CN112549706A - Thermoplastic composite board and preparation method and product thereof - Google Patents

Thermoplastic composite board and preparation method and product thereof Download PDF

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Publication number
CN112549706A
CN112549706A CN201910914244.3A CN201910914244A CN112549706A CN 112549706 A CN112549706 A CN 112549706A CN 201910914244 A CN201910914244 A CN 201910914244A CN 112549706 A CN112549706 A CN 112549706A
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CN
China
Prior art keywords
reinforced
thermoplastic composite
area
layer
thermoplastic
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Pending
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CN201910914244.3A
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Chinese (zh)
Inventor
袁协尧
李一兰
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Covestro Deutschland AG
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Covestro Deutschland AG
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Publication date
Application filed by Covestro Deutschland AG filed Critical Covestro Deutschland AG
Priority to CN201910914244.3A priority Critical patent/CN112549706A/en
Priority to CN202080067327.4A priority patent/CN114585512A/en
Priority to PCT/EP2020/076838 priority patent/WO2021058714A1/en
Publication of CN112549706A publication Critical patent/CN112549706A/en
Pending legal-status Critical Current

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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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • A—HUMAN NECESSITIES
    • A45—HAND OR TRAVELLING ARTICLES
    • A45C—PURSES; LUGGAGE; HAND CARRIED BAGS
    • A45C5/00—Rigid or semi-rigid luggage
    • A45C5/02—Materials therefor
    • A—HUMAN NECESSITIES
    • A45—HAND OR TRAVELLING ARTICLES
    • A45C—PURSES; LUGGAGE; HAND CARRIED BAGS
    • A45C13/00—Details; Accessories
    • A—HUMAN NECESSITIES
    • A45—HAND OR TRAVELLING ARTICLES
    • A45C—PURSES; LUGGAGE; HAND CARRIED BAGS
    • A45C5/00—Rigid or semi-rigid luggage
    • A45C5/03—Suitcases
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/887—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced locally reinforced, e.g. by fillers
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    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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    • B32B3/02—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 features of form at particular places, e.g. in edge regions
    • B32B3/08—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 features of form at particular places, e.g. in edge regions characterised by added members at particular parts
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    • B32—LAYERED PRODUCTS
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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
    • 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
    • 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
    • B32B5/12—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 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • A—HUMAN NECESSITIES
    • A45—HAND OR TRAVELLING ARTICLES
    • A45C—PURSES; LUGGAGE; HAND CARRIED BAGS
    • A45C5/00—Rigid or semi-rigid luggage
    • A45C5/03—Suitcases
    • A45C2005/037—Suitcases with a hard shell, i.e. rigid shell as volume creating element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • 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
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
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    • B32B2262/10—Inorganic fibres
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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    • B32B2439/00—Containers; Receptacles
    • B32B2439/40—Closed containers
    • B32B2439/62—Boxes, cartons, cases

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention relates to a thermoplastic composite board and a processing method and a product thereof. The thermoplastic composite panel comprises an upper surface layer (11) and a lower surface layer (13) which are laminated together and one or more intermediate layers (12) between the upper surface layer (11) and the lower surface layer (13), and has an upper surface constituted by the upper surface layer (11), a lower surface constituted by the lower surface layer (13) and a first side surface (14), a second side surface (15), a third side surface (16) and a fourth side surface (17) which are adjacent in sequence, and the thermoplastic composite panel (1) has at least one first local reinforcing area (18-21) near the intersection of the adjacent side surfaces and at least one second local reinforcing area (22-23) near any one side surface (14-17). The thermoplastic composite board has a local reinforced area, and the product prepared from the thermoplastic composite board is locally reinforced, so that the local impact resistance and/or static load capacity are improved, and the better balance among the strength, the rigidity and the light weight of the final product can be realized under the condition of keeping the weight of the whole structure not to be remarkably increased.

Description

Thermoplastic composite board and preparation method and product thereof
Technical Field
The invention relates to the technical field of composite material manufacturing. Specifically, the invention relates to a thermoplastic composite board, a preparation method thereof and a product.
Background
Luggage (also known as traveling case) includes draw-bar box, which is a box for placing articles when going out. Luggage cases are bulky, can be pulled and can greatly reduce the towing force of a user, and therefore, the use of luggage cases is becoming more and more common.
Early luggage cases were made of wood or other heavy materials, which tended to be lighter and lighter in weight, hard plastic or cloth, as air travel became popular. In the current market of luggage material, composite material is one of the materials that can be selected for manufacturing high-strength and high-hardness luggage, but at the same time, high strength and high hardness often mean that the luggage is relatively thick and heavy.
In the conventional manufacturing process of the carbon fiber composite material luggage shell, a thermosetting resin is generally adopted, as described in chinese patent CN109291467A, and the thermosetting resin material can meet the use requirements of strength, hardness, water resistance and pressure resistance. However, several commonly used molding processes for thermosetting resin materials, such as resin vacuum infusion, prepreg molding, autoclave molding, etc., have long molding cycles, often requiring over ten minutes, and thus the processing cost is high.
The carbon fiber reinforced thermoplastic composite material luggage case is a product which is gradually developed in recent years, and most of the carbon fiber prepregs and the unidirectional tape prepregs which adopt a woven cloth form or are manufactured by mixing the unidirectional tape prepregs and the woven cloth prepregs. Before the carbon fiber reinforced thermoplastic composite material is produced into the luggage case, the carbon fiber reinforced thermoplastic composite material is stacked into a flat plate and laminated to be extruded into a plate, and then the plate is hot-extruded into a semi-finished product of the luggage case through a die. Since the woven fabric prepreg is usually woven by carbon fiber tows in two directions, such as the 0-degree direction and the 90-degree direction, and the number of the carbon fiber yarns in the two directions is the same, the mechanical strength of the plate stacked by the woven fabric prepreg in the two fiber directions is almost the same. The sheet material formed by stacking unidirectional tape prepregs can be designed such that the fiber direction of each layer is 0 °/90 °/90 °/0 ° or 0 °/90 °/0 °/90 °/0 ° while ensuring that the fiber direction is symmetrical with respect to the sheet material intermediate layer. Asymmetric lamination can lead to warpage of composite panels and parts. Taking the 0 °/90 ° laminate as an example, since the fibers are uniformly distributed in the 0-degree direction of the sheet material, the mechanical strength in the 0-degree direction is the same in the different regions, and the same effect is also obtained in the 90-degree direction. The thickness of the unidirectional tape sheet and the mechanical properties in a certain fiber direction are also uniform.
When the continuous fiber reinforced thermoplastic composite material is used for manufacturing the luggage case, a thin woven fabric prepreg or unidirectional tape prepreg (the prepreg is a composition of a resin matrix and a reinforcement body prepared by impregnating continuous fibers or fabrics with a thermoplastic resin matrix under strictly controlled conditions, the woven fabric prepreg is impregnated with continuous fibers, the unidirectional tape prepreg is prepared by impregnating the continuous fibers parallel to each other, the woven fabric prepreg is called as a woven fabric prepreg, and the unidirectional tape prepreg is prepared by impregnating the continuous fibers parallel to each other) is laminated and hot-pressed to form a continuous fiber reinforced composite board with a certain thickness, the composite board is manufactured into a semi-finished luggage case by a mold hot-press molding process, and then the semi-finished case is assembled with other fabrics or leather materials into a complete luggage case.
For example, 5 layers of 0.25mm thick carbon fiber-polycarbonate 3K woven cloth prepreg were stacked together and subjected to a flat plate hot pressing process to obtain a 1.25mm thick woven cloth plate (3K means that each bundle of fibers contains three thousand fiber filaments, and 3K woven cloth means a cloth woven with 3K tow carbon fibers). Then the woven cloth plate is placed in an infrared heating furnace to be heated to 240 ℃, and the plate in a softened state is transferred to a hot-pressing mould of a trunk within 10 seconds. And rapidly closing and applying pressure to the hot-pressing mold, raising the temperature of the mold to 180 ℃, keeping the temperature for 1 minute, cooling the mold to 90 ℃, opening the mold, and taking out the semi-finished shell of the suitcase. Trimming the semi-finished shell of the suitcase, and assembling the semi-finished shell of the suitcase with cloth, a pull rod and the like to form the complete suitcase.
In order to pass drop-weight tests and weighted drop tests on luggage cases, luggage cases made of carbon fiber reinforced thermoplastic resins are often made thicker, which results in a loss of weight reduction.
During the transportation of the luggage, especially when falling from high altitudes, there are often cases where strong impacts are locally applied, resulting in that these parts are easily broken.
Locally reinforced luggage cases have not been disclosed in the prior art.
Disclosure of Invention
It is an object of the present invention to provide a luggage case that is locally reinforced.
It is another object of the present invention to provide a thermoplastic composite sheet for use in the preparation of a locally reinforced luggage case.
Thus, according to a first aspect of the present invention, there is provided a thermoplastic composite panel comprising an upper skin and a lower skin laminated together and one or more intermediate layers between the upper skin and the lower skin, and having an upper surface constituted by the upper skin, a lower surface constituted by the lower skin and successively adjacent first, second, third and fourth sides, the thermoplastic composite panel having at least one first locally reinforced area adjacent at least one junction of adjacent sides and at least one second locally reinforced area adjacent at least one side.
According to a second aspect of the present invention, there is provided a method of making the above thermoplastic composite panel, comprising laminating together the upper skin layer, the one or more intermediate layers, the lower skin layer, the at least one first localized reinforcing region and the at least one second localized reinforcing region.
According to a third aspect of the present invention, there is provided an article made from the above thermoplastic composite sheet.
The thermoplastic composite board has a local reinforced area, and the product prepared from the thermoplastic composite board is locally reinforced, so that the local impact resistance and/or static load capacity are improved, and the better balance among the strength, the rigidity and the light weight of the final product can be realized under the condition of keeping the weight of the whole structure not to be remarkably increased.
Drawings
The present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which like reference numerals refer to like parts and in which:
FIG. 1 shows a schematic view of a thermoplastic composite sheet according to one embodiment of the present invention;
FIG. 2 shows the size and location of localized reinforced areas relative to sides of a thermoplastic composite sheet according to one embodiment of the present invention;
FIG. 3 shows a schematic structural exploded view of a thermoplastic composite sheet according to one embodiment of the present invention.
Detailed description of the preferred embodiments
Some specific embodiments of the present invention will now be described for illustrative purposes, but not for limitation, with reference to the accompanying drawings.
Referring to fig. 1, according to a first aspect of the present invention, there is provided a thermoplastic composite sheet (1), comprising an upper skin (11) and a lower skin (13) laminated together and one or more intermediate layers (12) between the upper skin (11) and the lower skin (13), and having an upper surface constituted by said upper surface layer (11), a lower surface constituted by said lower surface layer (13) and a first side surface (14), a second side surface (15), a third side surface (16) and a fourth side surface (17) which are adjacent in that order, characterized in that the thermoplastic composite sheet material has at least one first locally reinforced area (18-21) near at least one intersection of adjacent side faces (14-17) and at least one second locally reinforced area (22-23) near at least one side face (14-17).
In some embodiments, the thermoplastic composite panel (1) comprises an upper skin (11) and a lower skin (13) laminated together and one or more intermediate layers (12) between the upper skin (11) and the lower skin (13), and has an upper surface comprised of the upper skin (11), a lower surface comprised of the lower skin (13), and successively adjacent first (14), second (15), third (16) and fourth (17) sides, with at least four first localized reinforcing regions (18-21) respectively proximate to the intersection of each adjacent side and at least two second localized reinforcing regions (22-23) respectively proximate to the first (14) and third (16) sides.
Preferably, the edges of the upper skin (11), the intermediate layer (12) and the lower skin (13) are aligned.
Preferably, the upper surface (11), the intermediate layer (12) and the lower surface (13) of the thermoplastic composite board (1) are simultaneously rectangular or square.
In some embodiments, the edges of the upper surface (11), the intermediate layer (12) and the lower surface (13) of the thermoplastic composite panel (1) are aligned and rectangular, and the second localized reinforcing region (18-21) is adjacent to the side of the aligned long edges of the upper surface (11), the intermediate layer (12) and the lower surface (13).
The at least one first local reinforcing area (18-21) is located in any one or more of the one or more intermediate layers (12), preferably the at least one first local reinforcing area (18-21) is the same thickness as the intermediate layer in which it is located.
Preferably, the number of layers of the intermediate layer (12) is 2 or more, for example 2 to 18 layers, preferably 2 to 8 layers.
Preferably, the thickness of the upper skin layer (11) is 0.1-0.25mm, preferably 0.15-0.25mm, more preferably 0.15-0.2 mm.
Preferably, the thickness of each of the one or more intermediate layers (12) is independently 0.1-0.25mm, preferably 0.15-0.25mm, more preferably 0.15-0.2 mm.
Preferably, the thickness of the lower skin layer (13) is 0.1-0.25mm, preferably 0.15-0.25mm, more preferably 0.15-0.2 mm.
Preferably, each first locally enhanced region has a thickness of from 0.1 to 0.25mm, preferably from 0.15 to 0.25mm, more preferably from 0.15 to 0.2 mm.
Preferably, each second localized reinforcing region has a thickness of 0.1 to 0.25mm, preferably 0.15 to 0.25mm, more preferably 0.15 to 0.2 mm.
Preferably, the thickness of the thermoplastic composite sheet is 1.0 to 2.0mm, preferably 1.0 to 1.5 mm.
Said at least one second localized reinforcing area (22-23) is located between any two adjacent layers of said upper skin layer (11), said one or more intermediate layers (12) and said lower skin layer (13), preferably said at least one second localized reinforcing area (22-23) is located at a distance from said upper surface (11) substantially equal to a distance from said lower surface (13).
For example, in case the one or more intermediate layers (12) are an even number of layers, such as 6 layers, it is preferred that the at least one second locally reinforced area (22-23) is located between the 3 rd and 4 th intermediate layers from above.
For example, in case the one or more intermediate layers (12) are an odd number of layers, e.g. 7 layers, it is preferred that the at least one first local enhancement region (22-23) is located between a 4 th and a 5 th layer intermediate layer from above.
As used herein, "two adjacent layers" refers to layers that are in contact with each other in areas that are not the second localized area of enhancement.
Preferably, the arrangement of the at least one first localized reinforcing region (18-21) and the at least one second localized reinforcing region (22-23) is such that the entire thermoplastic composite sheet material is of a substantially symmetrical configuration relative to the intermediate layer.
Preferably, the at least one first local reinforcing area (18-21) each represents 1-3% of the total thermoplastic composite sheet material, calculated as a projected area on the upper surface (11).
Preferably, the at least one second localized reinforcing region (22-23) comprises 3-10% of the entire thermoplastic composite sheet, calculated as a projected area on the upper surface (11), respectively.
The distance of the first locally reinforced areas (18-21) and the second locally reinforced areas (22-23) from the respective side can be determined by the person skilled in the art on the basis of the subsequent processing, so that the areas which are often subjected to impacts or heavy loads after processing into an article are reinforced.
For example, with reference to fig. 2, in the case of a thermoplastic composite sheet for the manufacture of a luggage case, the thermoplastic composite sheet (1) has four first localized reinforcing regions (18-21) and two second localized reinforcing regions (22-23) arranged symmetrically, where only the size of each localized reinforcing region and the position relative to each side are shown.
The distance (A) from the first local reinforcement area (18) to the fourth side (17) is 3-5% of the length (L) of the first side (14), the distance (C) from the first side (14) is 3-5% of the length (1) of the fourth side (17), the length (L4) on the fourth side is 10-15% of the length (1) of the fourth side (17), and the length (L1) on the first side is 10-15% of the length (L) of the first side (14).
The dimensions for the first local reinforcement area (18) and its distance from the side in proximity are adapted to the dimensions of the other first local reinforcement areas (19-21) and their distance from the side in proximity.
The distance (B) of the second locally enhanced region (22) to the first locally enhanced region (18) is 2-4% of the length (L) of the first side (14), the distance (D) to the first side (14) is 8-12% of the length (1) of the fourth side (17), the length (L3) on the fourth side (17) is 8-15% of the length (1) of the fourth side (17), and the length (L2) on the first side is 40-60% of the length (L) of the first side (14).
The dimensions for the second local reinforcing areas (22) and their distance from the side in proximity are adapted to the dimensions of the other second local reinforcing areas (23) and their distance from the side in proximity.
In some embodiments, the upper skin (11), the lower skin (13), and the at least one first localized reinforcing region are each independently formed from a material selected from the group consisting of: polycarbonate, polyurethane, polymethylmethacrylate and polypropylene, preferably the upper skin layer (11), the lower skin layer (13) and the at least one first local reinforcement area are formed from the same polymer material.
In some embodiments, the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are each independently formed from a fiber reinforced resin composite selected from the group consisting of: carbon fiber reinforced polycarbonate composite material, carbon fiber reinforced thermoplastic polyurethane composite material, carbon fiber reinforced polymethylmethacrylate composite material, carbon fiber reinforced polypropylene composite material, Kevlar fiber reinforced polycarbonate composite material, Kevlar fiber reinforced thermoplastic polyurethane composite material, Kevlar fiber reinforced polymethylmethacrylate composite material and Kevlar fiber reinforced polypropylene composite material, preferably, the one or more intermediate layers (12) and the at least one second local reinforcement area (22-23) are formed of the same fiber reinforced resin composite material.
In some embodiments, the upper skin (11), the lower skin (13) and the at least one first localized reinforcement area are all formed of polycarbonate resin, and the one or more intermediate layers (12) and the at least one second localized reinforcement area (22-23) are all formed of a fiber reinforced resin composite selected from the group consisting of carbon fiber reinforced polycarbonate composites and Kevlar fiber reinforced polycarbonate composites.
In some embodiments, the upper skin (11), the lower skin (13) and the at least one first localized reinforcing region are all formed of polyurethane, and the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber-reinforced resin composite selected from the group consisting of carbon fiber-reinforced polyurethane composites and Kevlar fiber-reinforced polyurethane composites.
In some embodiments, the upper skin layer (11), the lower skin layer (13) and the at least one first localized reinforcing region are all formed of polymethylmethacrylate, and the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber-reinforced resin composite selected from carbon fiber-reinforced polymethylmethacrylate composites and Kevlar fiber-reinforced polymethylmethacrylate composites.
In some embodiments, the upper skin (11), the lower skin (13) and the at least one first localized reinforcing region are all formed of polypropylene, and the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber reinforced resin composite material selected from the group consisting of carbon fiber reinforced polypropylene composites and Kevlar fiber reinforced polypropylene composites.
For example, as shown in fig. 3, in one embodiment, the thermoplastic composite sheet exhibits an up-down symmetrical structure and is composed of the following layers:
the first layer (top layer) is a PC film;
the second layer (middle layer) was a 0-degree carbon fiber reinforced polycarbonate unidirectional tape having four first local reinforcing regions formed by cutting out the 0-degree carbon fiber reinforced polycarbonate unidirectional tape at four regions and then replacing the cut-out regions with PC films;
the third layer (middle layer) is a 90-degree carbon fiber reinforced polycarbonate unidirectional tape;
the fourth layer (middle layer) is the same as the third layer;
the fifth layer (intermediate layer) is, as with the second layer, a 0-degree carbon fiber reinforced polycarbonate unidirectional tape having four first partial reinforcing regions formed by partially cutting out the 0-degree carbon fiber reinforced polycarbonate unidirectional tape and then replacing the cut-out portions with a PC film;
the sixth layer (lower surface layer) is the same as the first layer;
with the layers aligned at their edges, with two second locally enhanced regions between the third and fourth layers.
In the present application, polycarbonate and PC are used interchangeably.
In this application, polyurethane is used interchangeably with PU.
In the present application, polymethyl methacrylate is used interchangeably with PMMA.
In the present application, polypropylene is used interchangeably with PP.
The carbon fiber reinforced polycarbonate composite material, the carbon fiber reinforced thermoplastic polyurethane composite material, the carbon fiber reinforced polymethyl methacrylate composite material, the carbon fiber reinforced polypropylene composite material, the Kevlar fiber reinforced polycarbonate composite material, the Kevlar fiber reinforced thermoplastic polyurethane composite material, the Kevlar fiber reinforced polymethyl methacrylate composite material, the Kevlar fiber reinforced polypropylene composite material, the polycarbonate, the polyurethane, the polymethyl methacrylate and the polypropylene are materials commonly used in the field of composite materials.
Preferably, in the carbon fiber or Kevlar fiber reinforced resin composite, the fiber volume content is 35% to 60%, preferably 40% to 55%, more preferably 44% to 50%.
The polyurethane described herein is a thermoplastic polyurethane.
The thermoplastic composite sheet according to the present invention may be prepared by a lamination method commonly used in the art.
Thus, according to a second aspect of the present invention, there is provided a method of manufacturing the above thermoplastic composite board, comprising laminating together the upper skin layer (11), the one or more intermediate layers (12), the lower skin layer (13), the at least one first localized reinforcing area (18-21) and the at least one second localized reinforcing area (22-23).
Specifically, the thermoplastic composite material according to the present invention can be prepared, for example, in the following manner:
and cutting the resin film and the composite unidirectional tape prepreg by an automatic blanking machine according to a preset CAD program, wherein the resin film is used as an upper surface layer, a lower surface layer and a first local reinforced area, and the composite unidirectional tape prepreg is used as an intermediate layer and a second local reinforced area. And grabbing the cut unidirectional tape prepreg and the resin film by using a mechanical arm with a sucker, and superposing the grabbed unidirectional tape prepreg and the resin film layer by layer according to a set program. And the layers are temporarily fixed by an ultrasonic welding gun on a mechanical arm. And after the automatic lamination and the ultrasonic fixation are finished, transferring the laminated composite material into a flat hot press, pressing the material into a composite plate through high temperature and high pressure, cooling the composite plate, conveying the composite plate to a cutting device for cutting, and cutting off flash.
Because the mechanical arm has higher automation capability and positioning accuracy, resin films or composite unidirectional tape prepreg can be additionally applied to certain areas of the plate with higher accuracy to realize the effect of local reinforcement.
Bonding the layers together by lamination is a method known in the art and the skilled person can select suitable process parameters depending on the material, thickness of the layers used.
In some embodiments, the upper skin layer (11), the lower skin layer (13) and the at least one first localized reinforcing region are all formed of polycarbonate, the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber reinforced resin composite selected from the group consisting of carbon fiber reinforced polycarbonate composites and Kevlar fiber reinforced polycarbonate composites, and the lamination is carried out at a hot plate temperature of 200-.
In some embodiments, the upper skin layer (11), the lower skin layer (13) and the at least one first localized reinforcing region are all formed of polyurethane, the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber reinforced resin composite selected from the group consisting of carbon fiber reinforced polyurethane composites and Kevlar fiber reinforced polyurethane composites, and the lamination is carried out at a hot plate temperature of 180-.
In some embodiments, the upper surface layer (11), the lower surface layer (13) and the at least one first localized reinforcing region are all formed of polymethylmethacrylate, the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber-reinforced resin composite selected from the group consisting of carbon fiber-reinforced polymethylmethacrylate composites and Kevlar fiber-reinforced polymethylmethacrylate composites, and the hot plate temperature used during lamination is 160-230 ℃, the hot plate pressure is 1-2.5MPa, and the holding time is 3-10 minutes.
In some embodiments, the upper skin layer (11), the lower skin layer (13) and the at least one first localized reinforcing region are all formed of polypropylene, the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are all formed of a fiber reinforced resin composite selected from the group consisting of carbon fiber reinforced polypropylene composites and Kevlar fiber reinforced polypropylene composites, and the hot plate temperature used during lamination is 200-.
The thermoplastic composite sheet according to the present invention can be used to prepare various articles, particularly articles requiring local reinforcement.
Thus, according to a third aspect of the present invention, there is provided an article made from the above thermoplastic composite sheet material.
The article may be a luggage body, preferably a luggage body.
One skilled in the art can select appropriate process parameters depending on the materials used for the various layers.
The description of the various features of the present application may be combined without contradiction to each other and fall within the scope of the claims of the present application.
The terms "comprising" and "including" as used herein encompass the case where other elements not explicitly mentioned are also included or included and the case where they consist of the mentioned elements.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In the event that a definition of a term in this specification conflicts with a meaning commonly understood by those skilled in the art to which the invention pertains, the definition set forth herein shall govern.
Unless otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth herein are approximations that can vary depending upon the desired properties to be obtained.
Examples
The conception, specific structure, and technical effects of the present invention will be further described in conjunction with the embodiments and the accompanying drawings so that those skilled in the art can fully understand the objects, features, and effects of the present invention. It will be understood by those skilled in the art that the embodiments herein are for illustrative purposes only and the scope of the present invention is not limited thereto.
The apparatus used
Model VLPH-200 ton flat bed thermocompressor from Vigor corporation:
the size of the table top is as follows: 660mm x 760mm, temperature range: room temperature (25 ℃) to 400 ℃, table flatness: ± 0.5mm, hot plate temperature uniformity: . + -. 1.5 ℃.
HC-HG-28800 ultrasonic welding gun:
power: 800W, working frequency: 28 KHz.
Koka KR 6R 900 robot:
working radius: 900mm, 6 axes, maximum load: 6 kilograms, repeated positioning accuracy: 0.05 mm.
Longitude and latitude science and technology BR03II type cutting machine:
translation speed: 800-: 200-800mm/s, and the repetition precision is less than or equal to 0.1 mm.
The raw materials used
Polycarbonate (PC) film: the thickness is 0.175 mm.
Carbon fiber reinforced polycarbonate unidirectional tape: the thickness was 0.175mm and the volume content of carbon fibers was 44%.
The test method used
In the examples of the present application, the luggage body made of the thermoplastic composite sheet material of the present invention was tested using the following test methods:
the drop hammer impact test method of the case comprises the following steps: the method is carried out according to QB/T2918-2007, the weight of the drop hammer is 2-5 kg, the impact height of the drop hammer is 700mm, the passing standard is no cracking and no deformation, and the two sides of the luggage box need to be tested.
The case drop test method comprises the following steps: the method is carried out according to QB/T2921-2005, and the load condition is 19-21 inches and 16 kg; 22-24 cun, 18 kg; 25-28 cun loaded with 20 kg; 29-31 inches loaded with 25 kg; load 28 kg above 32 inches; the planar drop test height is 900mm and the edge and corner drop test height is 600 mm. Pass criteria are no cracking, no deformation.
And (3) testing the static pressure resistance of the luggage box body: the process is carried out according to QB/T2155-2018, the load condition is that the load is 40 kilograms when the length size is in the range of 535mm-660mm, and the load is 60 kilograms when the length size is in the range of 685mm-835mm, and the process is continued for 4 hours. The pass criteria are no cracking, no deformation, no collapse.
Inventive example 1
I: preparation of thermoplastic composite board
Referring to fig. 3, the thermoplastic composite sheet to be produced exhibits an up-down symmetrical structure and is composed of the following layers:
the first layer (upper skin) was a PC film with dimensions 650mm x 750 mm;
the second layer (intermediate layer) was a 0-degree carbon fiber reinforced polycarbonate unidirectional tape having four first local reinforcing regions formed by cutting out the 0-degree carbon fiber reinforced polycarbonate unidirectional tape in four regions and then replacing the cut-out regions with a PC film, the first local reinforcing regions having a size of 90mm × 78mm, a distance to the side of the adjacent 0-degree direction of 32.5mm, and a distance to the side of the adjacent 90-degree direction of 30 mm;
the third layer (middle layer) is a 90-degree carbon fiber reinforced polycarbonate unidirectional tape;
the fourth layer (middle layer) is the same as the third layer;
the fifth layer (intermediate layer) is the same as the second layer;
the sixth layer (lower surface layer) is the same as the first layer;
with the layers aligned at the edges, there were two second localized reinforced areas between the third and fourth layers, the second localized reinforced areas being 90 degree carbon fiber reinforced polycarbonate unidirectional tapes, measuring 375mm x 52mm, a distance of 65mm to the proximal 0 degree directional side, and a distance of 22.5mm (calculated as the distance between the projections to the upper surface) to the proximal first localized reinforced areas.
First, a composite board was prepared as follows:
and cutting the resin film and the composite material unidirectional tape prepreg by an automatic blanking machine according to a preset CAD program. And grabbing the cut unidirectional tape prepreg and the resin film by using a mechanical arm with a sucker, and superposing the grabbed unidirectional tape prepreg and the resin film layer by layer according to a set program. And the layers are temporarily fixed by an ultrasonic welding gun on a mechanical arm. Due to the high automation capacity and positioning precision of the mechanical arm, the unidirectional tape or the film can be additionally applied to certain areas of the plate material with high precision to realize the effect of local reinforcement. And after the automatic lamination and the ultrasonic fixation are finished, transferring the laminated composite material into a flat hot press, pressing the material into a composite plate through high temperature and high pressure, cooling the composite plate, conveying the composite plate to a cutting device for cutting, and cutting off flash. The technological parameters in the flat plate hot press are set as follows:
hot plate temperature: 240 ℃;
hot plate pressure: 2 MPa;
and (3) heat preservation time: and 8 min.
In the 0-degree carbon fiber reinforced polycarbonate unidirectional tape which is partially cut off, a PC film is used for replacing the cut-off part.
II: preparation of luggage case body
The position of the first local reinforced area corresponds to four angular positions of the luggage case, the second local reinforced area corresponds to the edge of the length direction of the luggage case, and the composite board is subjected to hot press forming by a hot press forming machine to form a semi-finished product of the luggage case for assembling the complete luggage case. The technological parameters in the hot-press forming machine are set as follows:
hot press forming process parameters
Infrared heating temperature (. degree.C.) 260
Heating time (min) 4
Tablet transfer time(s) 20
Closing time(s) 10
Locking mould force (T) 150
Dwell time (min) 3
Mold highest temperature (. degree. C.) 180
Mold release temperature (. degree. C.) 90
And (3) performing a box drop hammer impact test according to QB/T2918-2007, wherein the weight of the drop hammer is 5 kg, and the impact height of the drop hammer is 700mm, and the box body is not cracked and deformed.
And (3) performing a box drop test according to QB/T2921-2005, wherein the load is 16 kg, the plane drop test height is 900mm, and the edge and corner drop test height is 600mm, and no crack and no deformation are found.
And (3) carrying out static pressure bearing test on the case box body according to QB/T2155-2018, carrying out load of 40 kg, and continuously pressing for 4 hours to find that the box body has no crack, deformation or collapse.
Comparative example 1
I: preparation of thermoplastic composite board
The thermoplastic composite board to be prepared has a vertically symmetrical structure and consists of the following layers:
the first layer (upper skin) was a PC film with dimensions 650mm x 750 mm;
the second layer (middle layer) is a 0-degree carbon fiber reinforced polycarbonate unidirectional tape;
the third layer (middle layer) is a 90-degree carbon fiber reinforced polycarbonate unidirectional tape;
the fourth layer (middle layer) is the same as the third layer;
the fifth layer (intermediate layer) is the same as the second layer;
the sixth layer (lower surface layer) is the same as the first layer;
with the layers aligned edge to edge.
First, a composite board was prepared as follows:
and cutting the resin film and the composite material unidirectional tape prepreg by an automatic blanking machine according to a preset CAD program. And grabbing the cut unidirectional tape prepreg and the resin film by using a mechanical arm with a sucker, and superposing the grabbed unidirectional tape prepreg and the resin film layer by layer according to a set program. And the layers are temporarily fixed by an ultrasonic welding gun on a mechanical arm. And after the automatic lamination and the ultrasonic fixation are finished, transferring the laminated composite material into a flat hot press, pressing the material into a composite plate through high temperature and high pressure, cooling the composite plate, conveying the composite plate to a cutting device for cutting, and cutting off flash. Wherein the process parameters in the flat-bed hot press are the same as in inventive example 1.
II: preparation of luggage case body
And (3) carrying out hot press molding on the thermoplastic composite board by adopting a hot press molding machine to prepare a semi-finished product of the trunk, wherein the semi-finished product is used for assembling the complete trunk. Wherein the process parameters in the thermoforming machine are the same as those described in inventive example 1.
And (3) performing a box drop hammer impact test according to QB/T2918-2007, wherein the weight of the drop hammer is 5 kg, and the impact height of the drop hammer is 700mm, and the side surface of the box body is cracked.
Carrying out a bag drop test according to QB/T2921-2005, and loading 16 kg; the box corner was found to crack when the height of the plane drop test was 900mm and the height of the edge and corner drop test was 600 mm.
And (3) carrying out static pressure bearing test on the case box body according to QB/T2155-2018, carrying out load of 40 kg, continuously pressing for 4 hours, and finding that the edge of the box body in the length direction is cracked, deformed and cannot be recovered.
As can be seen from the comparison between the inventive example 1 and the comparative example 1, the composite material plate according to the present invention introduces the resin film on the basis of the original unidirectional tape prepreg, so as to increase the impact resistance of the plate at certain positions. Meanwhile, the stress load capacity of the area in a certain direction is further improved by adding the additional laminated layer in the local area. The impact resistance or force load at certain locations is increased while maintaining the overall structural weight without significant enhancement, resulting in a better balance of strength, stiffness and weight reduction in the final luggage case.
The foregoing describes only exemplary embodiments or examples of the present invention and is not intended to limit the present invention. The present invention may be modified and varied by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention are included in the scope of the claims of the present application.

Claims (14)

1. Thermoplastic composite panel (1) comprising an upper skin (11) and a lower skin (13) laminated together and one or more intermediate layers (12) between the upper skin (11) and the lower skin (13), and having an upper surface constituted by the upper skin (11), a lower surface constituted by the lower skin (13) and successively adjacent first (14), second (15), third (16) and fourth (17) sides, characterized in that the thermoplastic composite panel (1) has at least one first locally reinforced area (18-21) near at least one intersection of adjacent sides (14-17) and at least one second locally reinforced area (22-23) near at least one side (14-17).
2. Thermoplastic composite sheet material according to claim 1, characterized in that said at least one first local reinforcement area (18-21) is located in any one or more of said one or more intermediate layers (12), preferably said at least one first local reinforcement area (18-21) is of the same thickness as the intermediate layer in which it is located.
3. The thermoplastic composite panel as claimed in claim 1 or 2, wherein said at least one second locally reinforced area (22-23) is located between any two adjacent layers of said upper skin layer (11), said one or more intermediate layers (12) and said lower skin layer (13).
4. The thermoplastic composite sheet according to any one of claims 1-3, wherein the at least one first localized reinforcing region (18-21) comprises 1-2% of the entire thermoplastic composite sheet, calculated as a projected area on the upper surface (11).
5. The thermoplastic composite sheet according to any one of claims 1 to 4, wherein the at least one second localized reinforcing region (22-23) comprises 3 to 9% of the entire thermoplastic composite sheet, calculated as a projected area on the upper surface (11).
6. The thermoplastic composite panel according to any one of claims 1-5, wherein the upper skin (11), the lower skin (13), and the at least one first localized reinforcing region are each independently formed from a polymeric material selected from the group consisting of: polycarbonate, polyurethane, polymethylmethacrylate and polypropylene, preferably the upper skin layer (11), the lower skin layer (13) and the at least one first local reinforcement area (18-21) are formed from the same polymer material.
7. The thermoplastic composite panel according to any one of claims 1 to 6, wherein the one or more intermediate layers (12) and the at least one second localized reinforcing region (22-23) are each independently formed of a fiber reinforced resin composite selected from the group consisting of: carbon fiber reinforced polycarbonate composite material, carbon fiber reinforced thermoplastic polyurethane composite material, carbon fiber reinforced polymethylmethacrylate composite material, carbon fiber reinforced polypropylene composite material, Kevlar fiber reinforced polycarbonate composite material, Kevlar fiber reinforced thermoplastic polyurethane composite material, Kevlar fiber reinforced polymethylmethacrylate composite material and Kevlar fiber reinforced polypropylene composite material, preferably, the one or more intermediate layers (12) and the at least one second local reinforcement area (22-23) are formed of the same fiber reinforced resin composite material.
8. Thermoplastic composite board according to any of claims 1-5, characterized in that the upper skin layer (11), the lower skin layer (13) and the at least one first local reinforcement area (18-21) are all formed of polycarbonate, and the one or more intermediate layers (12) and the at least one second local reinforcement area (22-23) are all formed of a fiber-reinforced resin composite selected from carbon fiber-reinforced polycarbonate composites and Kevlar fiber-reinforced polycarbonate composites.
9. Thermoplastic composite panel according to any of claims 1 to 5, characterized in that the upper skin (11), the lower skin (13) and the at least one first local reinforcing area (18-21) are all formed of polyurethane, and the one or more intermediate layers (12) and the at least one second local reinforcing area (22-23) are all formed of a fibre-reinforced resin composite selected from carbon fibre-reinforced polyurethane composites and Kevlar fibre-reinforced polyurethane composites.
10. Thermoplastic composite board according to any of claims 1-5, wherein the upper surface layer (11), the lower surface layer (13) and the at least one first local reinforcement area (18-21) are all formed of polymethyl methacrylate, and the one or more intermediate layers (12) and the at least one second local reinforcement area (22-23) are all formed of a fiber-reinforced resin composite selected from carbon fiber-reinforced polymethyl methacrylate composites and Kevlar fiber-reinforced polymethyl methacrylate composites.
11. Thermoplastic composite board according to any of claims 1-5, characterized in that the upper skin layer (11), the lower skin layer (13) and the at least one first local reinforcement area (18-21) are all formed of polypropylene, and the one or more intermediate layers (12) and the at least one second local reinforcement area (22-23) are all formed of a fiber-reinforced resin composite material selected from carbon fiber-reinforced polypropylene composites and Kevlar fiber-reinforced polypropylene composites.
12. A method of making the thermoplastic composite panel according to any one of claims 1-11, characterized in that it comprises laminating the upper skin (11), the one or more intermediate layers (12), the lower skin (13), the at least one first locally reinforced area (18-21) and the at least one second locally reinforced area (22-23) together.
13. An article made from the thermoplastic composite sheet of any of claims 1-11.
14. Article according to claim 13, characterized in that it is a case, such as a luggage case.
CN201910914244.3A 2019-09-25 2019-09-25 Thermoplastic composite board and preparation method and product thereof Pending CN112549706A (en)

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