CN113211915A - 一种连续纤维增强热塑性复合材料结构及其制备方法 - Google Patents

一种连续纤维增强热塑性复合材料结构及其制备方法 Download PDF

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CN113211915A
CN113211915A CN202110405502.2A CN202110405502A CN113211915A CN 113211915 A CN113211915 A CN 113211915A CN 202110405502 A CN202110405502 A CN 202110405502A CN 113211915 A CN113211915 A CN 113211915A
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continuous fiber
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陈亨津
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Nanjing Lingrong Material Technology Co ltd
Shanghai Lingrong Mstar Technology Ltd
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Shanghai Lingrong Mstar Technology Ltd
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Abstract

本发明公开了一种连续纤维增强热塑性复合材料结构及其制备方法，该复合材料结构至少包含轻质中间层，位于所述轻质中间层的上、下方分别设有连续纤维增强热塑性复合材料层。制备上述复合材料结构的方法，包括以下步骤：(A)定制连续纤维增强热塑性复合材料板材和轻质中间层半成品，并放置于传送机构上，送入加热装置内进行加热处理；(B)加热处理后传送至成型模具内进行压制成型。本发明对比短纤维增强复合材料，具有更优异的力学性能，对比全金属零件，重量减重40％左右；成本低于或持平原金属和短纤维增强塑料件；相较于金属件，大大减少零件数量；相较于金属和短纤维增强塑料件，模具费用大大降低；可用于汽车白车身结构件上。

Description

一种连续纤维增强热塑性复合材料结构及其制备方法
技术领域
本发明涉及一种复合材料结构及其制备方法，尤其涉及一种连续纤维增强热塑性复合材料结构及其制备方法。
背景技术
专业数据显示，汽车的整体质量每降低10％，能耗就可以降低6％--8％。特别是随着国内外不断出台的去燃油车的截至时间表，电动汽车受到越来越多的关注。电动车自身重量与其续航里程有极大关系，如果想要提升电动汽车续航里程，电动汽车自重降低是首当其冲的。
汽车车身材料的应用发展经历从钢到钢铝混合到全铝最终到多种材料混合使用，现阶段正处于大量使用铝合金的阶段。传统的金属材料结构虽然能满足强度和刚度的条件，但是无法满足轻量化的要求。
热塑性塑料因其具有良好的成型性和可回收性，在燃油汽车中大量应用在汽车内外饰，某些短纤维增强的高强度工程塑料甚至已经开始拓展到汽车的半结构件和结构件上。但纯塑料或者短纤维增强塑料承载能力较低，减重仍然不明显，迫切需要一种材料或结构能够解决传统塑料制品的缺点，同时价格又不上升，以拓宽其应用场景。
发明内容
发明目的：本发明的第一个目的是提供一种承载能力低、减重效果好的连续纤维增强热塑性复合材料结构；
本发明的第二个目的是提供一种连续纤维增强热塑性复合材料结构的制备方法。
技术方案：本发明所述的连续纤维增强热塑性复合材料结构，至少包含轻质中间层，位于所述轻质中间层的上、下方分别设有连续纤维增强热塑性复合材料层。
优选地，所述轻质中间层与上、下方的连续纤维增强热塑性复合材料层之间分别设有热塑性树脂胶膜。
优选地，所述上、下方的连续纤维增强热塑性复合材料层中的纤维分别包括玻璃纤维、碳纤维、芳纶纤维或玄武岩纤维中的至少一种。
优选地，所述轻质中间层包括GMT和/或LWRT。
优选地，所述热塑性树脂胶膜和上、下方的连续纤维增强热塑性复合材料层中的热塑性树脂分别包括聚丙烯、聚乙烯或尼龙中的至少一种。
优选地，所述轻质中间层与上、下方的连续纤维增强热塑性复合材料层之间、上、下方的连续纤维增强热塑性复合材料层之间分别为相同厚度或者不同厚度。
优选地，所述上、下方的连续纤维增强热塑性复合材料层分别为单向带、编织物或无褶皱织物。
制备上述的连续纤维增强热塑性复合材料结构的方法，包括以下步骤：
(A)定制连续纤维增强热塑性复合材料板材和轻质中间层半成品，并放置于传送机构上，送入加热装置内进行加热处理；
(B)加热处理后传送至成型模具内进行压制成型，得到所述连续纤维增强热塑性复合材料结构。
优选地，所述步骤(B)中加热的温度为180℃-400℃，时间为30s-15min。
优选地，所述步骤(B)中，所述压制成型的过程中施加的压力为每平方米0.3-5MPa，压制的时间为15-300s。
有益效果：本发明与现有技术相比，取得如下显著效果：1、对比短纤维增强复合材料，具有更优异的力学性能，对比全金属零件，重量减重40％左右；2、成本低于或持平原金属和短纤维增强塑料件；3、相较于金属件，大大减少零件数量；4、相较于金属和短纤维增强塑料件，模具费用大大降低；5、可用于汽车白车身结构件上。
附图说明
图1为本发明的结构示意图；
图2为实施例1制备的零件结构示意图。
具体实施方式
下面结合说明书附图对本发明作进一步详细描述。
实施例1
如图1所示，本发明提供了一种连续纤维增强热塑性复合材料结构，包含轻质中间层1，在轻质中间层的上、下表面分别设有连续纤维增强热塑性复合材料层2、3，轻质中间层1与上下连续纤维增强热塑性复合材料层2、3之间分别设有热塑性树脂胶膜4。其中，连续纤维增强热塑性复合材料层2、3中的纤维可以是玻璃纤维、碳纤维、芳纶纤维或玄武岩纤维中的至少一种。轻质中间层1的材料可以是GMT或LWRT中的至少一种。热塑性树脂胶膜4和连续纤维增强热塑性复合材料层2、3中的热塑性树脂均可以是聚丙烯、聚乙烯或尼龙中的至少一种。
轻质中间层1与上、下表面的连续纤维增强热塑性复合材料层2、3之间及上、下表面的连续纤维增强热塑性复合材料层2、3之间均可以是相同厚度或者不同厚度。连续纤维增强热塑性复合材料层2、3可以是单向带、编织物或无褶皱织物。
本发明提供了一种连续纤维增强热塑性复合材料结构的制备方法，具体为汽车座椅底板的制造的方法，包括以下步骤：
(1)定制连续纤维增强聚丙烯复合材料板材和轻质中间层GMT半成品，两块连续纤维增强聚丙烯复合材料板材尺寸均为1500mm×700mm，厚度1mm，轻质中间层GMT尺寸1500mm×700mm，厚度4mm，上下表面覆有聚丙烯胶膜；
(2)将板材按一层连续纤维增强聚丙烯复合材料板材、一层轻质中间层GMT半成品、一层连续纤维增强聚丙烯复合材料板材的顺序自下而上堆叠，然后放置于运动的网链上；
(3)网链移动带动预先堆叠好的板材进入红外加热烘箱中进行烘烤，烘烤温度250℃，烘烤时间10分钟；
(4)烘烤完成后网链带动材料运动到成型模具上方；
(5)机器人拾取烘烤完成后的材料，然后转移放置到成型模具上，启动压机压制产品，压力每平方米0.3MPa，压制时间150秒。
(6)压制时间完成后，压机自动抬起，使用机器人取出成型好的零件。
(7)将零件放置于待检区。
制备得到的零件如图2所示。
实施例2
一种汽车座椅底板的制造的方法，包括以下步骤：
(1)定制连续纤维增强聚乙烯复合材料板材和轻质中间层LWRT半成品，连续纤维增强聚乙烯复合材料板材尺寸为1500mm×700mm，厚度分别为1mm、2mm，轻质中间层LWRT尺寸1500mm×700mm，厚度4mm，上下表面覆有聚乙烯胶膜；
(2)将板材按一层连续纤维增强聚乙烯复合材料板材、一层轻质中间层LWRT半成品、一层连续纤维增强聚乙烯复合材料板材的顺序自下而上堆叠，然后放置于运动的网链上；
(3)网链移动带动预先堆叠好的板材进入红外加热烘箱中进行烘烤，烘烤温度180℃，烘烤时间15分钟；
(4)烘烤完成后网链带动材料运动到成型模具上方；
(5)机器人拾取烘烤完成后的材料，然后转移放置到成型模具上，启动压机压制产品，压力每平方米5MPa，压制时间15秒。
(6)压制时间完成后，压机自动抬起，使用机器人取出成型好的零件。
(7)将零件放置于待检区。
实施例3
一种汽车座椅底板的制造的方法，包括以下步骤：
(1)定制连续纤维增强尼龙复合材料板材和轻质中间层热塑性泡沫半成品，连续纤维增强尼龙复合材料板材尺寸1500mm×700mm，厚度4mm，轻质中间层热塑性泡沫尺寸1500mm×700mm，厚度4mm，上下表面覆有尼龙胶膜；
(2)将板材按一层连续纤维增强尼龙复合材料板材、一层轻质中间层热塑性泡沫半成品、一层连续纤维增强尼龙复合材料板材的顺序自下而上堆叠，然后放置于运动的网链上；
(3)网链移动带动预先堆叠好的板材进入红外加热烘箱中进行烘烤，烘烤温度400℃，烘烤时间30秒；
(4)烘烤完成后网链带动材料运动到成型模具上方；
(5)机器人拾取烘烤完成后的材料，然后转移放置到成型模具上，启动压机压制产品，压力每平方米2MPa，压制时间100秒。
(6)压制时间完成后，压机自动抬起，使用机器人取出成型好的零件。
(7)将零件放置于待检区。

Claims (10)

1.一种连续纤维增强热塑性复合材料结构，其特征在于，至少包含轻质中间层(1)，位于所述轻质中间层(1)的上、下方分别设有连续纤维增强热塑性复合材料层(2)、(3)。
2.根据权利要求1所述的连续纤维增强热塑性复合材料结构，其特征在于，所述轻质中间层(1)分别与所述连续纤维增强热塑性复合材料层(2)、(3)之间分别设有热塑性树脂胶膜(4)。
3.根据权利要求1所述的连续纤维增强热塑性复合材料结构，其特征在于，所述连续纤维增强热塑性复合材料层(2)、(3)中的纤维分别包括玻璃纤维、碳纤维、芳纶纤维或玄武岩纤维中的至少一种。
4.根据权利要求1所述的连续纤维增强热塑性复合材料结构，其特征在于，所述轻质中间层(1)包括GMT和/或LWRT。
5.根据权利要求2所述的连续纤维增强热塑性复合材料结构，其特征在于，所述热塑性树脂胶膜(4)、连续纤维增强热塑性复合材料层(2)、(3)中的热塑性树脂分别包括聚丙烯、聚乙烯或尼龙中的至少一种。
6.根据权利要求1所述的连续纤维增强热塑性复合材料结构，其特征在于，所述轻质中间层(1)分别与连续纤维增强热塑性复合材料层(2)、(3)之间、所述连续纤维增强热塑性复合材料层(2)及连续纤维增强热塑性复合材料层(3)之间分别为相同厚度或者不同厚度。
7.根据权利要求1所述的连续纤维增强热塑性复合材料结构，其特征在于，所述连续纤维增强热塑性复合材料层(2)、(3)分别为单向带、编织物或无褶皱织物。
8.一种制备权利要求1所述的连续纤维增强热塑性复合材料结构的方法，其特征在于，包括以下步骤：
(A)定制连续纤维增强热塑性复合材料板材和轻质中间层半成品，并放置于传送机构上，送入加热装置内进行加热处理；
(B)加热处理后传送至成型模具内进行压制成型，得到所述连续纤维增强热塑性复合材料结构。
9.根据权利要求8所述的连续纤维增强热塑性复合材料结构的方法，其特征在于，所述步骤(B)中加热的温度为180℃-400℃，时间为30s-15min。
10.根据权利要求8所述的连续纤维增强热塑性复合材料结构的方法，其特征在于，所述步骤(B)中，所述压制成型的过程中施加的压力为每平方米0.3-5MPa，压制的时间为15-300s。
CN202110405502.2A 2021-04-15 2021-04-15 一种连续纤维增强热塑性复合材料结构及其制备方法 Pending CN113211915A (zh)

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Publication number Priority date Publication date Assignee Title
CN105818471A (zh) * 2016-03-23 2016-08-03 广州金发碳纤维新材料发展有限公司 一种连续纤维增强热塑性树脂复合片材及其应用
CN106393908A (zh) * 2016-08-30 2017-02-15 浙江华江科技股份有限公司 一种高吸音型超轻高强gmt复合板材
CN207747513U (zh) * 2017-11-01 2018-08-21 广州金发碳纤维新材料发展有限公司 一种复合材料厢板
CN110435180A (zh) * 2019-07-25 2019-11-12 上海沥高科技股份有限公司 一种热塑性复合材料结构及其成型方法

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CN106393908A (zh) * 2016-08-30 2017-02-15 浙江华江科技股份有限公司 一种高吸音型超轻高强gmt复合板材
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