CN112277394A - Composite material multilayer structure and method for manufacturing same - Google Patents

Composite material multilayer structure and method for manufacturing same Download PDF

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Publication number
CN112277394A
CN112277394A CN201910670553.0A CN201910670553A CN112277394A CN 112277394 A CN112277394 A CN 112277394A CN 201910670553 A CN201910670553 A CN 201910670553A CN 112277394 A CN112277394 A CN 112277394A
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China
Prior art keywords
layer
fiber
multilayer structure
filaments
resin
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Withdrawn
Application number
CN201910670553.0A
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Chinese (zh)
Inventor
王智永
庄文彦
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Uht Unitech Co ltd
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Uht Unitech Co ltd
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Priority to CN201910670553.0A priority Critical patent/CN112277394A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
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    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention discloses a composite material multilayer structure and a manufacturing method thereof, wherein the composite material multilayer structure comprises a core layer of a foaming or honeycomb structure, and the composite material multilayer structure comprises a first adhesive layer, a fiber material layer, a second adhesive layer and a metal material layer which are sequentially stacked on the upper surface and the lower surface of the core layer respectively, wherein the fiber material layer comprises a fiber net structure, and the fiber net structure is formed by mutually winding a plurality of discontinuous fiber yarns in a non-directional distribution manner. The manufacturing method of the composite material multilayer structure at least comprises a material providing step, a fitting step and a forming step in sequence. Therefore, compared with the prior art, the composite material multilayer structure of the invention has the characteristics of light weight, high rigidity, fire resistance, heat insulation, wear resistance, impact resistance and the like.

Description

Composite material multilayer structure and method for manufacturing same
Technical Field
The present invention relates to a composite material, and more particularly to a composite material multilayer structure having light weight, high rigidity, fire resistance, heat insulation, wear resistance, impact resistance, and the like, and a method for manufacturing the same.
Background
Accordingly, metal materials are widely used for vehicles such as automobiles, aircrafts, ships, and the like, and other parts such as housings of electronic devices, sports equipment, decorative parts, and the like can also be used, and thus it is seen that metal materials are one of the essential materials in various fields.
However, with the development of modern industry and technology, more and more structural devices are required to be light-weighted in order to meet the use requirements of the consumer or achieve better performance. For example, the inner structure of the bumper used in most automobiles is made of metal material, and although the bumper has the impact resistance and fire prevention function under a specific thickness, the weight of the bumper is also increased relatively, which indirectly affects the oil consumption and the acceleration performance of the automobile.
In the case of the bumper, if the material used in the inner structure can be modified or changed, the bumper can achieve light weight while having impact resistance and fire resistance, and the performance of the automobile can be improved, therefore, the present invention is to develop a composite material multi-layer structure to meet the above requirement.
Disclosure of Invention
In view of the above problems of the prior art, the present invention provides a composite material multilayer structure having light weight, high rigidity, fire resistance, heat insulation, wear resistance, impact resistance, and other properties, and a method for manufacturing the same.
The technical means adopted by the invention are as follows.
According to an object of the present invention, a composite multilayer structure is proposed, comprising: a core layer with a foam or honeycomb structure; one surface of each first adhesive layer is respectively connected with the upper surface and the lower surface of the core layer; the fiber material layer comprises a bonding resin structure and a fiber net structure, the fiber net structure is wrapped by the bonding resin structure, the fiber net structure is formed by a plurality of discontinuous fiber yarns which are distributed in a non-directional manner and are mutually wound, the bonding resin structure is filled in the space between the fiber yarns, and the average length of the plurality of fiber yarns is larger than or equal to 35 mm; one surface of each second adhesive layer is respectively connected with the other opposite surface of each fiber material layer connected with the first adhesive layer; and one surface of each metal material layer is respectively connected with the other opposite surface of each second adhesive layer connected with the fiber material layer.
According to the technical characteristics, the thickness of the core layer is 15mm, the thickness of the fiber material layer is 1mm to 5mm, and the thickness of the metal material layer is 1mm to 5 mm.
According to the technical characteristics, the thickness of the core layer is 15mm, the thickness of the fiber material layer is 1mm, and the thickness of the metal material layer is 1 mm.
According to the above technical features, the average length of the plurality of filaments is greater than or equal to 100mm and less than 500 mm.
According to the technical characteristics, the average length of the plurality of fiber filaments is more than 100mm and less than or equal to 500 mm.
According to the above technical feature, each of the fiber filaments includes a plurality of fibers, and the bonding resin structure fills the space between the plurality of fibers to cover the fibers.
According to the above technical feature, at least one of the plurality of fibers forms two independent piles.
According to the technical characteristics, the plush is distributed in a non-directional way.
According to the above technical feature, at least one of the fibers of at least one of the fiber filaments and at least one of the fibers of another of the fiber filaments of the fiber web structure are intertwined with each other in a non-directional distribution.
According to the above technical feature, at least one of the piles of at least one of the fiber filaments of the web structure and at least one of the fibers of another of the fiber filaments are intertwined with each other in a non-directional distribution.
According to the above technical feature, at least one of the naps of at least one of the fibers of the web structure and at least one of the naps of another one of the fibers of the web structure are intertwined with each other in a non-directional distribution.
According to the technical characteristics, the fiber yarns can adopt carbon fibers or glass fibers.
According to the above technical feature, the adhesive resin structure can be formed by using a thermosetting resin or a thermoplastic resin.
According to the above technical features, the bonding resin structure further comprises a solid filler selected from at least one of the group consisting of Calcium carbonate (Calcium carbonate), Magnesium oxide (Magnesium oxide), Zinc stearate (Zinc stearate), Aluminum hydroxide (Aluminum hydroxide), Antimony oxide (Antimony oxide), Polybrominated diphenyl ethers (Polybrominated diphenyl ethers), Polybrominated biphenyls (Polybrominated biphenyls), tetrabromobisphenol a (tetrabromobisphenol a), Hexabromocyclododecane (Hexabromocyclododecane), and N, N-Dimethylaniline.
According to the above technical features, the diameter of the fiber filament is preferably between 3 μm and 30 μm.
According to the above technical features, the total fiber content in the fiber material layer is between 5% and 30% by weight of the fiber material layer.
According to the above technical features, the core layer is made of Polyurethane (Polyurethane), Polyvinyl Chloride (Polyvinyl Chloride), polyethylene terephthalate (polyethylene terephthalate), acryl, aluminum, paper or fiber.
According to the object of the present invention, a method for manufacturing a composite material multilayer structure is further provided, which is suitable for manufacturing the composite material multilayer structure as described above, the method for manufacturing the composite material multilayer structure comprising the following steps: firstly, a material providing step: providing the core layer, the two fiber material layers, the two metal material layers and a resin material; a first attaching step: uniformly coating a resin material on one surface of the core layer to form the first adhesive layer, attaching one of the fiber material layers to the first adhesive layer, coating the resin material on the fiber material layer to form the second adhesive layer, and then attaching one of the metal material layers to the second adhesive layer to form a semi-finished product structure; a second attaching step: turning over the semi-finished product structure, uniformly coating a resin material on the other surface of the core layer to form a first adhesive layer, attaching the other fiber material layer to the first adhesive layer, coating the resin material on the fiber material layer to form a second adhesive layer, and attaching the other metal material layer to the second adhesive layer; and a forming step: and applying pressure to the two metal material layers at the two opposite ends so as to form the composite material multilayer structure by the core layer, the two first adhesive layers, the two fiber material layers, the two second adhesive layers and the two metal material layers. The molding step is not limited, and examples thereof include hot press molding, vacuum press molding, and vacuum resin transfer molding.
In summary, the composite material multilayer structure of the present invention mainly comprises a core layer, a fiber material layer and a metal material layer, wherein the core layer is made of polyurethane, polyvinyl chloride or paper, etc. to be foamed or honeycomb-shaped, and has buffering function when applied to the structure; the plurality of fiber yarns of the fiber material layer are mutually wound to form non-directional distribution, so that the tear strength, the bending strength and the bending modulus of the fiber material layer in all directions can be uniform, and the fiber material layer can resist destructive power from all directions; the metal material layer can be made of materials such as aluminum and the like, and has the functions of fire prevention, impact resistance and the like as the outermost layer of the structure; compared with the conventional structure body made of metal materials, the structure body has the characteristics of high rigidity, fire resistance, heat insulation, wear resistance, impact resistance and the like, and the weight of the whole structure is reduced due to the material characteristics of the core layer and the fiber material layer, so that the aim of light weight is fulfilled.
Drawings
Fig. 1 is a first schematic view of a first embodiment of a composite multilayer structure of the present invention.
Fig. 2 is a second schematic view of a first embodiment of the composite multilayer structure of the present invention.
Fig. 3 is a schematic view of a second embodiment of the composite multilayer structure of the present invention.
FIG. 4 is a flow chart of a method of manufacturing a composite multilayer structure of the present invention.
FIG. 5 is a schematic view of a method of manufacturing a composite multilayer structure of the present invention.
Fig. 6 is a schematic representation of the materials used to make the web structure of the present invention.
Fig. 7 is a schematic flow diagram of a method of making a web structure of the present invention.
Fig. 8 is a flow chart of a method of making a web structure of the present invention.
Description of the figure numbers:
100 composite multilayer structure
10 core layers
20 first glue layer
30 layers of fibrous material
31 adhesive resin structure
32-fiber web structure
40 second adhesive layer
50 layer of metallic material
S1 Material providing step
S2 first attaching step
S3 second attaching step
S4 Forming step
10a first resin layer
20a second resin layer
30a mixed layer
301a bonding resin layer
302a fibril web structure
P1a first plastic film
P2a second plastic film
S1a Material providing step
S2a attaching step
S3a pressing step
S4a demoulding step
And S5a hot pressing step.
Detailed Description
Please refer to fig. 1, which is a first schematic diagram of a composite material multilayer structure according to a first embodiment of the present invention. As shown in the figure, the composite material multilayer structure 100 of the present invention comprises a core layer 10, two first glue layers 20, two fiber material layers 30, two second glue layers 40 and two metal material layers 50.
In this embodiment, the core layer 10 may be a foamed structure, which may be made of Polyurethane (PU), Polyvinyl Chloride (PVC), polyethylene terephthalate (PET), acrylic, and the like. The first adhesive layer 20 and the second adhesive layer 40 can be made of resin or other adhesive material. The metal material layer 50 may be, for example, aluminum, but not limited thereto.
The fibrous material layer 30 includes a binder resin structure 31 and a web structure 32. The fiber net structure 32 is covered by the bonding resin structure 31, and the fiber net structure 32 is formed by a plurality of discontinuous fiber filaments which are distributed in a non-directional manner and mutually wound, and the bonding resin structure 31 is filled in the space between the fiber filaments, wherein the average length of the plurality of fiber filaments is greater than or equal to 35mm and less than or equal to a predetermined average length to form the discontinuity, for example, the average length is greater than or equal to 250mm and less than 500 mm; the average length is greater than 250mm and less than or equal to 500mm, preferably, the length of each fiber filament is greater than or equal to 35mm and less than or equal to 500 mm.
In the above, the plurality of filaments are intertwined with each other to form a non-directional distribution, the non-directional distribution means that the web structure 32 is projected on a two-dimensional plane (not shown), and the projections of the plurality of filaments on the two-dimensional plane extend in various directions randomly or randomly. Since the plurality of filaments are mutually wound to be distributed in a non-directional manner and the average length of the plurality of filaments is greater than or equal to 35mm, the properties of the fiber material layer 30 are uniform in all directions, in other words, the tear strength, the bending strength and the bending modulus of the fiber material layer 30 in all directions can be uniform, and the fiber material layer can resist the destructive power from all directions.
Further, the filament may comprise a single fiber or a plurality of fibers, for example, the filament may comprise one fiber or one hundred fibers or between one and one hundred fibers. In the embodiment where the filament comprises a plurality of fibers, the filament is not covered with the slurry, and the binder resin structure 31 can penetrate and fill the spaces between the plurality of fibers to cover the fibers, thereby further reinforcing the fiber material layer 30. In addition, at least one of the fibers in the fiber yarn forms two independent piles, the two piles are distributed in a non-directional manner, and the binding resin structure 31 also covers the piles, so that the tear strength, the bending strength and the bending modulus of the fiber material layer 30 in all directions are enhanced and can be uniform. Preferably, the plurality of fibers has a plurality of the piles.
It is particularly worth noting that at least one of the fibers of at least one of the fiber filaments and at least one of the fibers of another of the fiber filaments in the web structure 32 are intertwined with each other in a non-directional distribution. At least one of the piles of at least one of the fiber filaments in the fiber web structure 32 and at least one of the fibers of another of the fiber filaments are intertwined with each other in a non-directional distribution; more preferably, at least one of the piles of at least one of the filaments and at least one of the piles of another of the filaments in the web structure 32 are intertwined with each other in a non-directional distribution. Thus, the porosity of the fiber web structure 32 is reduced, and the tear strength, the bending strength and the bending modulus of the fiber material layer 30 in all directions are enhanced again and can be uniform.
In the above, the fiber filament or the fiber can be preferably carbon fiber, glass fiber or recycled fiber, and the diameter of the fiber filament is between 3 μm and 30 μm; in embodiments where the filament or the fiber is a carbon fiber, the diameter of the carbon fiber is between 3 μm and 8 μm; in embodiments where the filament or the fiber is a glass fiber, the diameter of the glass fiber is between 20 μm and 35 μm. Further, the total fiber content in the fibrous material layer 30 may be between 5% and 30% by weight in the fibrous material layer 30.
In the above, the adhesive resin structure 31 can be made of a thermosetting resin or a thermoplastic resin; the thermosetting resin may contain an epoxy resin, a vinyl resin or an unsaturated resin. Further, the bonding resin structure 31 may include a solid filler selected from at least one of Calcium carbonate (Calcium carbonate), Magnesium oxide (Magnesium oxide), Zinc stearate (Zinc stearate), Aluminum hydroxide (Aluminum hydroxide), Antimony oxide (Antimony oxide), Polybrominated diphenyl ethers (Polybrominated diphenyl ethers), Polybrominated biphenyls (Polybrominated biphenyls), tetrabromobisphenol a (tetrabromobisphenol a), Hexabromocyclododecane (Hexabromocyclododecane), and N, N-Dimethylaniline.
Please refer to fig. 2, which is a second schematic diagram of the composite material multilayer structure according to the first embodiment of the present invention. As shown in the figure, one surface of each first glue layer 20 is respectively connected to the upper surface and the lower surface of the core layer 10; one surface of each fiber material layer 30 is connected to the other surface of each first adhesive layer 20 opposite to the core layer 10; one surface of each second adhesive layer 40 is connected to the other surface of each fiber material layer 30 opposite to the surface connected to the first adhesive layer 20; one surface of each metal material layer 50 is connected to the other surface of each second adhesive layer 40 opposite to the fiber material layer 30. The core layer 10, the two first adhesive layers 20, the two fiber material layers 30, the two second adhesive layers 40, and the two metal material layers 50 may be formed into the composite material multilayer structure 100 by a forming method.
Among the above, the thickness of the core layer 10 is preferably 15 mm; the thickness of the fiber material layer 30 is preferably 1mm to 5mm, and most preferably 1 mm; the thickness of the metal material layer 50 is preferably 1mm to 5mm, and most preferably 1 mm. The thickness ratio of the fiber material layer 30 and the metal material layer 50 in the overall structure can be adjusted according to the requirement, and is not limited by the above-mentioned exemplary structure.
Specifically, the composite material multilayer structure 100 mainly comprises the core layer 10, the fiber material layer 30 and the metal material layer 50, wherein the core layer 10 is made of polyurethane, polyvinyl chloride or paper and the like, is foamed or honeycomb-shaped, and has the functions of buffering and the like when applied to the structure; the plurality of filaments of the fiber material layer 30 are mutually twisted to form a non-directional distribution, so that the tear strength, bending strength and bending modulus of the fiber material layer in all directions can be uniform, and the fiber material layer can resist the destructive power from all directions; the metal material layer 50 may be made of aluminum or other materials, and may have the functions of fire prevention, impact resistance and the like as the outermost layer of the structure; compared with the conventional structure body made of metal materials, the structure of the present invention has the characteristics of high rigidity, fire resistance, heat insulation, wear resistance, impact resistance, etc., and the weight of the whole structure is reduced due to the material characteristics of the core layer 10 and the fiber material layer 30, so as to achieve the purpose of light weight.
Please refer to fig. 3, which is a schematic diagram of a composite material multilayer structure according to a second embodiment of the present invention. This second embodiment differs from the first embodiment in that the core layer 10 is of a honeycomb structure, which may preferably be made of aluminum, paper or fiber.
In view of the above, the present invention further provides a method for manufacturing a composite material multilayer structure, please refer to fig. 4 and fig. 5. The manufacturing method of the composite material multilayer structure at least comprises the following flow steps.
A material providing step S1: the core layer 10, the two fiber material layers 30, the two metal material layers 50 and the resin material are provided.
A first attaching step S2: the resin material is uniformly coated on one surface of the core layer 10 to form the first adhesive layer 20, one of the fiber material layers 30 is attached to the first adhesive layer 20, the resin material is coated on the fiber material layer 30 to form the second adhesive layer 40, and then one of the metal material layers 50 is attached to the second adhesive layer 40 to form a semi-finished product structure.
A second attaching step S3: the semi-finished product structure is turned over, and resin material is uniformly coated on the opposite surface of the core layer 10 to form the first adhesive layer 20, then the other fiber material layer 30 is attached to the first adhesive layer 20, then resin material is coated on the fiber material layer 30 to form the second adhesive layer 40, and then the other metal material layer 50 is attached to the second adhesive layer 40.
A forming step S4: applying pressure to the two metal material layers 50 at the opposite ends to form the core layer 10, the two first glue layers 20, the two fiber material layers 30, the two second glue layers 40 and the two metal material layers 50 into the composite material multilayer structure 100. The molding step is not limited, and examples thereof include hot press molding, vacuum press molding, and vacuum resin transfer molding.
Please refer to the following table one, which shows the results of comparing the bending strength and the tensile strength of the five structural aspects of the composite material multi-layer structure 100 of the present invention with those of the conventional comparative example 1.
Watch 1
Figure BDA0002141562090000091
First, in table one, the overall structure of comparative example 1 is made of a metal material as in the prior art; examples 1 to 5 are all the composite multilayer structures 100 of the present invention, and in the case that the core layer 10 is a fixed thickness condition, and only the fiber material layer 30 and the metal material layer 50 account for the whole structural thickness ratio, the thickness ratio of the fiber material layer 30 and the metal material layer 50 of example 1 is 1: 9, the thickness ratio of the fiber material layer 30 and the metal material layer 50 of the embodiment 2 is 3: 7, the thickness ratio of the fiber material layer 30 and the metal material layer 50 of the embodiment 3 is 5: 5, the thickness ratio of the fiber material layer 30 and the metal material layer 50 of the embodiment 4 is 7: 3, the thickness ratio of the fiber material layer 30 and the metal material layer 50 of the embodiment 5 is 9: 1.
as can be seen from the table one, the bending strengths of the first to fifth embodiments of the composite material multi-layer structure 100 having the fiber material layers 30 with various thickness ratios according to the present invention are 186.2Mpa, 201.7Mpa, 238.4Mpa, 270Mpa and 306.6Mpa, respectively, and the data results are superior to the bending strength of the comparative example of 175 Mpa; the tensile strengths of the first to fifth examples are 222.9MPa, 271.4MPa, 326.3MPa, 389.1MPa and 461.5MPa, respectively, and the data result is also superior to that of the comparative example, which is 200.8 MPa; in addition, it is obvious that the higher the thickness ratio of the fiber material layer 30, the better the bending strength and the tensile strength of the composite material multilayer structure 100. In summary, when the composite material multilayer structure 100 of the present invention is aimed at reducing the weight, the bending strength and the tensile strength of the composite material multilayer structure 100 can be better than those of the prior art that only uses metal material, so as to maintain or improve the quality and the strength of the whole structure.
The present invention provides a method of manufacturing the web structure 32 including the following process steps, please refer to fig. 6, fig. 7 and fig. 8.
A material providing step S1 a: providing the first plastic film P1a, the first resin layer 10a, the fibril web structure 302a, the second resin layer 20a and the second plastic film P2a, wherein the first resin layer 10a is coated on the lower surface of the first plastic film P1a, and the second resin layer 20a is coated on the upper surface of the second plastic film P2 a.
A bonding step Sa 2: the first resin layer 10a is attached to the upper surface of the fibril web structure 302a, and the second resin layer 20a is attached to the lower surface of the fibril web structure 302 a.
A pressing step S3 a: applying pressure to the upper surface of the first plastic film P1a and the lower surface of the second plastic film P2a to form the bonding resin layer 301a on a portion of the first resin layer 10a and to wrap the fibril web structure 302a to form the hybrid layer 30 a; or forming a part of the second resin layer 20a into the bonding resin layer 301a and coating the fibril web structure 302a to form the mixed layer 30 a; alternatively, the bonding resin layer 301a is formed by bringing a part of the first resin layer 10a and a part of the second resin layer 20a into contact with each other and the mixed layer 30a is formed by coating the fibril web structure 302 a.
Basically, after the material providing step S1a, the attaching step Sa2 and the pressing step S3a are completed, the fiber web structure 32 is completed. Subsequently, a stripping step S4a may be performed in use. The demolding step S4a separates the first plastic film P1a from the first resin layer 10a and the second plastic film P2a from the second resin layer 20a to form the web structure 32.
Of course, as described above, when any one of the bonding resin layer 301a, the first resin layer 10a and the second resin layer 20a is the thermosetting resin, a hot pressing step S5a may be performed after the releasing step S4 a. The hot pressing step S5a is to perform a hot pressing process on the fiber web structure 32 obtained by the membrane releasing step S4a, for example, any one of the bonding resin layer 301a, the first resin layer 10a and the second resin layer 20a is vinyl resin, a hot pressing temperature of the hot pressing process is set to be 110-300 ℃, and a hot pressing pressure of the hot pressing process is set to be 20kgf/cm2To 200kgf/cm2A hot pressing time of the hot pressing process may be set to be between 0.5 minutes and 10 minutes.
Comparative example 1 carried out in accordance with the method for producing the web structure 32 described aboveThe results of example 1, example 2 and example 3 are shown in Table II. The adhesive resin layer 301a, the first resin layer 10a and the second resin layer 20a in comparative example 1, example 2 and example 3 are all vinyl resins, the hot pressing temperature is set at 130 degrees celsius, and the hot pressing pressure is set at 150kgf/cm2The hot pressing time was 2 minutes, and the fibril web structure 302a was made of carbon fibers.
Watch two
Figure BDA0002141562090000111
In Table two, the web structures 32 of example 1 and comparative example 1 have the same weight 4000g/m230 wt% of the same total fiber content; example 1 is different from comparative example 1 in that the plurality of filaments used in example 1 have an average length of 35mm, while comparative example 1 uses a plurality of filaments having an average length of 25 mm; since the embodiment 1 uses a plurality of the fiber yarns having a longer average length, the phenomenon that the plurality of the fiber yarns, the plurality of the fibers and the plurality of the piles are intertwined with each other to form a non-directional distribution is greater than that of the comparative example 1, so that the bending strength 225MPa and the bending modulus 14GPa of the embodiment 1 are much higher than those specified by ISO14125 by more than 100MPa and the bending modulus by more than 7GPa, and the bending strength 225MPa and the bending modulus 14GPa of the embodiment 1 are higher than those of the comparative example 1 by 150MPa and 8 GPa. Therefore, it is sufficient to verify that the plurality of filaments, the plurality of fibers and the plurality of piles formed by the average length of the plurality of filaments being greater than or equal to 35mm are mutually intertwined to form a non-directional distribution, so that the bending strength and the bending modulus of the fiber net structure 32 can be improved.
The difference between example 2 and comparative example 1 is that the total fiber content of example 2 is reduced to 10 wt% and the average length of a plurality of the fiber filaments is 35mm, however, the bending strength 188MPa and the bending modulus 9GPa of example 2 are higher than those of comparative example 1, namely 150MPa and 8 GPa. It is therefore sufficient to verify that the web structure 32 uses a plurality of filaments having an average length of greater than or equal to 35mm, which can achieve a reduction in the total fiber content to 10% by weight and can save costs.
Subsequently, based on example 2, in a state where the total fiber content is maintained at 10 wt%, example 2 employs a plurality of the filaments having an average length of 35mm, example 3 employs a plurality of the filaments having an average length of 100mm, example 4 employs a plurality of the filaments having an average length of 250mm, and example 5 employs a plurality of the filaments having an average length of 500 mm. Obviously, as the average length of the plurality of fibers increases, the phenomenon that the plurality of fibers, the plurality of fibers and the plurality of piles are intertwined with each other to form a non-directional distribution is more remarkable, so that the bending strength and the bending modulus of the fiber web structure 32 are enhanced. Therefore, the bending strength of example 3 is 195MPa and the bending modulus is 10GPa, the bending strength of example 4 is 210MPa and the bending modulus is 12GPa, the bending strength of example 5 is 235MPa and the bending modulus is 15GPa, which are higher than the standard specified in ISO14125 and higher than the bending strength and the bending modulus of comparative example 1, example 1 and example 2.
Since the plurality of filaments, the plurality of fibers, and the plurality of piles are entangled with each other to form a non-directional distribution in example 5, the bending strength of example 5 is similar to that of example 1 (14 GPa) and comparative example 1(8GPa) in which the total fiber content is 10 wt% and the bending modulus (15 GPa in example 5) is higher than that of example 1 (14 GPa) and comparative example 1(8GPa) in which the total fiber content is 30 wt%, and the description thereof is omitted. Therefore, it is sufficient to demonstrate the technical features of the present invention to increase the average length of a plurality of the filaments and to form a non-directional distribution phenomenon in which the filaments are highly intertwined with each other, so that the required total fiber content can be reduced and the bending strength and the bending modulus can be improved, thereby achieving the effect of reducing the manufacturing cost.
Example 6 differs from comparative example 1 in that the total fiber content of example 6 is reduced to 10 wt%, the average length of the plurality of filaments is 35mm, and the weight of the web structure 32 is reduced to 1150g/m2And the thickness was reduced from 2.0mm of comparative example 1 to 0.9mm, however the flexural strength 171MPa of example 6 is higher than the flexural strength 150MPa of comparative example 1. Therefore, it is sufficient to verify that the web structure 32 uses a plurality of the fiber filaments having an average length of 35mm or more, so as to reduce the total fiber content to 10%, reduce the weight of the web structure 32 and the thickness of the web structure 32, save the cost, and be widely applied to light and thin products.
Example 7 differs from comparative example 1 in that the total fiber content of example 7 is reduced to 5 wt%, the average length of the plurality of filaments is 35mm, and the weight of the web structure 32 is reduced to 1150g/m2And the thickness was reduced from 2.0mm of comparative example 1 to 0.9mm, whereas the flexural strength of example 7 was 160MPa higher than that of comparative example 1, which was 150 MPa. Therefore, it is sufficient to verify that the web structure 32 uses a plurality of the fiber filaments having an average length of 35mm or more, so as to reduce the total fiber content to 5%, reduce the weight of the web structure 32 and the thickness of the web structure 32, save the cost, and be widely applied to light and thin products.

Claims (19)

1. A composite multilayer structure, comprising:
a core layer (10) of a foamed or honeycomb structure;
two first glue layers (20), wherein one surface of each first glue layer (20) is respectively connected with the upper surface and the lower surface of the core layer (10);
two fiber material layers (30), wherein one surface of each fiber material layer (30) is respectively connected with the other opposite surface of each first adhesive layer (20) connected with the core layer (10), the fiber material layer (30) comprises a bonding resin structure (31) and a fiber net structure (32), the fiber net structure (32) is coated by the bonding resin structure (31), the fiber net structure (32) is formed by mutually winding a plurality of discontinuous fiber yarns in a non-directional distribution manner, the spacing between the fiber yarns is filled with the bonding resin structure (31), and the average length of the plurality of fiber yarns is greater than or equal to 35 mm;
two second glue layers (40), wherein one surface of each second glue layer (40) is respectively connected with the opposite surface of each fiber material layer (30) connected with the first glue layer (20); and
and one surface of each metal material layer (50) is respectively connected with the other opposite surface of each second glue layer (40) connected with the fiber material layer (30).
2. The composite multilayer structure according to claim 1, characterized in that the core layer (10) has a thickness of 15mm, the layer of fibrous material (30) has a thickness of 1mm to 5mm, and the layer of metallic material (50) has a thickness of 1mm to 5 mm.
3. A composite multilayer structure according to claim 2, characterized in that the core layer (10) has a thickness of 15mm, the layer of fibrous material (30) has a thickness of 1mm and the layer of metallic material (50) has a thickness of 1 mm.
4. The composite multilayer structure of claim 1 wherein the plurality of filaments have an average length of greater than or equal to 100mm and less than 500 mm.
5. The composite multilayer structure of claim 1 wherein the plurality of filaments have an average length greater than 100mm and less than or equal to 500 mm.
6. The composite multilayer structure of claim 1, wherein each of the filaments comprises a plurality of fibers, and the binder resin structure (31) fills the spaces between the plurality of fibers to encapsulate the fibers.
7. The composite multilayer structure of claim 6 wherein at least one of the plurality of fibers forms two separate tufts.
8. The composite multilayer structure of claim 7 wherein the pile is non-directional.
9. The composite multilayer structure of claim 6 wherein at least one of said fibers of at least one of said fiber filaments of said web structure (32) is intertwined with at least one of said fibers of another of said fiber filaments in a non-directional distribution.
10. The composite multi-layer structure of claim 7 wherein at least one of the pile of at least one of the filaments of the web structure (32) and at least one of the fibers of another of the filaments are intertwined with one another in a non-directional distribution.
11. The composite multi-layer structure of claim 7 wherein at least one of the piles of at least one of the filaments of the web structure (32) and at least one of the piles of another of the filaments are intertwined with each other in a non-directional distribution.
12. The composite multilayer structure of claim 1 wherein the filaments are carbon or glass fibers.
13. The composite multilayer structure of claim 1, wherein the binder resin structure (31) is formed of a thermosetting resin or a thermoplastic resin.
14. The composite multilayer structure of claim 1, wherein the binder resin structure (31) comprises a solid filler selected from at least one of the group consisting of calcium carbonate, magnesium oxide, zinc stearate, aluminum hydroxide, antimony oxide, polybromodiphenyl ether, polybromobiphenyl, tetrabromobisphenol a, hexabromocyclododecane, and N, N-dimethylaniline.
15. The composite multilayer structure of claim 1, wherein the fiber filaments have a diameter of between 3 μm and 30 μm.
16. The composite multilayer structure of claim 1, characterized in that the total fiber content of the fiber material layer (30) is between 5% and 30% by weight of the fiber material layer (30).
17. The composite multilayer structure according to claim 1, characterized in that the core layer (10) is made of polyurethane, polyvinyl chloride, polyethylene terephthalate, acrylic, aluminum, paper or fiber.
18. A method for manufacturing a composite multilayer structure, suitable for manufacturing the composite multilayer structure (100) according to claim 1, characterized in that the method for manufacturing the composite multilayer structure (100) comprises the following steps: a material providing step (S1): providing the core layer (10), the two fiber material layers (30), the two metal material layers (50) and a resin material; a first attaching step (S2): uniformly coating a resin material on one surface of the core layer (10) to form the first adhesive layer (20), attaching one of the fiber material layers (30) to the first adhesive layer (20), coating the resin material on the fiber material layer (30) to form the second adhesive layer (40), and then attaching one of the metal material layers (50) to the second adhesive layer (40) to form a semi-finished product structure; a second attaching step (S3): turning over the semi-finished product structure, uniformly coating a resin material on the other surface of the core layer (10) opposite to the core layer to form the first adhesive layer (20), attaching the other fiber material layer (30) to the first adhesive layer (20), coating the resin material on the fiber material layer (30) to form the second adhesive layer (40), and then attaching the other metal material layer (50) to the second adhesive layer (40); and a forming step (S4): applying pressure to the two metal material layers (50) at opposite ends to form the core layer (10), the two first glue layers (20), the two fiber material layers (30), the two second glue layers (40) and the two metal material layers (50) into the composite material multilayer structure (100).
19. The method of manufacturing a composite multilayer structure according to claim 18, wherein the forming step (S4) is selected from one of hot press forming, vacuum press forming, or vacuum resin transfer forming.
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Application publication date: 20210129