CN112677581B - Carbon fiber prepreg and preparation method and application thereof - Google Patents
Carbon fiber prepreg and preparation method and application thereof Download PDFInfo
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- CN112677581B CN112677581B CN202011587741.6A CN202011587741A CN112677581B CN 112677581 B CN112677581 B CN 112677581B CN 202011587741 A CN202011587741 A CN 202011587741A CN 112677581 B CN112677581 B CN 112677581B
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- 229920000049 Carbon (fiber) Polymers 0.000 title claims abstract description 159
- 239000004917 carbon fiber Substances 0.000 title claims abstract description 159
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 138
- 238000002360 preparation method Methods 0.000 title abstract description 14
- 229920005989 resin Polymers 0.000 claims abstract description 131
- 239000011347 resin Substances 0.000 claims abstract description 131
- 239000003822 epoxy resin Substances 0.000 claims abstract description 77
- 229920000647 polyepoxide Polymers 0.000 claims abstract description 77
- 239000000919 ceramic Substances 0.000 claims abstract description 26
- 229920005570 flexible polymer Polymers 0.000 claims abstract description 22
- 229910052751 metal Inorganic materials 0.000 claims abstract description 19
- 239000002184 metal Substances 0.000 claims abstract description 19
- 239000010410 layer Substances 0.000 claims description 102
- 239000011256 inorganic filler Substances 0.000 claims description 41
- 229910003475 inorganic filler Inorganic materials 0.000 claims description 41
- 239000002344 surface layer Substances 0.000 claims description 32
- 239000003795 chemical substances by application Substances 0.000 claims description 31
- 239000002313 adhesive film Substances 0.000 claims description 28
- 239000002131 composite material Substances 0.000 claims description 24
- 239000011248 coating agent Substances 0.000 claims description 23
- 238000000576 coating method Methods 0.000 claims description 23
- 239000011159 matrix material Substances 0.000 claims description 21
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 20
- 229920000570 polyether Polymers 0.000 claims description 20
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 16
- 239000000853 adhesive Substances 0.000 claims description 15
- 230000001070 adhesive effect Effects 0.000 claims description 15
- 238000007598 dipping method Methods 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 12
- 238000003618 dip coating Methods 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 10
- QGBSISYHAICWAH-UHFFFAOYSA-N dicyandiamide Chemical group NC(N)=NC#N QGBSISYHAICWAH-UHFFFAOYSA-N 0.000 claims description 8
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 8
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 235000012239 silicon dioxide Nutrition 0.000 claims description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical group [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 6
- 239000002518 antifoaming agent Substances 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 3
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical compound C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 claims description 2
- 229910052582 BN Inorganic materials 0.000 claims description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 2
- 239000004841 bisphenol A epoxy resin Substances 0.000 claims description 2
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 2
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 2
- 238000005034 decoration Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 claims 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims 1
- 239000003292 glue Substances 0.000 description 21
- 238000001816 cooling Methods 0.000 description 20
- 239000013530 defoamer Substances 0.000 description 19
- 229920001971 elastomer Polymers 0.000 description 18
- 239000005060 rubber Substances 0.000 description 18
- 238000007731 hot pressing Methods 0.000 description 14
- 229910000838 Al alloy Inorganic materials 0.000 description 10
- 239000000463 material Substances 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 238000005336 cracking Methods 0.000 description 7
- 238000002844 melting Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- 230000001681 protective effect Effects 0.000 description 7
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 6
- 239000000956 alloy Substances 0.000 description 6
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 6
- 230000035882 stress Effects 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 229910002110 ceramic alloy Inorganic materials 0.000 description 4
- 238000013329 compounding Methods 0.000 description 4
- 230000001788 irregular Effects 0.000 description 4
- 238000003892 spreading Methods 0.000 description 4
- 230000007480 spreading Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- GJYCVCVHRSWLNY-UHFFFAOYSA-N 2-butylphenol Chemical compound CCCCC1=CC=CC=C1O GJYCVCVHRSWLNY-UHFFFAOYSA-N 0.000 description 2
- 229930185605 Bisphenol Natural products 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- AMYRSDHRQFEUCF-UHFFFAOYSA-N buta-1,3-diene 2-phenylethenol Chemical group C=CC=C.OC=CC1=CC=CC=C1 AMYRSDHRQFEUCF-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- -1 for example Inorganic materials 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000004850 liquid epoxy resins (LERs) Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000002905 metal composite material Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000011208 reinforced composite material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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Abstract
The invention relates to a carbon fiber prepreg and a preparation method and application thereof. The carbon fiber prepreg consists of a bottom resin layer, a carbon fiber layer and a surface resin layer; the bottom resin layer is made of reactive flexible polymer modified epoxy resin, so that the toughness of the resin can be improved. The carbon fiber prepreg provided by the invention can solve the problems that the existing carbon fiber epoxy resin prepreg is easy to crack and has poor reliability after being hot pressed with metal and ceramic. In addition, the invention also provides preparation and application of the carbon fiber prepreg.
Description
Technical Field
The invention relates to the technical field of materials, in particular to a carbon fiber prepreg and a preparation method and application thereof.
Background
The carbon fiber composite material formed by hot-pressing and compounding the carbon fiber prepreg sheet and the base materials such as metal, ceramic or plastic has the performances of small density, high specific strength, corrosion resistance and the like, and can be used in the fields of aerospace, military industry, automobiles and the like, and also can be used for decorating parts such as structural parts or panels of household appliances.
Carbon fiber prepregs are key intermediate raw materials for preparing carbon fiber composites, which have important effects on the performance, particularly the reliability, of the carbon fiber composites. The most common carbon fiber prepreg is one in which unidirectional or woven carbon fiber cloth is impregnated with liquid epoxy resin and dried to partially crosslink the epoxy resin in a semi-cured state.
However, the matrix resin of conventional carbon fiber/epoxy prepregs is a neat epoxy resin having a coefficient of thermal expansion of about 100 x 10 -6 Per DEG C, and the coefficient of thermal expansion of the usual metals (steel, copper, aluminum) is (10-30) x 10 -6 Ceramic having a coefficient of thermal expansion of less than 1X 10 per DEG C -6 about/DEG C. Because the thermal expansion coefficient of the epoxy resin is greatly different from that of metal and ceramic, the carbon fiber composite material pressed by the prepreg and the metal or ceramic can generate certain internal stress in the material, particularly at the interface of resin/matrix, and the internal stress is increased along with the change of the ambient temperature, so that the interface cracking or resin cracking is very easy to occur when external force is impacted or the ambient temperature is changed.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems in the prior art described above. Therefore, the invention provides a novel carbon fiber prepreg to solve the problem that in the prior art, a composite material interface is cracked or resin is cracked in the application process of the carbon fiber prepreg.
Specifically, a first aspect of the present invention proposes a carbon fiber prepreg composed of a base resin layer, a carbon fiber layer, and a face resin layer; the bottom resin layer is epoxy resin added with inorganic filler.
According to one embodiment of the present invention, the primer resin layer, the carbon fiber layer and the topcoat resin layer are impregnated with each other.
According to an embodiment of the present invention, the resins of the under-layer resin layer and the over-layer resin layer may be independently selected from one or more of a phenolic epoxy resin, a bisphenol a epoxy resin, a bisphenol S epoxy resin.
According to the technical scheme of the invention, the inorganic filler is added into the bottom resin layer, so that the thermal expansion coefficient of the epoxy resin can be reduced, the epoxy resin is more matched with other matrix materials such as ceramics or metals, and the problem that the existing carbon fiber resin is extremely easy to crack after being compounded with other materials is solved.
According to an embodiment of the present invention, the inorganic filler may be one or a mixture of two or more of silica, alumina, boron nitride, aluminum nitride, and silicon carbide.
According to one embodiment of the invention, the mass ratio of the epoxy resin to the inorganic filler is 100:10-80.
According to an embodiment of the present invention, the mass ratio of the epoxy resin and the inorganic filler in the preferable primer layer is also different depending on the base material compounded with the carbon fiber prepreg. Specifically, when the epoxy resin is compounded with ceramic, the mass ratio of epoxy resin to inorganic filler in the bottom resin layer is 100:40-80, preferably 100:40-70. Compounding with a metal, for example, with aluminum or an alloy thereof, the mass ratio of the epoxy resin and the inorganic filler in the under-layer resin layer is 100:10-45, preferably 100:10-40.
According to one embodiment of the invention, the topcoat resin layer is a reactive flexible polymer modified epoxy resin.
According to one embodiment of the invention, the reactive flexible polymer is a liquid styrene-butadiene rubber, an epoxy-terminated polyether, or a combination thereof. Compared with common epoxy resin, the reactive flexible polymer is copolymerized with the epoxy resin, so that the surface layer resin has higher toughness, the generation of microcracks of the surface layer resin under internal stress or mechanical external force can be avoided, and the surface layer resin is transparent after being cured, so that the pattern appearance display of the carbon fiber is not affected; but also may enhance the aesthetic and aesthetic properties of parts made from the prepreg.
According to one embodiment of the present invention, the carbon fiber layer may be a unidirectional or woven carbon fiber layer.
According to one embodiment of the invention, the carbon fiber strands in the carbon fiber layer are between 3K and 12K; preferably between 3K and 7K.
According to one embodiment of the present invention, the carbon fiber bottom resin layer, the carbon fiber layer, and the carbon fiber top resin layer are integrated by impregnation between resins and fibers.
The invention also relates to a preparation method of the carbon fiber prepreg, and specifically, the carbon fiber prepreg can be prepared by the following method steps:
1) Preparing a bottom resin adhesive film and a surface resin adhesive film respectively;
2) Forming a sandwich structure by the bottom resin adhesive film, the carbon fiber and the surface resin adhesive film;
3) And heating to melt the resin to obtain the carbon fiber prepreg with the bottom resin layer, the carbon fiber layer and the surface resin layer mutually immersed.
According to one embodiment of the invention, the bottom resin film is prepared by the following method:
1) Mixing inorganic filler, curing agent, defoaming agent and epoxy resin to prepare dipping glue;
according to one embodiment of the invention, the curing agent is a dicyandiamide type curing agent; the defoaming agent is modified silicon polyether, modified polyether defoaming agent or a combination thereof.
According to one embodiment of the invention, the epoxy resin comprises the following components in percentage by mass: inorganic filler: curing agent: the defoamer is 100:10-80:0.5-5:0.5-5; preferably 100:10-70:0.7-4:0.7-4.
Also, according to the embodiment of the present invention, the amount of the inorganic filler added in the preferable primer layer varies depending on the base material compounded with the carbon fiber prepreg. Specifically, the inorganic filler is compounded with ceramic in an amount of 40 to 80 parts by mass, preferably 40 to 70 parts by mass, based on 100 parts by mass of the epoxy resin. Compounded with a metal, for example, aluminum or an alloy thereof, the inorganic filler in the primer resin layer is 10 to 45 parts by mass, preferably 10 to 40 parts by mass.
According to one embodiment of the invention, the temperature of the mixing is from room temperature to 70 ℃.
According to one embodiment of the invention, the temperature of the mixing is between 30 ℃ and 70 ℃.
2) And coating the dip-coating adhesive into an adhesive film.
According to one embodiment of the invention, the dip coating glue is coated into a film, which specifically comprises the following steps: and uniformly coating dip-coating glue on release paper through a glue spreading roller, and adjusting the distance and speed of the glue spreading roller to prepare glue films with different thicknesses.
According to one embodiment of the present invention, the top resin film is prepared by the steps of: uniformly coating the reactive flexible polymer modified epoxy resin on release paper through a glue spreading roller, and adjusting the distance and speed of the glue spreading roller to prepare glue films with different thicknesses;
according to one embodiment of the invention, the carbon fiber prepreg is prepared by the following method:
and leading out the prefabricated adhesive films from the upper rubber roller and the lower rubber roller, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot press rollers, embedding the carbon fibers into the resin matrix, and finally cooling to cover the PE protective film on the surface layer of the carbon fibers to obtain the carbon fiber prepreg.
According to one embodiment of the invention, the temperature of the hot press roller is 60-120 ℃ and the pressure is 0.5-1 MPa; preferably, the temperature of the hot press roll is 70-110 ℃ and the pressure is 0.6-0.8 MPa.
The carbon fiber prepreg provided by the invention effectively solves the problem of interfacial or prepreg resin internal stress cracking when the traditional carbon fiber prepreg is compounded with other materials.
Another aspect of the invention relates to a composite material comprising the carbon fiber prepreg and a matrix described above.
According to one embodiment of the invention, the substrate is metal or ceramic.
According to one embodiment of the invention, the metal is aluminum and its alloys, copper and its alloys, magnesium and its alloys, iron and its alloys.
According to one embodiment of the invention, the ceramic is an alumina ceramic or a zirconia ceramic.
Another aspect of the invention relates to the use of the carbon fiber prepreg described above for the preparation of the composite material described above.
Another aspect according to the invention relates to the use of the above composite material as a structural part or a decorative part of an air conditioner.
Another aspect of the invention relates to a device comprising a structural member or trim piece made of the composite material according to the invention as described above.
According to one embodiment of the invention, the device is a household appliance or an air treatment device.
According to one embodiment of the invention, the device is an air conditioner.
According to one embodiment of the invention, the structural member or trim part made of the composite material is a decorative strip, a panel or other structural member. The decorative strip, the panel or other structural members comprise a carbon fiber layer and a surface resin layer, the surface resin layer has the effects of transparency and toughness, the carbon fiber layer has the characteristics of light weight, good strength and toughness of carbon fiber, and the carbon fiber layer can realize various grain patterns, so that the appearance of the decorative strip, the panel or other structural members is more personalized and scientific, the decorative strip, the panel or other structural members can be used for replacing various plastic members, metal members and the like, and the structure and appearance performance of the decorative strip, the panel or other structural members are improved.
Drawings
FIG. 1 is a schematic diagram of a carbon fiber prepreg structure according to an embodiment of the present invention; wherein, 100, carbon fiber layer, 200, bottom resin layer, 300, surface resin layer.
FIG. 2 is an exploded view of an air conditioner according to an embodiment of the present invention; the air conditioner comprises a panel assembly 400, an air duct component 500, an opening and closing door 510, an air outlet frame 520, an air duct 530, an evaporator assembly 600, a rear shell 700 and an air inlet grille 800.
Detailed Description
The foregoing and/or additional aspects and advantages of the present invention will become apparent and may be better understood from the following description of embodiments with reference to the accompanying drawings.
Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the invention.
In the description of the present invention, the description of the first, second, third, etc. is only for the purpose of distinguishing technical features, and should not be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated or implicitly indicating the precedence of the technical features indicated.
In the description of the present invention, it should be understood that references to orientation descriptions, such as directions of up, down, left, right, etc., are based on the orientation or positional relationship shown in the drawings, are merely for convenience of description and simplification of the description, and do not indicate or imply that the apparatus or element in question must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention.
In the description of the present invention, unless explicitly defined otherwise, terms such as arrangement, installation, connection, etc. should be construed broadly and the specific meaning of the terms in the present invention can be determined reasonably by a person skilled in the art in combination with the specific content of the technical solution.
The carbon fiber prepreg is a key intermediate material for designing and preparing a carbon fiber reinforced composite material, resin in the traditional carbon fiber prepreg is pure epoxy resin, and the carbon fiber composite material prepared by hot pressing the epoxy resin and metal and ceramic is easy to generate stress cracking in the temperature change process because the thermal expansion coefficient of the epoxy resin is far greater than that of metal, ceramic or other matrixes. The carbon fiber prepreg provided by the invention is composed of the bottom resin layer, the carbon fiber layer and the surface resin layer, and the bottom resin can be more matched with the thermal expansion coefficient of metal, ceramic or other matrixes by adding a certain amount of inorganic filler, so that the thermal stress of the final carbon fiber composite material is reduced; the surface layer resin is reactive flexible polymer modified epoxy resin, and has high toughness and transparency. The carbon fiber prepreg provided by the invention can solve the problems that the composite material is easy to crack and has poor reliability after the existing carbon fiber/epoxy resin prepreg is hot-pressed with a metal, ceramic and other matrixes.
Meanwhile, according to the preparation method of the carbon fiber prepreg, on one hand, carbon fibers, bottom resin and surface resin can be fully impregnated and fused with each other, so that the carbon fiber prepreg has good interfacial binding force, on the other hand, the types and the contents of inorganic fillers can be adjusted according to different properties of a base material to be compounded of the carbon fiber prepreg, the components and the properties of the inorganic fillers are designed, and a proper prepreg intermediate is provided for obtaining the carbon fiber composite material with no bubbles, high transparency and good adhesion reliability in the later stage.
Example 1
A carbon fiber prepreg according to a first aspect of an embodiment of the present invention is described with reference to fig. 1.
The carbon fiber prepreg of the present embodiment includes a base resin layer 200, a carbon fiber layer 100, and a face resin layer 300.
The bottom layer resin comprises the following components in parts by mass: epoxy resin: inorganic filler: curing agent: the defoamer is 100:50:1:2;
the epoxy resin is bisphenol A type epoxy resin;
the inorganic filler is spherical alumina;
the curing agent is dicyandiamide curing agent;
the defoamer is modified silicon polyether;
the surface layer resin is a reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is a hydroxy styrene-butadiene liquid rubber;
the carbon fiber layer 100 is woven carbon fibers, and the carbon fiber tows are 9K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) Inorganic filler, curing agent, defoamer and epoxy resin are placed in a container to be uniformly mixed to prepare dipping glue, and the mixing temperature is 60 ℃. And uniformly coating the dip-coating adhesive on release paper through an adhesive coating roller, and cooling to obtain the bottom resin adhesive film.
2) And uniformly coating the hydroxyl butylbenzene liquid rubber modified epoxy resin on release paper through a glue spreader, and cooling to obtain the surface layer resin adhesive film.
3) And leading out the prefabricated bottom layer and surface layer resin adhesive films from the upper rubber roller and the lower rubber roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the bottom layer and the surface layer resin matrix through a plurality of groups of hot pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering the PE protective film to obtain the carbon fiber prepreg. Wherein the temperature of the hot pressing roller is 100 ℃ and the pressure is 0.7MPa.
Example 2:
referring to fig. 1, the carbon fiber prepreg of the present example includes a carbon fiber layer 100, a primer resin layer 200, and a top resin layer 300.
The bottom layer resin comprises the following components in parts by mass: epoxy resin: inorganic filler: curing agent: the defoamer is 100:80:0.5:1.2;
the epoxy resin is phenolic epoxy resin;
the inorganic filler is irregularly-shaped silicon dioxide;
the curing agent is dicyandiamide curing agent;
the defoamer is modified polyether;
the surface layer resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fibers, and the carbon fiber tows are 6K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) Inorganic filler, curing agent, defoamer and epoxy resin are placed in a container to be uniformly mixed to prepare dipping glue, and the mixing temperature is 100 ℃. And uniformly coating the dip-coating adhesive on release paper through an adhesive coating roller, and cooling to obtain the bottom resin adhesive film.
2) And uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader, and cooling to obtain the surface layer resin adhesive film.
3) And leading out the prefabricated bottom layer and surface layer resin adhesive films from the upper rubber roller and the lower rubber roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the bottom layer and the surface layer resin matrix through a plurality of groups of hot pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering the PE protective film to obtain the carbon fiber prepreg. Wherein the temperature of the hot pressing roller is 110 ℃ and the pressure is 0.9MPa.
Example 3:
referring to fig. 1, the carbon fiber prepreg of the present example includes a carbon fiber layer 100, a primer resin layer 200, and a top resin layer 300.
The bottom layer resin comprises the following components in parts by mass: epoxy resin: inorganic filler: curing agent: the defoamer is 100:50:0.5:1.2;
the epoxy resin is bisphenol S-type epoxy resin;
the inorganic filler is irregular silicon dioxide and spherical alumina, and the mass ratio of the irregular silicon dioxide to the spherical alumina is 3:1, a step of;
the curing agent is dicyandiamide curing agent;
the defoamer is modified silicon polyether;
the surface layer resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fibers, and the carbon fiber tows are 3K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) Inorganic filler, curing agent, defoamer and epoxy resin are placed in a container to be uniformly mixed to prepare dipping glue, and the mixing temperature is 90 ℃. And uniformly coating the dip-coating adhesive on release paper through an adhesive coating roller, and cooling to obtain the bottom resin adhesive film.
2) And uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader, and cooling to obtain the surface layer resin adhesive film.
3) And leading out the prefabricated bottom layer and surface layer resin adhesive films from the upper rubber roller and the lower rubber roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the bottom layer and the surface layer resin matrix through a plurality of groups of hot pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering the PE protective film to obtain the carbon fiber prepreg. Wherein the temperature of the hot pressing roller is 100 ℃ and the pressure is 0.5MPa.
Examples 4 to 6
The carbon fiber prepreg of the embodiment 1-3 is respectively coated on the surface of zirconia ceramic, and is heated and pressurized by a die at 160-190 ℃ for 5-7 h and at 0.5-1 MPa, so that the carbon fiber prepreg is compounded with the ceramic through the bottom resin, and finally cooled to normal temperature to obtain the carbon fiber ceramic composite structure.
Example 7
A carbon fiber prepreg according to a first aspect of an embodiment of the present invention is described with reference to fig. 1.
The carbon fiber prepreg of the present embodiment includes a base resin layer 200, a carbon fiber layer 100, and a face resin layer 300.
The bottom layer resin comprises the following components in parts by mass: epoxy resin: inorganic filler: curing agent: the defoamer is 100:30:1:2;
the epoxy resin is bisphenol A type epoxy resin;
the inorganic filler is spherical alumina;
the curing agent is dicyandiamide curing agent;
the defoamer is modified silicon polyether;
the surface layer resin is a reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is a hydroxy styrene-butadiene liquid rubber;
the carbon fiber layer 100 is woven carbon fibers, and the carbon fiber tows are 9K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) Inorganic filler, curing agent, defoamer and epoxy resin are placed in a container to be uniformly mixed to prepare dipping glue, and the mixing temperature is 60 ℃. And uniformly coating the dip-coating adhesive on release paper through an adhesive coating roller, and cooling to obtain the bottom resin adhesive film.
2) And uniformly coating the hydroxyl butylbenzene liquid rubber modified epoxy resin on release paper through a glue spreader, and cooling to obtain the surface layer resin adhesive film.
3) And leading out the prefabricated bottom layer and surface layer resin adhesive films from the upper rubber roller and the lower rubber roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the bottom layer and the surface layer resin matrix through a plurality of groups of hot pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering the PE protective film to obtain the carbon fiber prepreg. Wherein the temperature of the hot pressing roller is 100 ℃ and the pressure is 0.7MPa.
Example 8:
referring to fig. 1, the carbon fiber prepreg of the present example includes a carbon fiber layer 100, a primer resin layer 200, and a top resin layer 300.
The bottom layer resin comprises the following components in parts by mass: epoxy resin: inorganic filler: curing agent: the defoamer is 100:25:0.5:1.2;
the epoxy resin is phenolic epoxy resin;
the inorganic filler is irregularly-shaped silicon dioxide;
the curing agent is dicyandiamide curing agent;
the defoamer is modified polyether;
the surface layer resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fibers, and the carbon fiber tows are 6K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) Inorganic filler, curing agent, defoamer and epoxy resin are placed in a container to be uniformly mixed to prepare dipping glue, and the mixing temperature is 100 ℃. And uniformly coating the dip-coating adhesive on release paper through an adhesive coating roller, and cooling to obtain the bottom resin adhesive film.
2) And uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader, and cooling to obtain the surface layer resin adhesive film.
3) And leading out the prefabricated bottom layer and surface layer resin adhesive films from the upper rubber roller and the lower rubber roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the bottom layer and the surface layer resin matrix through a plurality of groups of hot pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering the PE protective film to obtain the carbon fiber prepreg. Wherein the temperature of the hot pressing roller is 110 ℃ and the pressure is 0.9MPa.
Example 9:
referring to fig. 1, the carbon fiber prepreg of the present example includes a carbon fiber layer 100, a primer resin layer 200, and a top resin layer 300.
The bottom layer resin comprises the following components in parts by mass: epoxy resin: inorganic filler: curing agent: the defoamer is 100:10:0.5:1.2;
the epoxy resin is bisphenol S-type epoxy resin;
the inorganic filler is irregular silicon dioxide and spherical alumina, and the mass ratio of the irregular silicon dioxide to the spherical alumina is 3:1, a step of;
the curing agent is dicyandiamide curing agent;
the defoamer is modified silicon polyether;
the surface layer resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fibers, and the carbon fiber tows are 3K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) Inorganic filler, curing agent, defoamer and epoxy resin are placed in a container to be uniformly mixed to prepare dipping glue, and the mixing temperature is 90 ℃. And uniformly coating the dip-coating adhesive on release paper through an adhesive coating roller, and cooling to obtain the bottom resin adhesive film.
2) And uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader, and cooling to obtain the surface layer resin adhesive film.
3) And leading out the prefabricated bottom layer and surface layer resin adhesive films from the upper rubber roller and the lower rubber roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the bottom layer and the surface layer resin matrix through a plurality of groups of hot pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering the PE protective film to obtain the carbon fiber prepreg. Wherein the temperature of the hot pressing roller is 100 ℃ and the pressure is 0.5MPa.
Examples 10 to 12
And respectively coating the carbon fiber prepreg of the examples 7-9 on the surface of an aluminum alloy, heating and pressurizing by a die at 160-190 ℃ for 5-7 h and under 0.5-1 MPa, compounding the carbon fiber prepreg with the aluminum alloy by virtue of a bottom resin, and finally cooling to normal temperature to obtain the carbon fiber aluminum alloy composite structure.
Comparative example 1
A carbon fiber prepreg was prepared according to a similar process route as in example 2, except that: the carbon fiber bottom layer resin is common phenolic epoxy resin, and inorganic filler is not added; the carbon fiber facing resin is also a conventional phenolic epoxy resin, rather than a reactive flexible polymer modified epoxy resin.
Comparative example 2
Carbon fiber ceramic composites were prepared following a similar process route as in examples 4-6, except that: the carbon fiber prepreg of comparative example 1 was used to composite with zirconia ceramics.
Comparative example 3
A carbon fiber prepreg was prepared according to a similar process route as in example 8, except that: the carbon fiber bottom layer resin is common phenolic epoxy resin, and inorganic filler is not added; the carbon fiber facing resin is also a conventional phenolic epoxy resin, rather than a reactive flexible polymer modified epoxy resin.
Comparative example 4
Carbon fiber metal composites were prepared following a similar process route as examples 10-12, except that: the carbon fiber prepreg of comparative example 3 was used for compounding with an aluminum alloy.
Test case
The carbon fiber ceramic/aluminum alloy composite materials prepared according to examples 4-6, 10-12 and comparative examples 2 and 4 are placed in a high-low temperature test box for cycle of high-low temperature impact aging test at-40 ℃/1h to 60 ℃/1h, the high-low temperature conversion time is not more than 30min, and after the test is finished, a sample is taken out to observe whether the carbon fiber ceramic/aluminum alloy composite material has interface cracking or resin cracking, and the result is shown in Table 1.
TABLE 1
As can be seen from the data in table 1, the carbon fiber ceramic/aluminum alloy composite material according to the embodiment of the invention can effectively solve the problem of stress cracking of the interface or the resin inside of the conventional carbon fiber (ceramic/aluminum alloy) composite material in the temperature change process.
Application example
An exploded view of an air conditioner in which a panel member 400 made of the carbon fiber-aluminum alloy composite material according to any one of embodiments 10 to 12 is included is shown in fig. 2. The panel member 400, since the carbon fiber prepreg according to the present invention is included therein, the underlying resin layer thereof has a specific inorganic filler and proportion as shown in the above table 1, and the bonding of the carbon fiber layer and the base aluminum alloy is improved; the surface layer resin layer has transparent and toughening effects, the carbon fiber layer has the characteristics of light carbon fiber and good strength and toughness, and the carbon fiber layer can realize various grain patterns, so that the appearance of the decorative strip, the panel or other structural members is more personalized and scientific, the appearance can be customized according to different requirements of customers, traditional plastic parts, metal parts and the like are replaced, in the long-term use of the air conditioner, the parts cannot crack and the like, and due to the characteristics of light carbon fiber and high strength, the panel can be manufactured to be very thin, for example, the overall thickness is lower than 1mm, still can keep high strength and toughness, the whole quality of the air conditioner can be reduced, the wear resistance, scratch resistance, corrosion resistance and the like of the parts are improved, the air conditioner can be applied to a conventional indoor environment, various severe or extremely severe environments such as high temperature and high corrosion resistance and the like, and the like can still keep good appearance. On the other hand, the panel component is not damaged or deformed even if being frequently disassembled or knocked and the like based on the strong fatigue resistance of the metal and the carbon fiber; the air conditioner can keep good appearance for a long time, and really meets the requirement of durable household appliances.
The embodiments of the present invention have been described in detail with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge of one of ordinary skill in the art without departing from the spirit of the present invention.
Claims (7)
1. An air treatment device comprises a structural member or a decoration made of composite materials; the composite material consists of a carbon fiber prepreg and a matrix, and is characterized in that the carbon fiber prepreg consists of a bottom resin layer, a carbon fiber layer and a surface resin layer; wherein the bottom resin layer is epoxy resin doped with inorganic filler; the surface layer resin layer is reactive flexible polymer modified epoxy resin; the inorganic filler is one or a mixture of more of silicon dioxide, aluminum oxide, boron nitride, aluminum nitride and silicon carbide; the reactive flexible polymer is a liquid styrene-butadiene rubber, an epoxy-terminated polyether or a combination of the two;
the matrix is metal or ceramic, and when the matrix is compounded with the ceramic, the mass ratio of epoxy resin to inorganic filler in the bottom resin layer is 100:40-80 parts; when compounded with metal, the mass ratio of epoxy resin to inorganic filler in the bottom resin layer is 100:10-45.
2. The air treatment device according to claim 1, wherein the epoxy resin in the carbon fiber prepreg is one or a combination of two or more of a phenolic epoxy resin, a bisphenol a epoxy resin, and a bisphenol S epoxy resin.
3. The air treatment device according to claim 1, wherein the under resin layer, the carbon fiber layer and the surface resin layer in the carbon fiber prepreg are impregnated with each other.
4. An air treatment device according to claim 1, wherein the structural or decorative element made of composite material is a decorative strip or panel.
5. The method for producing a carbon fiber prepreg in an air treatment apparatus according to any one of claims 1 to 4, comprising the steps of:
preparing a bottom resin adhesive film and a surface resin adhesive film respectively;
forming a sandwich structure by the bottom resin adhesive film, the carbon fibers and the surface resin adhesive film;
and heating to melt the resin to obtain the carbon fiber prepreg in which the bottom resin layer, the carbon fiber layer and the surface resin layer are mutually immersed.
6. The method of claim 5, wherein the primer resin film is prepared by: mixing the inorganic filler, the curing agent, the defoaming agent and the epoxy resin to prepare a dipping adhesive; and then coating the dip-coating adhesive into a film.
7. The method according to claim 6, wherein the curing agent is dicyandiamide curing agent; the defoaming agent is modified silicon polyether, modified polyether defoaming agent or the combination of the two.
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| CN115593078A (en) * | 2022-10-17 | 2023-01-13 | 江苏联能电子技术有限公司（Cn） | Piezoelectric ceramic device based on vacuum hot-pressing curing bonding and preparation method thereof |
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