KR20170105667A - Composite laminate plate and manufacture method of it - Google Patents

Abstract

The present invention relates to a method for manufacturing a composite material laminate plate, which comprises the following steps: (a) preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated; (b) installing a lower mold at the lower side of the lamination member; (c) installing an upper mold at the upper side of the lamination member; (d) installing a breather at the upper side of the upper mold; (e) installing a vacuum film at the upper side of the breather; (f) sealing a portion in which the vacuum film and the lower mold come in contact with each other with a sealant; (g) installing a vacuum valve between the vacuum film and the breather; (h) using a vacuum pump connected to the vacuum valve to make a space in which the lower mold and the vacuum film are coupled to a vacuum state, and to close the vacuum valve to maintain a vacuum state, and (i) manufacturing a composite material laminate plate through a curing process after a step for maintaining the vacuum state. In addition, the present invention can provide the composite laminate manufactured using the method for manufacturing a composite material. The present invention aims to provide the composite laminate having various colors and patterns and excellent flame retardancy by using a low pressure melamine sheet to improve the flame retardancy and aesthetics of the composite material, and to provide a method for manufacturing a composite laminate.

Description

≪ Desc / Clms Page number 1 > COMPOSITE LAMINATE PLATE AND MANUFACTURE METHOD OF IT

The present invention relates to a composite laminate and a method of manufacturing the composite laminate, and more particularly, to a composite laminate having various colors and patterns using a low pressure melamine sheet to improve flame retardancy and aesthetics of a composite material, To a material laminate and a manufacturing method thereof.

In general, composite materials are materials that consist of fiber reinforcements and plastic bases. Composites are materials that are lighter than metals but have superior strength and inelasticity.

Fiber reinforcements include aramid fibers, glass fibers, and carbon fibers. Examples of the plastic substrate include a thermoplastic resin and a thermosetting resin.

The fiber-reinforced composite material of the composite material has excellent physical properties.

The fiber reinforced composite material is produced by impregnating a reinforcing material such as carbon fiber or aramid fiber with a resin such as epoxy, which is a known material. Fiber reinforced composites have high nose strength and inelasticity. For this reason, it is used as an industrial structural material for aircraft, building materials and automobiles. It is also used as a material for everyday products such as sports goods such as tennis rackets, golf shafts and fishing rods. As such, it is utilized as a lightweight material having high durability in various industrial fields.

The composite material can be used by applying coatings such as gel coating (GEL COAT) and film coating on the surface without applying a separate coating in order to utilize the woven shape or texture of the fiber used as the reinforcing material.

A gelcoat is a combination of a thermosetting resin and a pigment, and is a method of coating the product surface with a desired color using a brush or spray.

However, the gelcoat process must maintain an appropriate working temperature of 15-25 ° C for smooth surface coating during resin application. In addition, the gel coating method should be uniformly applied at a proper thickness (about 0.3-0.5 mm). In addition, when the gel coat laminating operation is performed using a mold, it is necessary to apply a releasing agent to the mold for the de-formation. After the application of the gel coat, the curing condition of the gel coat resin should be checked to prevent wrinkling or peeling on the surface, and the lamination operation should proceed. As described above, the gelcoat operation requires a skilled work technique, and there is a problem that the work requirement is severe.

Film coating is a method of coating polymeric materials such as PE, PET and OPP in film form. The film coating can impart various functions such as insulation, wettability, and adhesion by mixing other polymer materials on the film surface or by surface treatment such as corona or high vacuum treatment depending on the application. However, the polymeric materials for film coating described above are thermoplastic and are vulnerable to heat in a high temperature working environment.

To solve this problem, research on a composite material using a low-pressure melamine sheet has been sought.

An invention such as that disclosed in Korean Patent Laid-open Publication No. 10-2007-0010428 (the title of the invention: a composite sheet for shielding a mobile phone electromagnetic wave and a manufacturing method thereof) has been proposed by the prior art.

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above-mentioned problems and it is an object of the present invention to provide a composite material which has various colors and patterns using a low pressure melamine sheet to improve the flame retardancy and aesthetics of the composite material, And a method for manufacturing the same.

According to an aspect of the present invention, there is provided a method of manufacturing a laminated sheet, comprising the steps of: (a) preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated; (b) providing a lower mold on the lower side of the lamination member; (c) installing an upper mold on the upper side of the lamination member; (d) installing a breather on the upper mold; (e) installing a vacuum film on the upper side of the breather; (f) sealing the portion where the vacuum film and the lower mold abut each other with a sealant; (g) providing a vacuum valve between the vacuum film and the breather; (h) using a vacuum pump connected to the vacuum valve to make a space in which the lower mold and the vacuum film are coupled to a vacuum state, and closing the vacuum valve to maintain the vacuum state; And (i) after the step of maintaining the vacuum state, a composite laminate plate is manufactured through a curing process.

Wherein the step (i) comprises heating at a temperature of 70 ° C to 90 ° C for 30 minutes to 60 minutes; And curing at a temperature of 110 ° C to 140 ° C for 75 minutes to 120 minutes after the heating.

Wherein said step (a) comprises: stacking at least one prepreg above a low-pressure melamine sheet; And stacking the low-pressure melamine sheet on the prepreg after the step of stacking the prepreg.

The step (a) may further include forming at least one prepreg on the upper side of the low-pressure melamine sheet, and forming a release member between the lamination member and the upper mold.

The step (a) may further include forming a release member between the lamination member and the lower mold, wherein the low-pressure melamine sheet is laminated on at least one of the prepregs.

Further, it is possible to provide a composite material laminate characterized by being manufactured by a method of manufacturing a composite material laminate plate.

The present invention can provide a composite laminate in which a low-pressure melamine sheet is applied to improve the flame retardancy of the composite laminate according to the embodiment.

Further, the present invention can provide a composite laminate in which the low-pressure melamine sheet is applied to improve the wear resistance, heat resistance, water resistance, and stain resistance of the composite laminate according to the embodiment.

In addition, the present invention can provide a composite laminate suitable for use in the production of flame retardant panels that meet the flame retardant performance required for exterior materials such as sandwich panels for construction, industrial finishing materials and furniture.

Further, the present invention can provide a method capable of efficiently producing a composite laminate, and it is possible to reduce the cost of production economically.

1 (a) to 1 (c) are views showing a lamination member in which a low-pressure melamine sheet and a prepreg, which are components of a composite laminate according to an embodiment of the present invention, are laminated.
2 is a view showing an example of production of a vacuum blank for producing a composite laminate according to an embodiment of the present invention.
3 is a flow chart illustrating a method of manufacturing a composite laminate according to an embodiment of the present invention.

Hereinafter, the description of the present invention with reference to the drawings is not limited to a specific embodiment, and various transformations can be applied and various embodiments can be made. It is to be understood that the following description covers all changes, equivalents, and alternatives falling within the spirit and scope of the present invention.

In the following description, the terms first, second, and the like are used to describe various components and are not limited to their own meaning, and are used only for the purpose of distinguishing one component from another component.

Like reference numerals used throughout the specification denote like elements.

As used herein, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. It is also to be understood that the terms " comprising, "" comprising, "or" having ", and the like are intended to designate the presence of stated features, integers, And should not be construed to preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

Hereinafter, embodiments of the present invention will be described in detail with reference to FIGS. 1 to 3 attached hereto.

The present invention describes a composite laminate and a manufacturing method thereof.

1 (a) to 1 (c) are views showing a lamination member in which a low-pressure melamine sheet and a prepreg, which are components of a composite laminate according to an embodiment of the present invention, are laminated.

Referring to FIG. 1, a lamination member 40 according to an embodiment of the present invention may include a low-pressure melamine sheet 1 and a prepreg 2.

For reference, the lamination member 40 is a component included in the composite laminate.

The lamination member 40 can be manufactured by cutting and laminating the prepreg 2 to a desired size and thickness according to the application, and then stacking the low-pressure melamine sheet 1 on the upper and lower portions of the laminate of the prepreg 2, have. In addition, the lamination member 40 may be formed in a structure in which the low-pressure melamine sheet 1 is laminated on the prepreg 2. In addition, the lamination member 40 may be formed in a structure in which the low-pressure melamine sheet 1 is laminated on the lower portion of the prepreg 2.

The lamination member 40 can be manufactured by vacuum oven molding (VACUUM BAG / OVEN), autoclave molding method, compression molding method and the like.

The low-pressure melamine sheet (1) is produced by gravure printing on a paper sheet, which is impregnated with a melamine resin. The low-pressure melamine sheet 1 is advantageous in that it is inexpensive and easy to process. In addition, the low-pressure melamine sheet 1 can form various patterns and can be used as an interior and exterior material for appliances and furniture.

The low-pressure melamine sheet 1 can be cut to a desired size. Further, the low-pressure melamine sheet 1 can use a product of a color, pattern and design desired by the user.

The low-pressure melamine sheet (1) has a wider choice of design than other coating materials and can enhance the decorative and aesthetics of composite materials when used in composite materials. Further, the low-pressure melamine sheet 1 may be formed in plural.

The prepreg 2 is a material previously impregnated with a textile fabric. Carbon fiber, glass fiber and aramid fiber may be applied to the prepreg 2 depending on the application. As the prepreg 2, thermosetting resins such as epoxy, polyimide and phenol can be applied. The prepreg 2 may be a UNDIRECTIONAL or prepreg in the form of plain weave or twill weave. The trim size of the prepreg 2 can be easily selected according to the molding facility capacity of the user. In addition, the prepregs 2 may be formed in plural.

The lamination thickness of the prepreg 2 is preferably 0.1 to 50 mm. When the lamination thickness of the prepreg 2 is less than 0.1 mm, the material properties such as the mechanical strength of the laminate or the lamination member 40 can be made low.

If the lamination thickness of the prepreg 2 is more than 50 mm, the lamination thickness becomes too thick, and the curing reaction inside the lamination member 40 is not completely caused due to the uneven heat transfer inside the lamination member 40, 40 may be deteriorated and the molding time for fully curing the interior of the lamination member 40 may be prolonged.

The structure of the lamination member 40 will be described with reference to Figs. 1 (a) to 1 (c).

1 (a), the lamination member 40 comprises at least one prepreg 2 laminated on the low-pressure melamine sheet 1 and a low-pressure melamine sheet 1 laminated on the prepreg 2, . ≪ / RTI >

1 (b), the lamination member 40 may have a structure in which at least one prepreg 2 is laminated on the low-pressure melamine sheet 1.

1 (c), the lamination member 40 may have a structure in which the low-pressure melamine sheet 1 is laminated on the upper side of at least one prepreg 2.

As described above, the lamination member 40 can be manufactured by variously stacking the composite laminate plates to be produced according to desired property values or intended use.

2 is a view showing an example of production of a vacuum blank for producing a composite laminate according to an embodiment of the present invention.

Referring to FIG. 2, a vacuum blank for manufacturing a composite laminate according to an embodiment of the present invention includes a lower mold 10, a sealant 20, a release member 30, a lamination member 40, An upper mold 50, a breather 60, a vacuum film 70, and a vacuum valve 80.

The lower mold 10 is a part for producing a composite laminate or a molded article. The lower mold 10 may be formed of a metal such as iron and aluminum or a glass material. The lower mold 10 may be a structure formed of a flat plate.

The sealant 20 is a member that serves to bond the members to each other. The sealant 20 is a sealant for sealing. The sealant 20 can be used for the purpose of preventing leakage between the two adhesive portions. The sealant 20 may be a rubbery material, a soft or highly viscous liquid rubber composition. Also, the sealant 20 can use a reactive sealant and an unreacted sealant. The sealant 20 can seal the portion where the vacuum film 70 and the lower mold 10 abut so that air does not flow in or out. The sealant 20 is attached between the vacuum film 70 and the lower mold 10 so that the vacuum state is maintained. The sealant 20 is a member that keeps the interior of the vacuum chamber at a low pressure. The sealant 20 is used for various purposes in the vacuum blanking operation.

The mold releasing member 30 can be easily demolded after the molding process. The release member 30 may be formed as a release film. In addition, the release member 30 may be formed of a PEEL PLY. The release member 30 can be formed as a release film coated by adding a silicone composition and an inorganic particle exhibiting an antistatic effect to either or both sides of a polyester film (PET). The release member 30 can have a uniform peel force, residual adhesive force, and antistatic performance. The release member 30 can be used for protecting the temporary support and the adhesive layer as a tacky component material.

In addition, the release film can serve as a functional film for easily peeling off the product after the molding process.

In addition, PEEL PLY can control the roughness of the composite surface. The PEEL PLY can be formed to protect the surface of the product while not sticking to the resin and being easy to peel off. The PEEL PLY can be left in the forming or bonding process and can be used to prevent the foreign material from penetrating the composite surface before bonding.

The release member 30 can be selected from a release film and a PEEL PLY. The release member 30 can be used by laminating a release film and a PEEL PLY to each other.

The lamination member 40 is a member in which the low-pressure melamine sheet 1 and the prepreg 2 are laminated. The lamination member 40 is a component manufactured as a composite laminate through a molding process.

A method of manufacturing the composite laminate will be described with reference to FIG.

The upper mold 50 is a part for producing a composite laminate or a molded product. The upper mold 50 may be formed of a metal such as iron and aluminum or a glass material. The upper mold 50 may be a structure formed of a flat plate.

The breather 60 can play a role of being evenly transferred to the inside of the vacuum film 70. The breather 60 may serve to absorb the resin flowing out of the prepreg 2 during molding. The breather 60 may be formed of a cloth such as a nonwoven fabric that absorbs surplus resin or resin. The breather 60 may be formed with a predetermined pore structure.

The vacuum film 70 may serve to form a vacuum space. The vacuum film 70 is formed by vacuum forming the lower mold 10, the releasing member 30, the laminating member 40, the upper mold 50 and the breather 60 to fabricate the composite laminate The state can play a role.

The vacuum valve 80 may be connected to a separate vacuum line (not shown) and a vacuum pump (not shown). A vacuum valve 80 may be formed between the vacuum film 70 and the breather 60. In addition, the vacuum valve 80 may serve to seal the air inside the vacuum chamber when the vacuum chamber is evacuated by the vacuum pump.

3 is a flow chart illustrating a method of manufacturing a composite laminate according to an embodiment of the present invention.

Referring to FIG. 3, a method of manufacturing a composite laminate according to an embodiment of the present invention includes the steps of (a) preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated, A step (S30) of installing an upper mold on the upper side of the lamination member, (d) a step (S40) of installing a breather on the upper side of the upper mold, (e) a step (S50) of placing a vacuum film on the upper side of the breather, (f) a step (S60) of sealing a portion where the vacuum film and the lower mold abut each other with a sealant, (g) installing a vacuum valve between the vacuum film and the breather (H) a vacuum pump connected to the vacuum valve is used to make a space in which the lower mold and the vacuum film are coupled to a vacuum state, and a vacuum valve is closed to maintain a vacuum state (S80) and (i) ) After the step of maintaining the vacuum state, The fee laminate may include the step (S90) is made.

(a) preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated, a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated can be prepared . That is, the step (S10) of preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated can produce the lamination member (40).

For reference, the lamination member 40 can be prepared by cutting and laminating the prepreg 2 to a desired size and thickness according to the use, and then stacking the low-pressure melamine sheet 1 on the upper and lower portions of the laminate of the prepreg 2 have. In addition, the lamination member 40 may be formed in a structure in which the low-pressure melamine sheet 1 is laminated on the prepreg 2. In addition, the lamination member 40 may be formed in a structure in which the low-pressure melamine sheet 1 is laminated on the lower portion of the prepreg 2.

Specifically, step S10 of preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated can be formed in the following embodiment. The structure of the lamination member 40 will be described with reference to Fig.

(S10) of preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated is characterized in that at least one prepreg (2) is laminated on the low-pressure melamine sheet (1) (Step S11) of stacking the low-pressure melamine sheet 1 on the upper side of the prepreg 2, and stacking at least one prepreg 2 on the low-pressure melamine sheet 1 Forming a release member 30 between the lamination member 40 and the upper mold 50 and stacking the low pressure melamine sheet 1 on at least one of the prepregs 2, And a step S13 of forming a release member 30 between the lamination member 40 and the lower mold 10 may be selected and used.

The step of stacking the low-pressure melamine sheet 1 on the upper side of the prepreg 2 after the step of stacking at least one prepreg 2 on the low-pressure melamine sheet 1 and the step of stacking the prepregs 2 Step S11 is a step of stacking at least one prepreg 2 on the upper side of the low pressure melamine sheet 1 and a step of stacking the low pressure melamine sheet 1 on the upper side of the prepreg 2 after the prepreg 2 is laminated .

The step S12 of forming the release member 30 between the lamination member 40 and the upper mold 50 includes the step of stacking at least one prepreg 2 on the low pressure melamine sheet 1 Wherein at least one prepreg 2 is laminated on the low pressure melamine sheet 1 and the mold member 30 is formed between the lamination member 40 and the upper mold 50. [ Wherein at least one prepreg (2) is laminated on the low-pressure melamine sheet (1), and the step (S12) of forming the release member (30) between the lamination member (40) and the upper mold It is preferable that the width and length of the release film or the release member are larger than the size of the lamination member 40 by 5 to 20 mm. When the width and length of the release member 30 are larger than the size of the lamination member 40 by 5 mm or more, there is a possibility that the vacuum film 70 and the lamination member 40 may stick to each other during vacuum forming. In addition, when the width and length of the release member 30 are greater than 20 mm larger than the size of the lamination member 40, there is a problem that the material is wasted and the economic cost is increased.

The step of forming a release member 30 between the lamination member 40 and the lower mold 10 includes the step of stacking the low pressure melamine sheet 1 on at least one prepreg 2, Pressure melamine sheet 1 on the upper side of the at least one prepreg 2 so that the release member 30 can be formed between the laminate member 40 and the lower mold 10. [

Wherein the step of forming the release member 30 between the laminate member 40 and the lower mold 10 comprises the step of stacking the low-pressure melamine sheet 1 on at least one prepreg 2, It is preferable that the width and length of the release film or the release member are larger than the size of the lamination member 40 by 5 to 20 mm. When the width and length of the release member 30 are larger than the size of the lamination member 40 by 5 mm or more, there is a possibility that the vacuum film 70 and the lamination member 40 may stick to each other during vacuum forming. In addition, when the width and length of the release member 30 are greater than 20 mm larger than the size of the lamination member 40, there is a problem that the material is wasted and the economic cost is increased.

Here, the prepregs 2 may be formed in plural.

The low-pressure melamine sheet 1 is made of a material having a releasing property, so that the releasing member 30 can be omitted on the side of the low-pressure melamine sheet 1 formed on the lamination member 40. When the release member 30 is omitted on the surface of the low-pressure melamine sheet 1, the width and length of the low-pressure melamine sheet 1 are preferably 5 to 20 mm larger than the size of the prepreg 2.

If the width and the vertical size of the low-pressure melamine sheet 1 are larger than the size of the prepreg 2 by 5 mm or more, there is a possibility that the vacuum film 70 and the prepreg 2 may stick to each other during vacuum forming. Further, when the width and length of the low-pressure melamine sheet 1 are larger than the size of the prepreg 2 by 20 mm or more, there is a problem that the material is wasted and the economic cost is increased.

(b) In the step S20 of installing the lower mold on the lower side of the laminating member, the lower mold 10 may be provided on the lower side of the laminating member 40. In addition, step S20 of installing the lower mold on the lower side of the lamination member may be a step of disposing the lower mold 10 on the lower side of the lamination member 40. [

(c) In the step (S30) of installing the upper mold on the upper side of the laminating member, the upper mold 50 may be provided on the upper side of the laminating member 40. In addition, the step S30 of installing the upper mold on the upper side of the lamination member may be a step of disposing the upper mold 50 on the upper side of the lamination member 40. [

(d) In step S40 of installing the breather on the upper mold, a breather 60 may be provided on the upper mold 50. In addition, step (S40) of installing a breather on the upper side of the upper mold may be a step of disposing the breather 60 on the upper side of the upper mold 50.

(e) In the step (S50) of installing the vacuum film on the upper side of the breather, the vacuum film 70 may be provided on the upper side of the breather 60. In addition, the step of installing the vacuum film on the upper side of the breather (S50) may be a step of disposing the vacuum film 70 on the upper side of the breather 60. [

(f) In the step (S60) of sealing the portion where the vacuum film and the lower mold abut each other with the sealant, the portion where the vacuum film 70 and the lower mold 10 abut each other can be sealed with the sealant 20. Here, the sealant 20 may be formed in plural. In the step S60 of sealing the portion where the vacuum film and the lower mold contact each other with the sealant, the vacuum film 70 abutting the upper surface of the edge of the lower mold 10 may be sealed using the sealant 20.

(g) In the step (S70) of installing the vacuum valve between the vacuum film and the breather, a vacuum valve 80 may be provided between the vacuum film 70 and the breather 60. The step of installing a vacuum valve between the vacuum film and the breather (S70) is a step of installing a vacuum valve (80) between the vacuum film (70) and the breather (60) to make the inside of the vacuum chamber a vacuum state or a low pressure state .

(h) Vacuuming the space in which the lower mold and the vacuum film are coupled by using a vacuum pump connected to the vacuum valve, and closing the vacuum valve to maintain the vacuum state (S80) It is possible to make the space (in the vacuum space) where the lower mold 10 and the vacuum film 70 are coupled to a vacuum state by using a pump (not shown) and to keep the vacuum state by closing the vacuum valve 80 .

In addition, by using the vacuum pump connected to the vacuum valve, the space in which the lower mold and the vacuum film are combined is made vacuum, and the vacuum valve is closed to maintain the vacuum state (S80) The lower mold 10 and the upper mold 50 make the laminate member 40 in a state in which the lower mold 10 and the upper mold 50 compress the laminate member 40 .

(i) after the step of maintaining the vacuum state, the step (S90) in which the composite laminate is manufactured through the curing step is a step in which the composite laminate is manufactured through the curing step after the step of maintaining the vacuum state (S80) have.

Specifically, after the step of maintaining the vacuum state, the step (S90) of producing the composite laminate through the curing step includes heating (S91) for 30 minutes to 60 minutes at a temperature of 70 to 90 degrees and heating S91), and then curing (S92) at a temperature of 110 to 140 degrees for 75 to 120 minutes.

The step (S91) of heating for 30 minutes to 60 minutes at a temperature of 70 to 90 degrees can heat the vacuum at a temperature of 70 to 90 degrees for 30 to 60 minutes through a heating unit (not shown).

The epoxy resin impregnated in the prepreg 2 is heated at a temperature of 70 ° C. to 90 ° C. for 30 minutes to 60 minutes through a step S 91 to form a laminated member 40 And the gap between the prepreg layers (PREPREG-LAYER) can be made uniform.

When heating is performed at a temperature condition of less than 70 degrees, the viscosity of the resin may not vary greatly. Further, when heating is carried out at a temperature condition exceeding 90 degrees, the flow of the resin may not be smooth.

In addition, the step of curing at a temperature of 110 ° to 140 ° C. for 75 minutes to 120 minutes (S 92) is a step of heating the hollow space at a temperature of 110 ° C. to 140 ° C. for 75 minutes through a heating unit (not shown) To < / RTI > 120 minutes.

In addition, the step (S92) for curing at a temperature of 110 to 140 degrees for 75 to 120 minutes may include heating the epoxy resin exiting through the step (S91) for 30 minutes to 60 minutes at a temperature of 70 to 90 degrees Can be hardened. Thus, the laminate member 40 can be made of a composite laminate while being cured by an epoxy resin.

If the temperature is lower than 110 ° C, the curing may not be performed properly. Further, when heating is carried out at a temperature condition of more than 140 degrees, there is a problem that curability is lowered.

If the molding is completed through the step S90 in which the composite laminate is manufactured through the curing process after the step of maintaining the vacuum state, the surface of the composite laminate can be manufactured so as to have almost no air bubbles and a smooth surface.

The method of manufacturing the composite laminate may be performed by a vacuum blank forming process, an oven forming process, an autoclave forming process, or a compression molding process. In addition, the molding time can be applied differently depending on the curing behavior characteristics of the resin.

The VACUUM BAG MOLDING PROCESS of the present invention can be easily used when producing a composite material requiring high quality.

For reference, the prepreg 2 is a material in which an epoxy resin is mixed with fibers in a partially cured state. The prepreg 2 contains about 30 to 45% by weight of resin. If the prepreg 2 is cured without loss of resin, the prepreg 2 contains about 50% by volume of the fiber. However, when the resin of about 10 to 15% by volume exits from the curing process and the prepreg 2 is cured to produce a composite laminate, the fiber content of the prepreg 2 is about 60% by volume . In this way, while the resin contained in the prepreg 2 is released from the prepreg 2 during the curing process, the air and the solvent remaining in the prepreg 2 are released, and the pre-condition of the composite laminate is reduced can do.

For reference, prepregs generally have a resin content of about 30-40%. The prepreg can be prepared by impregnating a single-component resin.

In particular, the one-part type resin of the present invention may be a resin in which the base material and the curing agent are mixed. Further, the one-component resin may be a resin in which the solid-phase resin and the liquid resin are mixed.

The solid phase resin may be 20 to 40 parts by weight.

If the solid-state resin is less than 20 parts by weight, the viscosity of the one-component resin becomes high, and the time required for the prepreg to cure may be increased. When the solid resin is more than 40 parts by weight, miscibility with the liquid resin may be deteriorated.

The liquid resin may be formed in an amount of 60 to 80 parts by weight.

If the amount of the liquid resin is less than 60 parts by weight, miscibility with the solid resin may be deteriorated. If the amount of the liquid resin is more than 80 parts by weight, the viscosity may increase and the time required for the prepreg to cure may be increased.

Further, in the method for manufacturing a composite laminate, the pressing using a roller can be further performed. The rollers can be used in combination with rubber or metal rollers.

As the composition of the prepreg, aramid fiber, glass fiber or carbon fiber may be used depending on the use.

The resin may be a thermosetting resin such as epoxy, vinyl ester, phenol, or polyimide.

In addition, a curing agent is essentially included, and if necessary, may contain additives such as additives, antifoaming agents, pigments, curing accelerators and the like.

Further, the composite laminate of the present invention will be described in more detail with reference to Examples 1 and 2 below.

The composite laminate production method and physical property evaluation method used in the examples are shown below. However, the present invention is not limited to the embodiments described below.

Example 1: Low-Pressure Melamine Sheet and Fabric Type Carbon fiber The prepreg  Fabrication of Composite Laminate

A low-pressure melamine sheet (Printech ELF, Korea) and a woven carbon fiber prepreg (WSN3K, SK Chemical, Korea) were laminated to form a lamination member. The low-pressure melamine sheet and the woven carbon fiber prepreg were cut to 300 * 300 mm (width * length) respectively. The fabric type carbon fiber prepreg was laminated with 2 plies (2 plies), and one low-pressure melamine sheet was laminated on the fabric-type carbon fiber prepreg. Thereafter, a blank space was formed in accordance with the above-described method for producing a hollow space, and a molding process was performed in an oven. In the molding process, the curing conditions were heated at 80 DEG C for 30 minutes and then molded at 125 DEG C for 90 minutes to prepare a composite laminate.

Example 2: Low-pressure melamine sheet and One direction Carbon fiber The prepreg  Fabrication of Composite Laminate

A low-pressure melamine sheet (Printech ELF, Korea) and a unidirectional carbon fiber prepreg (USN 150 B, SK Chemical, Korea) were laminated to form a lamination member. The low-pressure melamine sheet and the unidirectional carbon fiber prepreg were cut into 300 * 300 mm (width * length) size, respectively. The unidirectional carbon fiber prepregs were laminated by 3 ply (3 ply) in the order of 0 °, 90 ° and 0 °. One low-pressure melamine sheet was laminated on the upper side of the unidirectional carbon fiber prepreg. Thereafter, a blank space was formed in accordance with the above-described method for producing a hollow space, and a molding process was performed in an oven. In the molding process, the curing conditions were heated at 80 DEG C for 30 minutes and then molded at 125 DEG C for 90 minutes to prepare a composite laminate.

The composite laminate of the present invention and the method of manufacturing the same can form a lamination member in which a prepreg and a low-pressure melamine sheet are laminated without the need for a separate operation like a gel coat method, thereby saving time and cost for coating.

Further, the polymer film used in the film coating has a problem of being vulnerable to heat by using a thermoplastic polymer material. However, since the melamine resin applied to the low-pressure melamine sheet of the composite laminate according to the embodiment of the present invention is thermosetting, it can be used in a high-temperature working environment.

In addition, additional materials such as release film, PEEL PLY and release agent are required for mold and de-formation in the production of composite laminate. However, since the low-pressure melamine sheet of the present invention is formed of a material having de-molding, there is no need for a separate mold-forming sub-material on the low-pressure melamine sheet-attached surface, thereby reducing the use amount of the subsidiary material and the economic cost.

While the present invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, It will be clear to the person.

In addition, since the components shown in the drawings can be enlarged or reduced for convenience of description, the present invention is not limited to the size and the shape of the components shown in the drawings, Those skilled in the art will appreciate that various modifications and equivalent embodiments are possible. Accordingly, the true scope of the present invention should be determined by the technical idea of the appended claims.

1: Low-pressure melamine sheet
2: prepreg
10: Lower mold
20: Sealant
30: Release member
40:
50: upper mold
60: Breather
70: Vacuum film
80: Vacuum valve

Claims (6)

(a) preparing a lamination member in which at least one low-pressure melamine sheet and at least one prepreg are laminated;
(b) providing a lower mold on the lower side of the lamination member;
(c) installing an upper mold on the upper side of the lamination member;
(d) installing a breather on the upper mold;
(e) installing a vacuum film on the upper side of the breather;
(f) sealing the portion where the vacuum film and the lower mold abut each other with a sealant;
(g) providing a vacuum valve between the vacuum film and the breather;
(h) using a vacuum pump connected to the vacuum valve to make a space in which the lower mold and the vacuum film are coupled to a vacuum state, and closing the vacuum valve to maintain the vacuum state; And
(i) after the step of maintaining the vacuum state, the composite laminate is manufactured through a curing process.
The method according to claim 1,
The step (i)
Heating at a temperature of 70 ° C to 90 ° C for 30 minutes to 60 minutes; And
And curing the laminate at a temperature of 110 to 140 degrees C for 75 to 120 minutes after the heating.
The method according to claim 1,
The step (a)
Stacking at least one prepreg above the low-pressure melamine sheet; And
And stacking the low-pressure melamine sheet onto the prepreg after lamination of the prepreg.
The method according to claim 1,
The step (a)
Wherein at least one prepreg is laminated on top of the low-pressure melamine sheet,
And forming a release member between the lamination member and the upper mold. ≪ RTI ID = 0.0 > 11. < / RTI >
The method according to claim 1,
The step (a)
And a low pressure melamine sheet laminated on at least one prepreg side,
And forming a release member between the lamination member and the lower mold. ≪ Desc / Clms Page number 20 >
A composite laminate produced by the manufacturing method according to any one of claims 1 to 5.

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