CN112277398A - Carbon fiber reinforced thermoplastic resin composite material and preparation method and application thereof - Google Patents

Carbon fiber reinforced thermoplastic resin composite material and preparation method and application thereof Download PDF

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Publication number
CN112277398A
CN112277398A CN202011108330.4A CN202011108330A CN112277398A CN 112277398 A CN112277398 A CN 112277398A CN 202011108330 A CN202011108330 A CN 202011108330A CN 112277398 A CN112277398 A CN 112277398A
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composite material
thermoplastic resin
carbon fiber
layer
welding
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Inventor
石鑫鑫
王璜
陈群芳
李梦
左梦玲
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Dongfeng Off Road Vehicle Co Ltd
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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
    • 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
    • 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
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical 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
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention discloses a carbon fiber reinforced thermoplastic resin composite material and a preparation method and application thereof, belonging to the technical field of chemical materials. The composite material is a multilayer structure formed by sequentially and alternately laminating thermoplastic resin matrixes and carbon fibers, wherein the top layer and the bottom layer of the multilayer structure are both thermoplastic resin matrixes, each layer of thermoplastic resin matrixes and the carbon fibers are arranged between a welding head and a clamp of an ultrasonic welding machine after being laminated, certain pulling force is applied to the left end and the right end of each layer, preloading force, stamping time, welding force and welding time are controlled, welding at a certain position is completed, each layer of material is horizontally moved, and the operation is repeated to obtain the composite material. The preparation method designed by the invention is convenient and rapid to form, the prepared composite material keeps the characteristics of high tensile strength, high yield strength and high elastic modulus of the carbon fiber on the basis of no need of adding auxiliary materials, and the composite material has better application in lightweight automobile covering parts.

Description

Carbon fiber reinforced thermoplastic resin composite material and preparation method and application thereof
The invention relates to a composite material, belongs to the technical field of chemical materials, and particularly relates to a carbon fiber reinforced thermoplastic resin composite material as well as a preparation method and application thereof.
Background
Carbon fiber CF is a new material with high tensile strength and large elastic modulus. It is made up by stacking graphite microcrystal fibre along axial direction, and is carbonized to obtain the invented microcrystal graphite material with ultrahigh carbon content. The carbon fiber has soft outer surface and hard inner surface, is lighter than aluminum, has higher strength than steel, has the electrical and thermal conductivity of metal materials, and has excellent heat resistance and corrosion resistance.
Composite materials prepared by compounding carbon fibers and other materials are widely applied to various industries, such as the automobile industry, aerospace, electromechanical industry, constructional engineering and the like, wherein more than half of the composite materials are used in the automobile industry, and the weight reduction of automobiles can improve the controllability of the automobiles and reduce the oil consumption on the premise of keeping the integral quality of the automobiles unchanged. The composite material has the advantages of lower density and higher specific strength compared with the traditional automobile material, so that the weight of the whole automobile can be greatly reduced after the composite material is made into an automobile structural member.
In the composite material, the combination of two-phase interfaces is crucial, and usually the main functions are hydrogen bond and chemical bond mechanical force, and the two-phase combination problem is always the key point for researching the composite material.
In order to realize the connection between different materials, most of composite materials are formed by injection molding and compression molding at present, but the size and the complexity of the structure of the composite materials are limited by a mold, and large or complex plastic parts which cannot be produced are generally connected, adhered and welded mechanically. The mechanical connection mode cannot effectively prolong the fatigue life of the joint; the adhesion force of the adhesion is affected by many factors such as the bonding process conditions, the technical state of the adhesive, the surface characteristics of the adherend and the like, and is also affected by factors such as the environmental temperature and the like, so the actual adhesion condition is complicated. Fusion bonding is the heating of composite materials to a molten, fluid state and the formation of a bond by pressure cooling. The ultrasonic welding technology is taken as a hot melting connection technology which is most widely applied at present, the welding principle is that power frequency current is converted into high-frequency electric energy through an ultrasonic generator, then the high-frequency electric energy is converted into mechanical vibration with the same frequency through an ultrasonic transducer, then the high-frequency vibration is transmitted to a welding head through an amplitude transformer which can change the amplitude, the welding head transmits the received vibration energy to a joint of workpieces to be welded, local high temperature can be generated due to large acoustic resistance at the interface of the workpieces, the vibration energy is converted into heat energy in a friction mode at the moment, and the plastic is melted and then cooled under the action of pressure to form a welding line.
The master's academic paper "ultrasonic welding process research of carbon fiber reinforced nylon 66 composite material" explores that short carbon fibers are added into nylon 66 and the composite material is prepared by adopting an ultrasonic welding process, and as a result, the influence of ultrasonic welding parameters such as time, pressure and the like on the welding strength of the carbon fiber reinforced nylon 66 composite material is found to be large. However, this paper deals with short carbon fibers and does not refer to long carbon fibers.
Disclosure of Invention
The invention discloses a carbon fiber reinforced thermoplastic resin composite material and a preparation method and application thereof in order to explore the condition of ultrasonic welding of long carbon fibers and thermoplastic resin. The preparation method comprises the steps of sequentially staggering and laminating each layer of thermoplastic resin matrix and carbon fiber, then placing the thermoplastic resin matrix and the carbon fiber between a welding head and a clamp of an ultrasonic welding machine, applying certain tensile force to the left end and the right end of each layer, controlling the preload force, the stamping time, the welding force and the welding time, and completing the welding at a certain position.
In order to achieve the technical purpose, the invention discloses a carbon fiber reinforced thermoplastic resin composite material which is a multilayer structure formed by sequentially and alternately laminating a thermoplastic resin matrix and carbon fibers, wherein the top layer and the bottom layer of the multilayer structure are both thermoplastic resin matrixes, and the thermoplastic resin matrixes are made of at least one of nylon 6, high-density polyethylene or polypropylene; the density of the carbon fiber is 1.75g/cm3An elastic modulus of 275 to 400GPa and a tensile stress of 3000 to 5700N/mm2The elongation of the cross section is 0.5-3%.
Further, the multilayer structure is at least one of 3-19 layers.
Further, the mass percentage of the carbon fibers in the composite material is 8.9-43.6%.
Further, the tensile stress of the composite material is 236.6-336.6N/mm2。
In addition, the invention also discloses a preparation method of the carbon fiber reinforced thermoplastic resin composite material, which comprises the steps of stacking each layer of thermoplastic resin matrix and carbon fiber, placing the stacked layers between a welding head and a clamp of an ultrasonic welding machine, applying certain tension to the left end and the right end of each layer, controlling the preload force to be 500-700N, the stamping time to be 1-3 s, the welding force to be 500-700N, the welding time to be 0.4-0.8 s, controlling the amplitude of ultrasonic waves to be 25-35 mu m, completing welding at a certain position, horizontally moving each layer of material, and repeating the operations to obtain the composite material.
Further, the pre-load force is 550-600N.
Furthermore, the stamping force is 550-600N, and the stamping time is 1-2 s.
Furthermore, the welding force is 550-600N, and the welding time is 0.45-0.6 s.
Furthermore, two ends of each layer of material are wound on the surface of the roller, and the pulling force applied to the left end and the right end of each layer is 300-600N.
In addition, the invention also discloses application of the carbon fiber reinforced thermoplastic resin composite material in lightweight automobile covering parts, such as automobile bodies.
Has the advantages that:
1. the density of the composite material prepared by the invention is 1.17-1.31 g/cm3The tensile stress is 236.6-336.6N/mm2；
2. The composite material prepared by the invention has the advantages of low density and strong external force deformation resistance, and has good application in lightweight automobile covering parts.
3. The preparation method designed by the invention has a single production cycle period of only about 2 seconds, and can be quickly formed without the operation steps of glue adhesion, hot pressing and the like, so that the product can be quickly and flexibly shaped, the preparation method with lower requirements on manufacturing site space and environment can be used for carrying out high-automation manufacturing process design on conventional pieces processed in batches, and the manufacturing cost is favorably reduced.
Drawings
FIG. 1 is a schematic structural view of a composite material of the present invention;
FIG. 2 is a schematic view of a welding process;
FIG. 3 is a schematic view of the microstructure of the composite material prepared in the example;
wherein, the numbers in the drawings are as follows:
thermoplastic resin matrix 1, carbon fiber 2, welding head 3, clamp 4 and roller 5.
Detailed Description
The invention discloses a carbon fiber reinforced thermoplastic resin composite material, which is a multilayer structure formed by sequentially and alternately laminating a thermoplastic resin matrix 1 and carbon fibers 2 as shown in figure 1, wherein the top layer and the bottom layer of the multilayer structure are both the thermoplastic resin matrix 1, and the omitted parts in figure 1 are all the materials of the layers which are alternately laminated. In order to ensure that the composite material can be well prepared without greatly changing the preparation process and the structure and the performance of the long carbon fiber in the composite material are kept, the invention preferably selects the multilayer structure as at least one of 3-19 layers. Further preferably, the multilayer structure comprises at least one of 3 to 15 layers.
Among them, as the carbon fiber, it is preferable in the present invention that it is a long carbon fiber, of whichThe density was 1.75g/cm3An elastic modulus of 275 to 400GPa and a tensile stress of 3000 to 5700N/mm2The elongation of the cross section is 0.5-3%. The long carbon fiber with the performance parameters is compounded in the thermoplastic resin matrix to prepare the composite material, and the composite material has greatly improved strength, impact resistance, energy absorption rate and the like on the basis of keeping the excellent quality of the long carbon fiber, so that the composite material becomes a good choice for internal and external structural members and semi-structural members of automobiles.
The material of the thermoplastic resin matrix is preferably at least one of nylon 6, high-density polyethylene or polypropylene; and each thermoplastic resin matrix selected in the present invention has the properties as listed below.
TABLE 1 thermoplastic resin matrix Properties List
Figure BDA0002730837460000041
The invention selects each thermoplastic resin matrix with the above table 1, and has the advantages of strong plasticity, small density and portability for preparing composite materials.
The invention also preferably selects the mass percentage content of the carbon fiber in the composite material to be 8.9-43.6%, the carbon fiber and the thermoplastic resin matrix in the content range are well compounded, and the tensile stress of the prepared composite material is 236.6-336.6N/mm2The density is 1.17 to 1.31g/cm3In the meantime.
In order to better explain the performance of the composite material, the invention also discloses a preparation method of the composite material, which comprises the steps of stacking layers of the thermoplastic resin matrix 1 and the carbon fibers 2 according to the figure 2 and then placing the stacked layers between a welding head 3 and a clamp 4 of an ultrasonic welding machine, wherein as shown in the figure 2, two ends of each layer of the material are wound on the surface of a roller 5, and the tension applied to the left end and the right end of each layer is 300-600N. The roller 5 is preferably arranged on an automatic roller assembly line, the influence of vibration force generated during ultrasonic welding can be well counteracted by the pulling force applied to the left end and the right end of each layer, and the carbon fiber can be ensured not to generate anisotropic divergence during welding. When welding is started, the welding head 3 and the clamp 4 are close to a material positioned in the middle in the vertical direction, the preload force of the ultrasonic welding machine is controlled to be 500-700N, the stamping force is 500-700N, the stamping time is 1-3 s, the welding force is 500-700N, the welding time is 0.4-0.8 s, the amplitude of ultrasonic waves is controlled to be 25-35 mu m, and the best welding effect can be achieved under the condition that the thermoplastic material is prevented from being damaged by overhigh energy performance, so that the carbon fiber and the thermoplastic material are tightly combined.
After welding at a certain position is completed, the welding head 3 and the clamp 4 are far away from the material positioned in the middle, each layer of material is horizontally moved, and the operations are repeated to obtain the composite material. The preparation process designed by the invention has a single production cycle period of only about 2 seconds, and can be quickly formed without the operation steps of glue adhesion, hot pressing and the like, so that the product can be quickly and flexibly shaped, the preparation method with lower requirements on manufacturing site space and environment can be used for carrying out high-automation manufacturing process design on conventional pieces processed in batches, and the manufacturing cost is favorably reduced.
In order to better explain the present invention, the following detailed description is given in conjunction with specific examples.
Example 1
The embodiment discloses a preparation method of a composite material with a three-layer structure, which comprises the steps of placing a layer of carbon fiber between upper and lower high-density polyethylene, applying tensile stress of 300N to the left and right ends of each layer under the action of a roller, starting an ultrasonic welding machine, and enabling the process parameters to be shown in the following table 2;
table 2 list of welding process parameters for example 1
Figure BDA0002730837460000051
Figure BDA0002730837460000061
After the single production is finished, each layer of material is horizontally moved, and the operations are repeated to obtain the composite materialThe tensile stress of the composite material is 300.5N/mm2Wherein the carbon fiber content is 22.7 percent, and the density is 1.17g/cm3。
Example 2
The embodiment discloses a preparation method of a composite material with a five-layer structure, which comprises the steps of placing carbon fibers between upper and lower high-density polyethylene, applying 350N of pulling force to the left and right ends of each layer under the action of a roller, starting an ultrasonic welding machine, and enabling the process parameters to be shown in the following table 3;
table 3 list of welding process parameters for example 2
Figure BDA0002730837460000062
After the single production is finished, each layer of material is horizontally moved, the operations are repeated, and the composite material is prepared, wherein the tensile stress of the composite material is 273.9N/mm2Wherein the carbon fiber content is 28.1 percent, and the density is 1.23g/cm3。
Example 3
The embodiment discloses a preparation method of a composite material with a nine-layer structure, which comprises the steps of placing carbon fibers between upper and lower high-density polyethylene, applying 450N tensile force to the left and right ends of each layer under the action of a roller, starting an ultrasonic welding machine, and enabling the process parameters to be shown in the following table 4;
table 4 list of welding process parameters for example 3
Figure BDA0002730837460000071
After the single production is finished, each layer of material is horizontally moved, the operation is repeated, and the composite material is prepared, wherein the schematic view of the microstructure of the composite material after the longitudinal cutting is shown in figure 3, and the five layers of thermoplastic materials and the four layers of carbon fibers are tightly combined together by combining the figure 3, but the structure of the carbon fibers is not damaged, and the tensile stress of the composite material is 236.6N/mm2Wherein the carbon fiber content is 31.7%, and the density is 1.23g/cm3。
Example 4
The embodiment discloses a preparation method of a composite material with a fifteen-layer structure, which comprises the steps of placing carbon fibers between upper and lower high-density polyethylene, enabling the tensile force applied by the left end and the right end of each layer under the action of a roller to be 600N, starting an ultrasonic welding machine, and enabling the process parameters to be shown in the following table 5;
table 5 list of welding process parameters for example 4
Figure BDA0002730837460000072
After the single production is finished, each layer of material is horizontally moved, and the operations are repeated to obtain the composite material, wherein the tensile stress of the composite material is 336.6N/mm2Wherein the carbon fiber content is 33.7%, and the density is 1.31g/cm3。
As can be seen from the above description of the embodiments, the tensile stress of the composite material prepared by the invention is 236.6-336.6N/mm2The density is 1.17-1.31 g/cm3The automobile panel light weight reducing device has a good application prospect in light weight of automobile panels on the basis of light weight.
The above examples are merely preferred examples and are not intended to limit the embodiments of the present invention. In addition to the above embodiments, the present invention has other embodiments. All technical solutions formed by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the claims of the present invention.

Claims (10)

1. The carbon fiber reinforced thermoplastic resin composite material is characterized by being of a multilayer structure formed by sequentially and alternately laminating a thermoplastic resin matrix and carbon fibers, wherein the top layer and the bottom layer of the multilayer structure are both thermoplastic resin matrixes which are made of at least one of nylon 6, high-density polyethylene or polypropylene; the density of the carbon fiber is 1.75g/cm3An elastic modulus of 275 to 400GPa and a tensile stress of 3000 to 5700N/mm2The elongation of the cross section is 0.5-3%.
2. The carbon fiber-reinforced thermoplastic resin composite material according to claim 1, wherein the multilayer structure comprises at least one of 3 to 19 layers.
3. The carbon fiber-reinforced thermoplastic resin composite material according to claim 1 or 2, wherein the mass percentage of the carbon fibers in the composite material is 8.9 to 43.6%.
4. The carbon fiber-reinforced thermoplastic resin composite material according to claim 3, wherein the density of the composite material is 1.17 to 1.31g/cm3The tensile stress is 236.6-336.6N/mm2。
5. A preparation method of the carbon fiber reinforced thermoplastic resin composite material as claimed in claim 1, characterized in that, the method comprises the steps of stacking each layer of the thermoplastic resin matrix and the carbon fiber, placing the stacked layers between a welding head and a clamp of an ultrasonic welding machine, applying a certain pulling force to the left and right ends of each layer, controlling the preload force to be 500-700N, the stamping time to be 1-3 s, the welding force to be 500-700N, the welding time to be 0.4-0.8 s, and controlling the amplitude of the ultrasonic wave to be 25-35 μm, completing the welding at a certain position, horizontally moving each layer of the material, and repeating the operations to obtain the composite material.
6. The method for producing a carbon fiber-reinforced thermoplastic resin composite material according to claim 5, wherein the preload force is 550 to 600N.
7. The method for producing a carbon fiber-reinforced thermoplastic resin composite material according to claim 5, wherein the punching force is 550 to 600N and the punching time is 1 to 2 seconds.
8. The method for producing a carbon fiber-reinforced thermoplastic resin composite material according to claim 5, wherein the welding force is 550 to 600N and the welding time is 0.45 to 0.6 s.
9. The method for preparing a carbon fiber reinforced thermoplastic resin composite material according to claim 5, 6, 7 or 8, wherein both ends of each layer of material are wound on the surface of a roller, and the tension applied to the left and right ends of each layer is between 300 and 600N.
10. Use of the carbon fiber-reinforced thermoplastic resin composite material as claimed in claim 1 for lightweight automobile panels.
CN202011108330.4A 2020-10-19 2020-10-19 Carbon fiber reinforced thermoplastic resin composite material and preparation method and application thereof Pending CN112277398A (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104249462A (en) * 2013-06-27 2014-12-31 蓝星（北京）特种纤维技术研发中心有限公司 Method for preparing carbon fiber reinforced thermoplastic composite material
CN105346101A (en) * 2015-12-02 2016-02-24 中国商用飞机有限责任公司北京民用飞机技术研究中心 Fiber-reinforced thermoplastic resin matrix composite laminate mold pressing method and mold pressing device
CN107498879A (en) * 2016-06-14 2017-12-22 通用汽车环球科技运作有限责任公司 The ultra-sonic welded of thermoplastic composite

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104249462A (en) * 2013-06-27 2014-12-31 蓝星（北京）特种纤维技术研发中心有限公司 Method for preparing carbon fiber reinforced thermoplastic composite material
CN105346101A (en) * 2015-12-02 2016-02-24 中国商用飞机有限责任公司北京民用飞机技术研究中心 Fiber-reinforced thermoplastic resin matrix composite laminate mold pressing method and mold pressing device
CN107498879A (en) * 2016-06-14 2017-12-22 通用汽车环球科技运作有限责任公司 The ultra-sonic welded of thermoplastic composite

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