KR101783080B1 - Continuous fiber reinforced composite material - Google Patents

Abstract

Wherein the first surface layer and the second surface layer are each a resin-impregnated carbon fiber layer formed by impregnating a carbon fiber with a polyamide resin, and the intermediate layer is a glass- And a resin-impregnated glass fiber layer formed by impregnating the fiber with a polyolefin-based resin.

Description

{CONTINUOUS FIBER REINFORCED COMPOSITE MATERIAL}

Fiber reinforced resin composite material.

The composite material can be manufactured in such a form that a reinforcing material such as fibers, plates, and particles is embedded in a matrix material by combining two or more materials.

Reinforcing materials should have high strength and high stiffness properties. For example, when continuous fibers are used, a length of 5-50 mm length such as long fiber-reinforced thermoplastic (LFT) or glass mat-reinforced thermoplastic (GMT) Compared to fiber-reinforced plastics, it has superior mechanical strength, stiffness and impact performance.

The matrix provides lateral support of the reinforcement and transmits the load.

An embodiment of the present invention provides a fiber reinforced resin composite material which is economical in terms of cost and is given excellent mechanical properties.

In one embodiment of the present invention, the first surface layer and the second surface layer each have a laminated structure including a first surface layer, an intermediate layer, and a second surface layer, wherein the first surface layer and the second surface layer are each formed of a resin impregnated Wherein the intermediate layer is a resin-impregnated glass fiber layer formed by impregnating a glass fiber with a polyolefin-based resin.

The glass fiber or the carbon fiber may be a continuous fiber.

The glass fiber or the carbon fiber may be a fabric or may be included as a unidirectional fiber sheet in a form in which continuous fibers are arranged side by side in one direction.

The first surface layer, the second surface layer or all of them may comprise a single-sided carbon fiber sheet or a woven fabric of single or multi-layer carbon fibers.

When the first surface layer or the second surface layer includes the multi-layered unidirectional carbon fiber sheet, the carbon fiber sheet may be laminated so that the fiber direction of the carbon fiber sheet of each layer crosses in a direction perpendicular to the first direction.

The intermediate layer may comprise a mono-layer or multi-layer glass fiber woven fabric or a unidirectional glass fiber sheet.

When the intermediate layer includes the multi-layered unidirectional glass fiber sheet, the glass fiber sheets may be stacked so that the fiber directions of the glass fiber sheets of the respective layers cross at right angles.

An interfacial adhesion layer may be provided between the first surface layer and the intermediate layer, between the second surface layer and the intermediate layer, or both.

The interfacial adhesion layer may comprise a maleic anhydride-grafted polyolefin-based resin.

The interfacial adhesion layer may comprise a maleic anhydride grafted polyolefin resin in an amount ratio of about 100 parts by weight of a polyolefin resin and about 0.1 to about 5 parts by weight of maleic anhydride.

The polyamide based resin may include at least one selected from the group consisting of polyamide 6, polyamide 12, polyamide 66, and combinations thereof.

The thickness of the intermediate layer may be from about 100 mu m to about 3000 mu m.

The first surface layer and the second surface layer may each be about 10 to about 30% of the thickness of the intermediate layer.

The glass fiber and the carbon fiber may be completely impregnated with the resin.

The fiber-reinforced resin composite material is excellent in mechanical properties and lowers the production cost and is economical in terms of cost.

1 is a cross-sectional view of a fiber-reinforced resin composite material according to an embodiment of the present invention.
2 is a cross-sectional view of a fiber-reinforced resin composite according to another embodiment of the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, which will be readily apparent to those skilled in the art to which the present invention pertains. The present invention may be embodied in many different forms and is not limited to the embodiments described herein.

In order to clearly illustrate the present invention, parts not related to the description are omitted, and the same or similar components are denoted by the same reference numerals throughout the specification.

In the drawings, the thickness is enlarged to clearly represent the layers and regions. In the drawings, for the convenience of explanation, the thicknesses of some layers and regions are exaggerated.

Hereinafter, the formation of any structure in the "upper (or lower)" or the "upper (or lower)" of the substrate means that any structure is formed in contact with the upper surface (or lower surface) of the substrate However, the present invention is not limited to not including other configurations between the substrate and any structure formed on (or under) the substrate.

1 is a cross-sectional view of a fiber-reinforced resin composite material 100 according to an embodiment of the present invention.

The fiber reinforced resin composite material 100 has a laminated structure including a first surface layer 10, an intermediate layer 30, and a second surface layer 20 sequentially.

The first surface layer 10 and the second surface layer 20 are each a resin-impregnated carbon fiber layer, and the intermediate layer 30 is a resin-impregnated glass fiber layer.

The first surface layer 10 and the second surface layer 20 are each a resin-impregnated carbon fiber layer formed by impregnating a carbon fiber with a polyamide resin.

Specific examples of the polyamide-series resin include, but are not limited to, polyamide 6, polyamide 66, polyamide 6.6, and the like, or combinations thereof.

The intermediate layer 30 is a resin-impregnated glass fiber layer formed by impregnating a glass fiber with a polyolefin resin.

The fiber reinforced resin composite material 100 is a composite material containing glass fiber and carbon fiber as reinforcement materials and resin as a matrix material. Such a composite material can realize excellent mechanical properties and can be usefully used for various purposes.

For example, the fiber reinforced resin composite material may be usefully applied as a lightweight reinforcing material in automobiles, aircraft, building materials, wind power fields, and the like.

The fiber reinforced resin composite material (100) uses glass fiber and carbon fiber together to reduce the production cost by incorporating low-cost glass fiber while utilizing high mechanical properties of carbon fiber.

The resin-impregnated carbon fiber layer in the fiber-reinforced resin composite material 100 is formed as a surface layer, so that the fiber-reinforced resin composite material 100 can have flexural properties more effectively.

Specific examples of the polyamide-based resin include, but are not limited to, polyamide 6, polyamide 12, polyamide 66, etc., or combinations thereof.

The glass fiber and the polyolefin resin contained in the intermediate layer 30 are lower in cost than the carbon fiber and the polyamide resin contained in the first surface layer 10 and the second surface layer 20, The composite material 100 is a material having excellent mechanical properties and at the same time, securing price competitiveness. Since the polyolefin resin generally has a relatively low processing temperature and a wide processing temperature range as compared with the polyamide resin, the fiber-reinforced resin composite material 100 can be supplied with thermal energy required for product molding at a short processing time It becomes possible.

The glass fiber or the carbon fiber may be a continuous fiber. Specifically, the glass fiber or the carbon fiber may be a fabric or a unidirectional sheet (UD sheet) in which continuous fibers are arranged side by side in one direction.

The first surface layer 10, the intermediate layer 30 and the second surface layer 20 may each be a resin-impregnated fiber layer, as described above, as a continuous fiber or a unidirectional fiber sheet. A fabric or a unidirectional fiber sheet may be included as a single layer, or may include multiple layers.

The resin-impregnated fiber layer can be produced by a known method, for example, by laminating a fabric or a unidirectional fiber sheet and a resin sheet together, and then applying heat and pressure to melt the resin, To thereby impregnate the metal foil. As another example, a method of passing a cylinder containing a bath-type resin may be used.

In one embodiment, in order to produce continuous fibers in a multilayer structure, a resin sheet is laminated between a multi-layered fabric or a unidirectional fiber sheet, and then heat and pressure are applied to the resin Impregnated fiber layer can be produced.

The melt-pressing can be performed without limitation by a known process. Specifically, a double belt can be used as a heat source for impregnating the resin with the resin, and for example, hot pressing by a car rendering method can be performed.

The resin-impregnated fiber layer may be prepared so that the glass fiber and the carbon fiber are completely impregnated with the resin by a known method.

Generally, the fibers are formed of fiber bundles. The number of the fiber bundles of the glass fibers or the carbon fibers is not limited. For example, 2k, 3k, 4k, 6k, 12k, 24k 50k and the like commercially available forms can be used. Such glass fibers or carbon fibers may have an average diameter of about 5 占 퐉 to about 20 占 퐉. The fiber reinforced resin composite material 100 comprising glass fibers or carbon fibers having a size within the above range is suitable for realizing the impregnation property so as to have mechanical strength while being given appropriate flexibility.

The carbon fiber and the glass fiber may further be treated with a coupling agent or a sizing agent.

In one embodiment, the intermediate layer 30 may comprise a multi-layer continuous fibrous layer, for example, by allowing the multi-layer unidirectional fiber sheet to laminate such that the fiber direction of each layer intersects in a right angle direction .

2 is a cross-sectional view of a fiber-reinforced resin composite material 200 according to another embodiment of the present invention.

The fiber reinforced resin composite material 200 includes an interfacial adhesion layer 40 between the first surface layer 10 and the intermediate layer 30, between the second surface layer 20 and the intermediate layer 30, .

The interfacial adhesion layer 40 may include a maleic anhydride-grafted polyolefin-based resin. By forming the interfacial adhesion layer 40 as described above, the interfacial adhesion between the first surface layer 10 or the second surface layer 20 and the intermediate layer 30 is improved.

The maleic anhydride-grafted polyolefin-based resin has a high interfacial adhesion to both the polyolefin-based resin and the polyamide-based resin. Therefore, although the polyolefin resin and the polyamide resin have a low interfacial adhesion to each other, the fiber-reinforced resin composite material 200 having the above structure can have a high interfacial adhesion strength to each layer.

The maleic anhydride-grafted polyolefin-based resin has a high interfacial adhesion to both the polyolefin-based resin and the polyamide-based resin, and has a processing temperature similar to that of the polyolefin-based resin, And is also effective in terms of heat transfer between the intermediate layers 30, between the second surface layer 20 and the intermediate layer 30, that is, at the interface between different resins. Since such a structure uses a resin with a good heat transfer from the surface layer 10 or 20 and a low processing temperature at the intermediate layer 30, it is possible to reduce the time required for transferring the necessary heat so that the intermediate layer 30 is suitable for processing to be.

The interfacial adhesion layer 40 may comprise a maleic anhydride grafted polyolefin resin at a ratio of 100 parts by weight of a polyolefin resin and about 0.1 to about 5 parts by weight of maleic anhydride.

The content of the maleic anhydride in the maleic anhydride grafted polyolefin-based resin is within the above-mentioned range, whereby the improvement of the adhesion to the polyamide-based resin is suitably provided while preventing the cost from being increased excessively, .

The thickness of the intermediate layer may be from about 100 [mu] m to about 3000 [mu] m.

The first surface layer and the second surface layer may each be formed to have a thickness of about 10 to about 30% of the thickness of the intermediate layer.

The thickness of the intermediate layer and the surface layer may be in the range or in the above ratio so that the mechanical strength characteristics of the carbon fiber can be expressed without excessively increasing the cost.

Hereinafter, examples and comparative examples of the present invention will be described. The following embodiments are only examples of the present invention, and the present invention is not limited to the following embodiments.

( Example )

Example  One

(1) to (5) were prepared as follows.

(1) Four polyimide 6 films (manufactured by Hyosung Co.) having a thickness of 25 탆 were laminated to prepare sheets having a thickness of 100 탆.

(2) Prepare a twill fabric (manufactured by Toray) having a basis weight of 200 g / m < ² > woven with 3k continuous carbon fibers.

(3) Maleic anhydride grafted polyolefin resin (polyethylene resin copolymerized with maleic anhydride at a content of 5 wt%) was extruded to prepare a sheet having a thickness of 100 탆.

(4) Prepare a fabric (manufactured by Owens Corning) having a basis weight of 600 g / m < ² > woven with 4k continuous glass fiber.

(5) Prepare a 100 μm thick polypropylene sheet.

(1) - (2) - (1) - (3) - (5) - (4) - (5) - (4) - (5) - ) - (1), put in a mold, preheated at 260 DEG C for 5 minutes by hot press, and then compression-molded at the same temperature and pressure of 4 MPa for 5 minutes to prepare a fiber reinforced resin composite material having a total thickness of 4 mm Respectively. After cooling to 100 ° C, it was taken out of the mold.

Comparative Example  One

A total of three layers of (5) - (2) - (5) - (2) out of the sheets or fabrics prepared in Example 1 were laminated to produce a fiber reinforced resin composite having a total thickness of 4 mm.

Comparative Example  2

A total of five layers of (5) - (4) - (5) - (4) of the sheets or fabrics prepared in Example 1 were laminated to form a fiber reinforced resin composite having a total thickness of 4 mm.

Comparative Example  3

A total of three layers of (1) - (2) - (1) - (2) out of the sheets or fabrics prepared in Example 1 were laminated to form a fiber reinforced resin composite material having a total thickness of 4 mm.

Comparative Example  4

Four layers of (1) - (4) - (1) - (4) of the sheet or fabric prepared in Example 1 were laminated in total to form a fiber reinforced resin composite having a total thickness of 4 mm.

evaluation

Experimental Example  One

The flexural strength and flexural rigidity of the fiber-reinforced resin composite material produced in Example 1 and Comparative Example 1-4 were measured according to ASTM D790 and are shown in Table 1 below.

division Bending strength (MPa) Bending Stiffness (GPa) Example 1 500 40 Comparative Example 1 90 22 Comparative Example 2 300 24 Comparative Example 3 600 48 Comparative Example 4 350 24

From the results shown in Table 1, it can be confirmed that the bending strength and the bending rigidity are excellent in the same thickness when the structure of Example 1 is used.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, And falls within the scope of the invention.

10: First surface layer
20: Second surface layer
30: middle layer
40: Interfacial adhesion layer
100, 200: Fiber reinforced resin composite material

Claims (14)

A laminated structure including a first surface layer, an intermediate layer and a second surface layer sequentially,
Wherein the first surface layer and the second surface layer are each a resin-impregnated carbon fiber layer formed by impregnating a carbon fiber with a polyamide resin, and the intermediate layer is a resin-impregnated glass fiber layer formed by impregnating a glass fiber with a polyolefin resin,
Wherein the first surface layer and the second surface layer are respectively 10 to 30% of the thickness of the intermediate layer,
An interfacial adhesion layer between the first surface layer and the intermediate layer, between the second surface layer and the intermediate layer, or both.
The method according to claim 1,
The glass fiber or the carbon fiber is a continuous fiber
Fiber reinforced resin composite.
The method according to claim 1,
The glass fiber or the carbon fiber may be a fabric or may be a single-directional fiber sheet in which continuous fibers are arranged side by side in one direction
Fiber reinforced resin composite.
The method according to claim 1,
The first surface layer, the second surface layer or all of them may comprise a mono-layer or multi-layer carbon fiber woven fabric or a unidirectional carbon fiber sheet
Fiber reinforced resin composite.
5. The method of claim 4,
When the first surface layer or the second surface layer includes the multi-layered unidirectional carbon fiber sheet, the carbon fiber sheet is laminated so that the fiber directions of the carbon fiber sheets of the respective layers cross in a direction perpendicular to the direction
Fiber reinforced resin composite.
The method according to claim 1,
The intermediate layer may comprise a single layer or multi-layer glass fiber woven fabric or a unidirectional glass fiber sheet
Fiber reinforced resin composite.
The method according to claim 6,
When the intermediate layer includes the multi-layered unidirectional glass fiber sheet, the glass fiber sheets are stacked so that the fiber directions of the glass fiber sheets of the respective layers intersect at right angles to each other
Fiber reinforced resin composite.
delete The method according to claim 1,
Wherein the interfacial adhesion layer comprises a maleic anhydride grafted polyolefin-based resin
Fiber reinforced resin composite.
The method according to claim 1,
Wherein the interfacial adhesion layer comprises a maleic anhydride-grafted polyolefin-based resin in an amount ratio of 100 parts by weight of a polyolefin resin and 0.1 to 5 parts by weight of maleic anhydride
Fiber reinforced resin composite.
The method according to claim 1,
Wherein the polyamide based resin comprises at least one selected from the group consisting of polyamide 6, polyamide 12, polyamide 66, and combinations thereof
Fiber reinforced resin composite.
The method according to claim 1,
Wherein the thickness of the intermediate layer is 100 mu m to 3000 mu m
Fiber reinforced resin composite.
delete The method according to claim 1,
Wherein the glass fiber and the carbon fiber are completely impregnated with the resin
Fiber reinforced resin composite.

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