or may be disposed between (adjacent) two intermediate layers 140. Thereby further increasing the moment of inertia of the composite panel 10.
Preferably, the intermediate layer 140 is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet. The mechanical properties of the composite plate 10 can thereby be further improved.
In manufacturing the composite panel 10 including the first facing 110, the second facing 130, the intermediate layer 140, and the core layer 120, the first facing 110, the second facing 130, and the intermediate layer 140 may be provided into the mold, and the melt-plasticized mixture (non-continuous fiber reinforced thermoplastic composite) is combined with the first facing 110, the second facing 130, and the intermediate layer 140 in the mold to obtain the composite panel 10.
As shown in fig. 3, for example, composite panel 10 includes a first facing 110, a second facing 130, an intermediate layer 140, and two core layers 120. Wherein an upper end portion of each of the standing plate 121, the first sloping plate 1221 and the second sloping plate 1222 of one core layer 120 is connected to the first face layer 110, and a lower end portion of each of the standing plate 121, the first sloping plate 1221 and the second sloping plate 1222 of the core layer 120 is connected to the intermediate layer 140.
An upper end portion of each of the riser 121, the first sloping plate 1221, and the second sloping plate 1222 of the other core layer 120 is connected to the intermediate layer 140, and a lower end portion of each of the riser 121, the first sloping plate 1221, and the second sloping plate 1222 of the core layer 120 is connected to the second face layer 130.
The first facing layer 110 and the second facing layer 130 may further have a functional film 50 thereon, and the functional film 50 may be a UV resistant film or a scratch resistant film, etc.
Preferably, the width W1 of the composite panel 10 is 10 mm to 2000 mm, the thickness of the first facing 110 is 0.1 mm to 100 mm, the thickness H1 of the second facing 130 is 0.1 mm to 100 mm, and the thickness of the middle layer 140 is 0.1 mm to 100 mm.
The width W3 of the vertical plate 121 is 0.5 mm to 50 mm, the height H2 of the vertical plate 121 is 3 mm to 500 mm, and the distance W5 between two adjacent vertical plates 121 in the width direction of the composite plate 10 is 5 mm to 500 mm.
The width W2 of the first sloping plate 1221 is 0.5 mm to 50 mm, and the angle θ 1 between the first sloping plate 1221 and the first face layer 110 (the second face layer 130) is greater than 0 degrees and less than 90 degrees. The width W4 of the second sloping plate 1222 is 0.5 mm-50 mm, and the angle θ 2 between the second sloping plate 1222 and the first facing 110 (the second facing 130) is greater than 0 degree and less than 90 degrees.
The invention also provides a composite board. The composite panel according to an embodiment of the present invention includes a first face layer 110 and a core layer 120. The first facing 110 is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet. A core layer 120 is attached to the first face layer 110, the core layer 120 being made of a non-continuous fiber reinforced thermoplastic composite.
Therefore, the core layer 120 with a relatively complex shape but low requirement on mechanical properties can be manufactured by utilizing the excellent processability of the discontinuous fiber reinforced thermoplastic composite material, and the first surface layer 110 with a strict requirement on mechanical properties but a relatively simple structure can be manufactured by utilizing the excellent mechanical properties of the continuous fiber reinforced thermoplastic composite material, so that the composite plate 10 has both excellent processability and excellent mechanical properties.
The composite board according to the embodiment of the invention has both excellent processability and excellent mechanical properties.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and are therefore not to be considered limiting of the invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.
In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; may be mechanically coupled, may be electrically coupled or may be in communication with each other; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.
Claims (11)
1. A method of manufacturing a composite panel, the composite panel comprising a core layer made of a non-continuous fiber reinforced thermoplastic composite material and a facing layer provided on the core layer, the facing layer made of at least one of a continuous fiber reinforced thermoplastic composite material, a non-continuous fiber reinforced thermoplastic composite material, an inorganic filler filled thermoplastic composite material, an organic filler filled thermoplastic composite material, and a metal sheet, the method comprising the steps of:
A) melt plasticizing a mixture including discontinuous fibers and a thermoplastic resin, providing the melt plasticized mixture into a mold; and
B) providing the facing into the mold, wherein the melt-plasticized mixture is combined with the facing within the mold so as to obtain the composite panel.
2. A method of manufacturing a composite board according to claim 1, wherein the mixture is melt-plasticized using a screw extruder.
3. A method for manufacturing a composite board according to claim 1, wherein step B) comprises:
b-1) providing the facing into the mould;
b-2) bonding the melt-plasticized mixture to the face layer so as to form the core layer; and
b-3) before the core layer is cooled and set, allowing the surface layer and the core layer to leave the mold, and then carrying out vacuum adsorption on the surface layer and the core layer so as to obtain the composite plate.
4. A method of manufacturing a composite panel according to claim 3, further comprising: cooling and/or slitting the composite panel.
5. A composite board manufacturing apparatus (20) for carrying out the composite board manufacturing method according to any one of claims 1 to 4, characterized by comprising:
a screw extruder (210); and
a die (220), the die (220) being located downstream of the screw extruder (210).
6. The composite board manufacturing apparatus (20) according to claim 5, further comprising:
a vacuum suction device (230), the vacuum suction device (230) being located downstream of the mold (220);
a cooling device (240), the cooling device (240) being located downstream of the vacuum adsorption device (230); and
a cutting device (250), the cutting device (250) being located downstream of the cooling device (240).
7. A composite panel (10) comprising:
a first facing (110), preferably the first facing (110) is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet; and
a core layer (120), the core layer (120) comprising:
the vertical plate (121), the vertical plate (121) is connected with the first surface layer (110), and the vertical plate (121) is perpendicular to the first surface layer (110); and
a set of inclined plates (122), the set of inclined plates (122) comprising a first inclined plate (1221) and a second inclined plate (1222) arranged crosswise, each of the first inclined plate (1221) and the second inclined plate (1222) being connected to the core layer (120), preferably the core layer (120) being made of a non-continuous fiber reinforced thermoplastic composite material.
8. The composite plate according to claim 7, wherein the vertical plate (121) is plural, the inclined plate groups (122) are plural, the plural vertical plates (121) and the plural inclined plate groups (122) are alternately arranged along the width direction of the first face layer (110), preferably, the first inclined plate (1221) of each inclined plate group (122) is connected with the adjacent vertical plate (121), and the second inclined plate (1222) of each inclined plate group (122) is connected with the adjacent vertical plate (121),
more preferably, an end of the first inclined plate (1221) of each inclined plate group (122) adjacent to the first face layer (110) is connected to one of the two adjacent vertical plates (121), an end of the first inclined plate (1221) of each inclined plate group (122) away from the first face layer (110) is connected to the other of the two adjacent vertical plates (121), an end of the second inclined plate (1222) of each inclined plate group (122) adjacent to the first face layer (110) is connected to the other of the two adjacent vertical plates (121), and an end of the second inclined plate (1222) of each inclined plate group (122) away from the first face layer (110) is connected to the one of the two adjacent vertical plates (121).
9. A composite board according to claim 7, further comprising a second facing (130), the first end part of the vertical plate (121) is connected with the first surface layer (110), the second end part of the vertical plate (121) is connected with the second surface layer (130), the first end of the first sloping plate (1221) is connected with the first facing (110), the second end of the first sloping plate (1221) is connected with the second surface layer (130), a first end of the second sloping plate (1222) is connected with the first facing (110), the second end of the second sloping plate (1222) is connected to the second facing (130), preferably, the second facing (130) is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet.
10. The composite panel according to claim 9, wherein the core layer (120) is a plurality of core layers (120), a plurality of the core layers (120) being provided between the first facing layer (110) and the second facing layer (130), wherein an intermediate layer (140) is provided between two adjacent core layers (120), the intermediate layer (140) being connected to each of the riser (121), the first sloping plate (1221) and the second sloping plate (1222) of the adjacent core layer (120), preferably the intermediate layer (140) is made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite and a metal sheet.
11. A composite panel (10) comprising:
a first facing (110), the first facing (110) being made of at least one of a continuous fiber reinforced thermoplastic composite, a discontinuous fiber reinforced thermoplastic composite, an inorganic filler filled thermoplastic composite, an organic filler filled thermoplastic composite, and a metal sheet; and
a core layer (120), said core layer (120) being connected to said first face layer (110), said core layer (120) being made of a non-continuous fiber reinforced thermoplastic composite material.
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