CN117341320A - Thermoplastic composite board, preparation method thereof and product prepared from thermoplastic composite board - Google Patents
Thermoplastic composite board, preparation method thereof and product prepared from thermoplastic composite board Download PDFInfo
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- CN117341320A CN117341320A CN202210741882.1A CN202210741882A CN117341320A CN 117341320 A CN117341320 A CN 117341320A CN 202210741882 A CN202210741882 A CN 202210741882A CN 117341320 A CN117341320 A CN 117341320A
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- 239000002131 composite material Substances 0.000 title claims abstract description 181
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 153
- 239000004416 thermosoftening plastic Substances 0.000 title claims abstract description 153
- 238000002360 preparation method Methods 0.000 title description 2
- 239000010410 layer Substances 0.000 claims abstract description 74
- 239000002344 surface layer Substances 0.000 claims abstract description 54
- 229920006289 polycarbonate film Polymers 0.000 claims abstract description 52
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 41
- 239000004917 carbon fiber Substances 0.000 claims abstract description 41
- 239000002699 waste material Substances 0.000 claims abstract description 36
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 35
- 239000004417 polycarbonate Substances 0.000 claims abstract description 28
- 229920000515 polycarbonate Polymers 0.000 claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 claims description 29
- 239000002245 particle Substances 0.000 claims description 28
- 238000012545 processing Methods 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 14
- 239000010786 composite waste Substances 0.000 claims description 6
- 238000010030 laminating Methods 0.000 claims description 5
- 239000000835 fiber Substances 0.000 description 47
- 230000000052 comparative effect Effects 0.000 description 46
- 238000007667 floating Methods 0.000 description 42
- 238000005520 cutting process Methods 0.000 description 5
- 239000000047 product Substances 0.000 description 5
- 238000000227 grinding Methods 0.000 description 4
- 238000004064 recycling Methods 0.000 description 4
- 239000002759 woven fabric Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 238000010998 test method Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
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- 230000004048 modification Effects 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 238000002679 ablation Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
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- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
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- 239000012778 molding material Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
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- 239000000243 solution Substances 0.000 description 1
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- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 238000013519 translation Methods 0.000 description 1
Classifications
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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
-
- 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
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
-
- 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
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- 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
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
-
- 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
- B32B2250/03—3 layers
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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
- B32B2250/00—Layers arrangement
- B32B2250/24—All layers being polymeric
- B32B2250/244—All polymers belonging to those covered by group B32B27/36
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
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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
- B32B2272/00—Resin or rubber layer comprising scrap, waste or recycling material
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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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
Abstract
The present invention relates to thermoplastic composite sheets, methods of making the same, and articles made therefrom. The thermoplastic composite board comprises an upper surface layer, a lower surface layer and an intermediate layer, wherein the upper surface layer and the lower surface layer are laminated together, and the intermediate layer is between the upper surface layer and the lower surface layer and is characterized in that the upper surface layer and the lower surface layer are polycarbonate films, each of the upper surface layer and the lower surface layer independently has a thickness in the range of 20-110 mu m, the intermediate layer is formed by carbon fiber reinforced polycarbonate composite material waste materials and has a thickness in the range of 1.5-5.5mm, and the volume content of carbon fibers in the intermediate layer is 35-60% based on the volume of the intermediate layer. The obtained thermoplastic composite board has excellent mechanical property and appearance performance.
Description
Technical Field
The invention relates to the technical field of composite material manufacturing. In particular, the present invention relates to a thermoplastic composite sheet material, a method of making the same, and articles made therefrom.
Background
The carbon fiber reinforced polycarbonate composite material has high specific strength, high specific modulus and very good appearance effect and designability, and is particularly suitable for manufacturing various appearance parts, such as 3C product (computer, communication and consumer electronics) shells, automobile inner and outer decorations and other consumer products.
In the production of a component using a carbon fiber-reinforced polycarbonate composite material, a sheet of a thermoplastic composite material having a certain thickness is usually laminated and hot-pressed by a relatively thin woven fabric prepreg (the prepreg is a sheet of a thermoplastic composite material having a thermoplastic or thermosetting resin matrix impregnated with continuous fibers or fabrics under the condition of strictly controlling processing parameters (such as temperature, time, speed, etc.), to thereby form a resin matrix and reinforcing carbon fibers combined body, the woven fabric prepreg being impregnated with continuous fibers of the woven fabric) or a unidirectional tape prepreg being impregnated with continuous fibers of the woven fabric (the unidirectional tape prepreg being impregnated with continuous fibers in parallel with each other), and the composite sheet is then hot-pressed into a semifinished product by a mold, and then subjected to subsequent processing. In this process, a certain amount of waste is generated. For example, in the production of unidirectional tape or woven cloth prepregs, waste prepregs are produced; the scrapped plate is generated when the plate is produced; when the plate is pre-cut, cutting waste is generated; when the plate is hot-pressed, a certain amount of scrap pieces and processing scraps exist. Thus, about 30% to 40% of the scrap can be accumulated during the full processing cycle of composite manufacture. In addition, recycling problems are encountered when such products reach the life cycle. Recycling means that a suitable method is required to treat these used composite parts and that the surface of the parts is often lacquered and exposed for a long time, the surface properties being relatively complex.
At present, most of the waste materials are treated by a conventional method of burying or directly burning, or resin components in the waste materials are ablated by high temperature, so as to obtain the recycled carbon fiber. But the high-temperature ablation process has high energy consumption and high equipment investment. There is currently no mature, low carbon, environmentally friendly process to recycle these wastes.
Accordingly, it is desirable to develop a waste utilization method that enables efficient utilization of carbon fiber reinforced polycarbonate composite waste and achieves a composite material that is good in mechanical properties and appearance properties.
Disclosure of Invention
An object of the present invention is to obtain thermoplastic composite boards excellent in mechanical properties and appearance properties by using carbon fiber reinforced polycarbonate composite waste.
Thus, according to one aspect, the present invention provides a thermoplastic composite sheet comprising an upper skin layer and a lower skin layer laminated together and an intermediate layer between the upper skin layer and the lower skin layer, characterized in that the upper skin layer and the lower skin layer are polycarbonate films, each independently having a thickness in the range of 20-110 μm, the intermediate layer being formed from carbon fiber reinforced polycarbonate composite scrap and having a thickness in the range of 1.5-5.5mm, the volume content of carbon fibers in the intermediate layer being 35-60% based on the volume of the intermediate layer.
According to another aspect, the present invention provides a method for preparing the thermoplastic composite sheet material described above, characterized by comprising:
i) Processing the carbon fiber reinforced polycarbonate composite material waste into crushed materials;
ii) processing the resulting particles into particle board; and
iii) And paving polycarbonate films on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer respectively, and laminating the upper surface layer, the lower surface layer and the crushed aggregates plate as an intermediate layer together to obtain the thermoplastic composite plate.
According to yet another aspect, the present invention provides an article prepared using the thermoplastic composite sheet material described above.
The invention realizes the recycling of the carbon fiber reinforced polycarbonate composite material waste, and can obtain a composite board with good mechanical property and appearance property. Compared with short fiber injection molding materials, the composite board prepared part has the advantages that the cost of raw materials of the part can be remarkably reduced under the condition that the whole weight and the appearance quality are kept the same, so that the composite board prepared part has better cost performance and environmental friendliness.
Drawings
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described and explained in more detail below with reference to the accompanying drawings, in which:
FIG. 1 shows a schematic view of a thermoplastic composite sheet material of the present invention.
Fig. 2 shows the appearance of the particle board obtained in comparative example 1.
Fig. 3 shows the appearance of the thermoplastic composite sheet material obtained in inventive example 1.
Detailed Description
Some embodiments of the invention will now be described for purposes of illustration and not limitation.
Thermoplastic composite board
According to one aspect, the present invention provides a thermoplastic composite sheet material comprising an upper skin layer and a lower skin layer laminated together and an intermediate layer between the upper skin layer and the lower skin layer, characterized in that the upper skin layer and the lower skin layer are polycarbonate films, each independently having a thickness in the range of 20-110 [ mu ] m, the intermediate layer is formed from carbon fiber reinforced polycarbonate composite waste material and has a thickness in the range of 1.5-5.5mm, and the volume content of carbon fibers in the intermediate layer is 30-55% based on the volume of the intermediate layer.
FIG. 1 shows a schematic view of a thermoplastic composite sheet material of the present invention.
As shown in fig. 1, the thermoplastic composite sheet of the present invention comprises an upper skin layer 1 and a lower skin layer 3 laminated together, and an intermediate layer 2 between the upper skin layer and the lower skin layer.
Upper surface layer
The upper skin layer may be composed of one layer or of a plurality of sublayers.
The upper surface layer is a polycarbonate film having a thickness in the range of 20-110 [ mu ] m.
Preferably, the thickness of the upper surface layer is 30-100 mu m.
Optionally, the thickness of the upper surface layer is 30 [ mu ] m, 50 [ mu ] m, 75 [ mu ] m or 100 [ mu ] m.
Intermediate layer
The intermediate layer is formed from carbon fiber reinforced polycarbonate composite scrap and has a thickness in the range of 1.5-5.5mm, the volume content of carbon fibers in the intermediate layer being 35-60%, based on the volume of the intermediate layer.
The intermediate layer is a single layer.
Preferably, the thickness of the intermediate layer is in the range of 2 mm-5 mm. More preferably, the thickness of the intermediate layer is in the range of 1.5 mm-2.5 mm.
Optionally, the waste material is derived from processing waste or scrap pieces of carbon fiber reinforced polycarbonate composites.
For example, waste prepregs generated in the production of unidirectional tapes or woven cloth prepregs, scrap sheets generated in the production of sheets, cutting scraps generated in the pre-cutting of sheets, scrap pieces and processing scraps generated in the hot press forming of sheets, scrap pieces generated during use, and the like can be the sources of scraps for the intermediate layer of the composite sheet of the present invention.
Lower surface layer
The lower skin layer may consist of one layer or of a plurality of sublayers.
The lower surface layer is a polycarbonate film having a thickness in the range of 20-110 [ mu ] m.
Preferably, the thickness of the lower surface layer is 30-100 μm.
Optionally, the thickness of the lower surface layer is 30 [ mu ] m, 50 [ mu ] m, 75 [ mu ] m or 100 [ mu ] m.
Advantageously, the thickness of the thermoplastic composite sheet is in the range 1.55mm to 5.7mm, preferably 2.05mm to 5.2mm.
In some embodiments, the thermoplastic composite sheet exhibits an up-down symmetrical structure, i.e., the upper skin and lower skin are identical.
Method for producing thermoplastic composite sheet material
According to another aspect, the present invention provides a method for preparing the thermoplastic composite sheet material described above, characterized by comprising:
i) Processing the carbon fiber reinforced polycarbonate composite material waste into crushed materials;
ii) processing the resulting particles into particle board; and
iii) And paving polycarbonate films on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer respectively, and laminating the upper surface layer, the lower surface layer and the crushed aggregates plate as an intermediate layer together to obtain the thermoplastic composite plate.
The carbon fiber reinforced polycarbonate composite material waste may be derived from, for example, scrap pieces or processing waste generated during production and use.
The carbon fiber reinforced polycarbonate composite material waste material has the volume content of 35-60% based on the volume of the waste material.
The carbon fiber content in the waste material is herein the average content. For example, waste materials having a carbon fiber content of less than 30% by volume may be used together with waste materials having a higher carbon fiber content so that the carbon fiber content of the waste materials used is in the range of 35 to 60% by volume.
Advantageously, the carbon fiber reinforced polycarbonate composite material waste has a carbon fiber content of 40-55%, preferably 44-50% by volume, based on the volume of the waste.
The method may also comprise, if desired, a step of cleaning and/or drying the waste material before step i) to remove contaminants and/or moisture from the surface.
Preferably, in step i), the carbon fiber reinforced polycarbonate composite waste is crushed to a size of not more than 10mm, preferably 3mm-8 mm, more preferably 4mm-6mm.
The comminution may be carried out using a comminuting mill.
Step i) may comprise first performing a crushing treatment to obtain crushed aggregates and then pressing the crushed aggregates into a crushed aggregate panel.
Step i) may be performed using a press (e.g. a cold/hot twin unit press).
In step ii), the step may be performed at 240 o C-280 oC The crushed aggregates are processed into particle board at a temperature of 2MPa to 4 MPa.
Step ii) may be carried out using a hot press.
Bonding the layers together by lamination is a method known in the art and one skilled in the art can select appropriate process parameters depending on the materials, thicknesses used for each layer.
For example, in step iii), at 180 o C-220 o Laminating the upper and lower skin layers with the intermediate layer at a temperature of C and a pressure of 1MPa to 2MPa to obtain the thermoplastic composite sheet. The lamination duration may be, for example, within 3-10 minutes.
Step iii) may be carried out using a hot press.
According to the method, junk pieces or processing scraps and the like generated in the production and use processes are crushed, then processed into a particle board, and finally polycarbonate films are arranged on the upper surface and the lower surface of the particle board and laminated, so that the thermoplastic composite board with mechanical properties meeting certain application requirements and excellent appearance performance is obtained.
The method of the invention can simultaneously achieve the purposes of recycling waste materials, increasing mechanical properties (particularly bending properties) and reducing cost.
Article of manufacture
The thermoplastic composite sheet material according to the present invention can be used to prepare various articles.
Thus, according to a further aspect of the present invention there is provided an article prepared using the thermoplastic composite sheet material described above.
The article may be an exterior part and a secondary load bearing structure, such as a 3C product (i.e., computer, communication, and consumer electronics) housing, an automotive interior trim, an automotive exterior trim, etc., specifically, an a cover for a notebook computer, a hub piece for an automobile, etc.
The descriptions of the various features in this application may be combined with each other without contradiction, and all fall within the scope of protection of this application.
The terms "comprising" and "including" as used in this application encompass the situation in which other elements not explicitly mentioned are also included or included as well as the situation in which they consist of the elements mentioned.
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. To the extent that the definitions of terms in this specification are inconsistent with the ordinary understanding of those skilled in the art to which this invention pertains, the definitions described herein control.
Unless otherwise indicated, all numbers expressing quantities of ingredients, process parameters 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 may 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 with reference to examples so that those skilled in the art can fully understand the objects, features, and effects of the present invention. Those skilled in the art will appreciate that the embodiments herein are for illustrative purposes only and that the scope of the present invention is not limited thereto.
Apparatus used
Grinding mill: model 450 grinding mill from Long Jun mechanical limited.
And (3) a hot press: VLPH-250 ton flat plate press from Vigor, table top size: 800mm x 800mm, temperature range: room temperature (25) oC ) To 350 o C, flatness of the table top: heat plate temperature uniformity, ±0.5. 0.5 mm: 1.5 oC 。
Cutting machine: BR03 type II cutter from longitude and latitude science and technology company, translation speed: 800-1500 mm/s, cutting speed: 200-800 mm/s, and the repetition precision is less than or equal to 0.1mm.
Raw materials used
Polycarbonate film: the thicknesses are respectively 30 mu m, 50 mu m, 75 mu m, 100 mu m, 125 mu m and 250 mu m.
Carbon fiber reinforced polycarbonate scrapped plate: the volume content of the carbon fiber is 44 percent, and the volume of the scrapped plate is taken as a reference.
Test method used
In the examples herein, the following test methods were used to test thermoplastic composite boards:
flexural strength and flexural modulus: the bending property test method of the GB/T1449-2005 fiber reinforced plastic is adopted.
Comparative example 1 (CE 1)
Grinding the carbon fiber reinforced polycarbonate scrapped plates into crushed materials with the size smaller than 6mm by using a grinding mill. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 1mm.
Fig. 1 shows the appearance of the resulting particle board. As can be seen from fig. 1, the resulting particle board surface exhibits a floating fiber appearance.
The resulting particle board was tested for tensile and flexural strength and the results are summarized in table 1.
Comparative example 2 (CE 2)
Reference was made to comparative example 1, except that a particle board having a thickness of 2mm was formed.
The surface of the obtained crushed aggregates plate presents a floating fiber appearance.
The resulting particle board was tested for tensile and flexural strength and the results are summarized in table 1.
Comparative example 3 (CE 3)
Reference was made to comparative example 1, except that a particle board having a thickness of 3mm was formed.
The surface of the obtained crushed aggregates plate presents a floating fiber appearance.
The resulting particle board was tested for tensile and flexural strength and the results are summarized in table 1.
Comparative example 4 (CE 4)
Reference was made to comparative example 1, except that a particle board having a thickness of 4mm was formed.
The surface of the obtained crushed aggregates plate presents a floating fiber appearance.
The resulting particle board was tested for tensile and flexural strength and the results are summarized in table 1.
Comparative example 5 (CE 5)
Reference was made to comparative example 1, except that a particle board having a thickness of 5mm was formed.
The surface of the obtained crushed aggregates plate presents a floating fiber appearance.
The resulting particle board was tested for tensile and flexural strength and the results are summarized in table 1.
Comparative example 6 (CE 6)
Reference was made to comparative example 1, except that a particle board having a thickness of 6mm was formed.
The surface of the obtained crushed aggregates plate presents a floating fiber appearance.
The resulting particle board was tested for tensile and flexural strength and the results are summarized in table 1.
Comparative example 7 (CE 7)
The carbon fiber reinforced polycarbonate composite material waste was ground into small pieces of less than 6mm in size using a grinder. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 1mm.
Then respectively laying a layer of polycarbonate film with the thickness of 30 mu m on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer, respectively, and putting the upper surface layer, the lower surface layer and the obtained crushed aggregates plate as an intermediate layer into a flat plate hot press at 200 DEG C o C and a pressure of 2MPa for 5 minutes to laminate together to obtain a thermoplastic composite sheet having a thickness of 1.06 mm.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 1.
Comparative example 8 (CE 8)
Reference is made to comparative example 7, except that a polycarbonate film with a thickness of 50 μm is used and a thermoplastic composite sheet with a thickness of 1.1mm is formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 1.
Comparative example 9 (CE 9)
Reference was made to comparative example 7, except that a polycarbonate film with a thickness of 75 μm was used and a thermoplastic composite sheet with a thickness of 1.15mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 1.
Comparative example 10 (CE 10)
Reference is made to comparative example 7, except that a polycarbonate film with a thickness of 100 μm is used and a thermoplastic composite sheet with a thickness of 1.2mm is formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 1.
Inventive example 1 (IE 1)
The carbon fiber reinforced polycarbonate composite material waste was ground into small pieces of less than 6mm in size using a grinder. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 2mm.
Then respectively laying a layer of polycarbonate film with the thickness of 30 mu m on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer, respectively, and putting the upper surface layer, the lower surface layer and the obtained crushed aggregates plate as an intermediate layer into a flat plate hot press at 200 DEG C o C and a pressure of 2MPa for 5 minutes to laminate together to obtain a thermoplastic composite sheet having a thickness of 2.06 mm.
Fig. 2 shows the appearance of the thermoplastic composite sheet. As can be seen from fig. 2, the surface of the obtained thermoplastic composite sheet material has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 2 (IE 2)
Reference was made to inventive example 1, except that a polycarbonate film with a thickness of 50 μm was used and a thermoplastic composite sheet with a thickness of 2.1mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 3 (IE 3)
Reference was made to inventive example 1, except that a polycarbonate film with a thickness of 75 μm was used and a thermoplastic composite sheet with a thickness of 2.15mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 4 (IE 4)
Reference was made to inventive example 1, except that a polycarbonate film with a thickness of 100 μm was used and a thermoplastic composite sheet with a thickness of 2.2mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 5 (IE 5)
The carbon fiber reinforced polycarbonate composite material waste was ground into small pieces of less than 6mm in size using a grinder. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 3 mm.
Then respectively laying a layer of polycarbonate film with the thickness of 30 mu m on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer, respectively, and putting the upper surface layer, the lower surface layer and the obtained crushed aggregates plate as an intermediate layer into a flat plate hot press at 200 DEG C o C and a pressure of 2MPa for 5 minutes to laminate together to obtain a thermoplastic composite sheet having a thickness of 3.06 mm.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 6 (IE 6)
Reference was made to inventive example 5, except that a polycarbonate film with a thickness of 50 μm was used and a thermoplastic composite sheet with a thickness of 3.10mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 7 (IE 7)
Reference was made to inventive example 5, except that a polycarbonate film with a thickness of 75 μm was used and a thermoplastic composite sheet with a thickness of 3.15mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 8 (IE 8)
Reference was made to inventive example 5, except that a polycarbonate film with a thickness of 100 μm was used and a thermoplastic composite sheet with a thickness of 3.2mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 9 (IE 9)
The carbon fiber reinforced polycarbonate composite material waste was ground into small pieces of less than 6mm in size using a grinder. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 4 mm.
And then in the resulting particle boardRespectively paving a layer of polycarbonate film with the thickness of 30 mu m on the upper surface and the lower surface as an upper surface layer and a lower surface layer, respectively, and putting the upper surface layer, the lower surface layer and the obtained crushed aggregates plates as an intermediate layer into a flat plate hot press at 200 DEG C o C and a pressure of 2MPa for 5 minutes to laminate together to obtain a thermoplastic composite sheet having a thickness of 4.06 mm.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 10 (IE 10)
Reference was made to inventive example 9, except that a polycarbonate film with a thickness of 50 μm was used and a thermoplastic composite sheet with a thickness of 4.1mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 11 (IE 11)
Reference was made to inventive example 9, except that a polycarbonate film with a thickness of 75 μm was used and a thermoplastic composite sheet with a thickness of 4.15mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 12 (IE 12)
Reference was made to inventive example 9, except that a polycarbonate film with a thickness of 100 μm was used and a thermoplastic composite sheet with a thickness of 4.2mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 13 (IE 13)
The carbon fiber reinforced polycarbonate composite material waste was ground into small pieces of less than 6mm in size using a grinder. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 5 mm.
Then respectively laying a layer of polycarbonate film with the thickness of 30 mu m on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer, respectively, and putting the upper surface layer, the lower surface layer and the obtained crushed aggregates plate as an intermediate layer into a flat plate hot press at 200 DEG C o C and a pressure of 2MPa for 5 minutes to laminate together to obtain a thermoplastic composite sheet having a thickness of 5.06 mm.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 14 (IE 14)
Reference was made to inventive example 13, except that a polycarbonate film with a thickness of 50 μm was used and a thermoplastic composite sheet with a thickness of 5.10mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 15 (IE 15)
Reference was made to inventive example 13, except that a polycarbonate film with a thickness of 75 μm was used and a thermoplastic composite sheet with a thickness of 5.15mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Inventive example 16 (IE 16)
Reference was made to inventive example 13, except that a polycarbonate film with a thickness of 100 μm was used and a thermoplastic composite sheet with a thickness of 5.20mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in table 2.
Comparative example 11 (CE 11)
The carbon fiber reinforced polycarbonate composite material waste was ground into small pieces of less than 6mm in size using a grinder. The resulting crushed aggregates are layered and then placed in a flat plate hot press at 260 o C, maintaining the temperature and the pressure of 3MPa for 5 minutes to obtain the crushed aggregates plates with the thickness of 6mm.
Then respectively laying a layer of polycarbonate film with the thickness of 30 mu m on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer, respectively, and putting the upper surface layer, the lower surface layer and the obtained crushed aggregates plate as an intermediate layer into a flat plate hot press at 200 DEG C o C and a pressure of 2MPa for 5 minutes to laminate together to obtain a thermoplastic composite sheet having a thickness of 6.06 mm.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 12 (CE 12)
Reference was made to comparative example 11, except that a polycarbonate film having a thickness of 50 μm was used and a thermoplastic composite sheet having a thickness of 6.10mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 13 (CE 13)
Reference was made to comparative example 11, except that a polycarbonate film with a thickness of 75 μm was used and a thermoplastic composite sheet with a thickness of 6.15mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 14 (CE 14)
Reference is made to comparative example 11, except that a polycarbonate film with a thickness of 100 μm is used and a thermoplastic composite sheet with a thickness of 6.20mm is formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 15 (CE 15)
Reference is made to comparative example 7, except that a polycarbonate film with a thickness of 125 μm is used and a thermoplastic composite sheet with a thickness of 1.25mm is formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 16 (CE 16)
Reference was made to comparative example 7, except that a polycarbonate film with a thickness of 250 μm was used and a thermoplastic composite sheet with a thickness of 1.50mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 17 (CE 17)
Reference was made to inventive example 1, except that a polycarbonate film with a thickness of 125 μm was used and a thermoplastic composite sheet with a thickness of 2.25mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 18 (CE 18)
Reference was made to inventive example 1, except that a polycarbonate film with a thickness of 250 μm was used and a thermoplastic composite sheet with a thickness of 2.50mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 19 (CE 19)
Reference was made to inventive example 5, except that a polycarbonate film with a thickness of 125 μm was used and a thermoplastic composite sheet with a thickness of 3.25mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 20 (CE 20)
Reference was made to inventive example 5, except that a polycarbonate film with a thickness of 250 μm was used and a thermoplastic composite sheet with a thickness of 3.50mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 21 (CE 21)
Reference was made to inventive example 9, except that a polycarbonate film with a thickness of 125 μm was used and a thermoplastic composite sheet with a thickness of 4.25mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 22 (CE 22)
Reference was made to inventive example 9, except that a polycarbonate film with a thickness of 250 μm was used and a thermoplastic composite sheet with a thickness of 4.50mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 23 (CE 23)
Reference was made to inventive example 13, except that a polycarbonate film with a thickness of 125 μm was used and a thermoplastic composite sheet with a thickness of 5.25mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 24 (CE 24)
Reference was made to inventive example 13, except that a polycarbonate film with a thickness of 250 μm was used and a thermoplastic composite sheet with a thickness of 5.50mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 25 (CE 25)
Reference was made to comparative example 11, except that a polycarbonate film with a thickness of 125 μm was used and a thermoplastic composite sheet with a thickness of 6.25mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
Comparative example 26 (CE 26)
Reference was made to comparative example 11, except that a polycarbonate film with a thickness of 250 μm was used and a thermoplastic composite sheet with a thickness of 6.50mm was formed.
The surface of the obtained thermoplastic composite board has no floating fiber.
The tensile strength and flexural strength of the obtained thermoplastic composite sheet were measured, and the results are summarized in Table 3.
TABLE 1
TABLE 2
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TABLE 3 Table 3
As can be seen from a comparison of inventive examples 1-12 with comparative examples 2-4, with the application of polycarbonate films having thicknesses of 30 μm, 50 μm, 75 μm and 100 μm, respectively, the flexural strength of the thermoplastic composite sheet material having intermediate layer particle sheet material thicknesses of 2.0mm, 3.0mm and 4.0mm, respectively, is significantly improved, while the flexural modulus is maintained at acceptable values.
As can be seen from a comparison of inventive examples 13 to 16 with comparative example 5, the flexural strength of thermoplastic composite sheets with a thickness of 5.0mm of the intermediate layer particle sheet material is also improved to some extent and the flexural modulus is maintained at similar values with the application of polycarbonate films with a thickness of 30 μm, 50 μm, 75 μm and 100 μm respectively.
As can be seen from comparative examples 11-14, the use of polycarbonate films of different thicknesses does not aid in the flexural strength and flexural modulus of thermoplastic composite boards having a thickness of 6.0mm for the intermediate particle board.
It can be seen from comparative examples 15-26 that the use of polycarbonate films with a thickness of 125 and 250 μm, respectively, does not contribute to the flexural strength and flexural modulus of the thermoplastic composite sheet material of various thicknesses for the intermediate particle sheet material.
The foregoing describes only exemplary embodiments or examples of the present invention and is not intended to limit the present invention. The present invention is susceptible to various modifications and changes by those skilled in the art. Any modification, equivalent replacement, improvement, etc. that comes within the spirit and principle of the present invention are included in the scope of the claims of the present application.
Claims (10)
1. Thermoplastic composite board comprising an upper skin and a lower skin laminated together and an intermediate layer between the upper skin and the lower skin, characterized in that the upper skin and the lower skin are polycarbonate films, each independently having a thickness in the range of 20-110 μm, the intermediate layer being formed from carbon fiber reinforced polycarbonate composite waste and having a thickness in the range of 1.5-5.5mm, the volume content of carbon fibers in the intermediate layer being 35-60% based on the volume of the intermediate layer.
2. The thermoplastic composite sheet material of claim 1, wherein the upper and lower skin layers each independently consist of one layer or consist of a plurality of sublayers.
3. Thermoplastic composite sheet material according to claim 1 or 2, characterized in that the upper and lower skin layers are each independently a polycarbonate film having a thickness in the range of 20-110 μm, preferably having a thickness in the range of 30-100 μm.
4. A thermoplastic composite sheet material according to any of claims 1-3, wherein the thickness of the intermediate layer is in the range of 2 mm-5 mm, preferably the thickness of the intermediate layer is in the range of 1.5 mm-2.5 mm.
5. A method of making the thermoplastic composite sheet material of any of claims 1-4, comprising:
i) Processing the carbon fiber reinforced polycarbonate composite material waste into crushed materials;
ii) processing the resulting particles into particle board; and
iii) And paving polycarbonate films on the upper surface and the lower surface of the obtained crushed aggregates plate as an upper surface layer and a lower surface layer respectively, and laminating the upper surface layer, the lower surface layer and the crushed aggregates plate as an intermediate layer together to obtain the thermoplastic composite plate.
6. The method of claim 5, wherein the carbon fiber reinforced polycarbonate composite waste material is derived from scrap pieces or processing waste material generated during production and use.
7. The method according to claim 5 or 6, wherein the carbon fiber reinforced polycarbonate composite material waste has a carbon fiber content of 35-60% by volume based on the volume of the waste.
8. The method according to any one of claims 5-7, wherein in step ii), at 240 o C-280 o C, processing the crushed aggregates into crushed aggregate plates at the temperature of C and the pressure of 2-4 MPa.
9. The method according to any one of claims 5-8, wherein in step iii), at 180 o C-220 o Laminating the upper and lower skin layers with the intermediate layer at a temperature of C and a pressure of 1MPa to 2MPa to obtain the thermoplastic composite sheet.
10. An article made using the thermoplastic composite sheet material of any of claims 1-4.
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