TW202000441A - Multi-material composite - Google Patents

Abstract

The present invention is related to a multi-material composite, comprising at least one thermosetting composite body and at least one welding portion. Each thermosetting composite body comprises at least one thermosetting composite layer containing fibers that have been impregnated with a thermosetting resin. The welding portion is applied onto at least one surface of the thermosetting composite body and comprises thermoplastic materials. In another embodiment, the multi-material composite further comprises at least one metallic layer adhering to the welding portion and/or the thermosetting composite body. The multi-material composite of the present invention simultaneously retains rigidity of the thermosetting resin and processability of the thermoplastic resin, so that the composite can be treated with various post-processing treatments and thus can be broadly applied to various fields.

Description

Multi-material composite board

The invention relates to a multi-material composite board, in particular to a composite board capable of providing diversified strength and meeting post-processing requirements, thereby improving the application field and scope of composite materials.

Fiber composite materials have the advantages of light weight, high strength, high modulus, etc., and have been widely used in sports equipment, aviation and automotive industries. Because fiber composite materials are divided into two categories: thermosetting and thermoplastic, thermosetting resins include epoxy resin, phenolic resin, polyurethane (PU), polyethylene terephthalate (PET), etc., and thermoplastic resins include polycarbonate (PC), Polypropylene (PP), polyamide (PA), polyurethane (PU), polyethylene terephthalate (PET), etc.

According to processability and physical properties considerations: thermosetting resin has high strength but long processing time; thermoplastic resin has high processing temperature and short time but low strength, so if you want to have both production speed and material characteristics, generally you must combine them in materials. Two or more materials.

In the prior art, if a carbon fiber composite material plate is to be implanted on the sole of the sports shoe to increase the elasticity of the sports shoe, the manufacturing method includes first impregnating the carbon fiber with the same thermoplastic resin as the shoe material, and then laminating it to the desired thickness, Hot pressed into a thermoplastic carbon fiber composite material board, and then the molded thermoplastic carbon fiber composite material board is cut into the shape of the sole design, and finally the sole is formed by injection or compression to form a high elastic sole, but this high elastic sole Only possible with the advantages of thermoplastic resin.

Moreover, due to the impregnation technology of thermoplastic carbon fiber composite materials, its strength is lower than that of thermosetting materials, and there will be bulging delamination on the surface after thermal processing. Therefore, there is currently a need to develop a production technology for double-effect composite boards with high strength and easy post-processing.

Taiwan Patent No. M470753 discloses a composite material structure, which includes a plurality of reinforcing fiber layers and a resin body covering the reinforcing fiber layers, wherein the resin body may be a thermoplastic resin or a thermosetting resin, which is pressed by hot pressing The reinforcing fiber layers and the resin body are combined to form a fiber-reinforced plate. However, this patent does not use both thermoplastic resin and thermosetting resin, so it is impossible to balance the characteristics of thermoplastic resin and thermosetting resin.

As mentioned in the prior art of Taiwan Patent No. M362111, the use of thermosetting resins as prepreg resins has such shortcomings as long curing time and poor adhesion, so the fiber cloths impregnated with thermoplastic resins are used instead, and then laminated after stacking To reinforce the fiber laminate, the fiber laminate is combined with the injection material. However, as mentioned above, although the processing time of the thermoplastic resin is short, the strength is lower than that of the thermosetting material, and the effect of impregnating the fiber is not good, which may cause surface defects such as bulging during the injection process.

Taiwan Patent No. M538876 discloses a single fiber prepreg material with metallic properties, which includes a fiber layer and a metal layer of a plurality of fiber stacks, the metal materials are integrated with the plurality of fiber stacks in a staggered stacking manner, and each layer of fiber is impregnated with Thermosetting resin or thermoplastic resin, thermoplastic plastic. However, this patent also does not use thermoplastic resin and thermosetting resin at the same time, so it is impossible to balance the characteristics of thermoplastic resin and thermosetting resin. Moreover, the post-processing processes of such single fiber prepregs with metallic properties are drilling, riveting, and locking screws , Welding, can not be applied to injection processing.

Taiwan Patent No. I304321 discloses a fiber partially impregnated with thermosetting resin and partly impregnated with thermoplastic resin, in which the resin of the thermoplastic resin layer appears in the gap between the multiple filaments constituting the reinforcing fiber group. In addition, the thermosetting resin The interface between the layer and the thermoplastic resin layer has a state of unevenness. By the presence of the uneven-shaped interface containing a plurality of monofilaments, the thermosetting resin layer and the thermoplastic resin layer can be firmly joined. Therefore, the patent is to join the thermosetting resin layer and the thermoplastic resin layer by the "concave-convex interface containing multiple monofilaments".

In summary, the disadvantage of thermosetting resin materials is that they take a long time to cure, they cannot be reshaped after curing, and they are incompatible with the materials of shoe materials, home appliances, and 3C products. Therefore, it is difficult to use them at the same time or perform subsequent processing. Therefore, it is currently necessary to find a composite material that allows thermosetting resin materials and thermoplastic resin materials to be used simultaneously, taking into account the rigidity of thermosetting resins and the ease of processing of thermoplastic resins.

The purpose of the present invention is to provide a multi-material composite board with adjustable strength and beneficial to post-processing requirements.

The present invention provides a multi-material composite board, which includes: at least one thermosetting composite material body, each thermosetting composite material body including at least one thermosetting composite material layer, each thermosetting composite material layer including fibers impregnated with thermosetting resin; and at least one welding portion, It is arranged on at least one side of the thermosetting composite material body, and the welding part includes a thermoplastic material.

The invention provides a method for manufacturing a multi-material composite board, which comprises: providing fibers and impregnating them with thermosetting resin to obtain a thermosetting composite material layer; using a single thermosetting composite material layer or stacking a plurality of thermosetting composite material layers, and Forming a thermosetting composite material body; providing a welding material, applying it to at least one side of at least one of the above thermosetting composite material bodies, to form a laminate, wherein the welding material includes a thermoplastic material; and heating and pressing the laminate to make The laminate is joined to obtain the multi-material composite board.

The present invention also provides a multi-material composite board, which includes: at least one thermosetting composite material body, each thermosetting composite material body including at least one thermosetting composite material layer, each thermosetting composite material layer including fibers impregnated with thermosetting resin; at least one welding part, It is disposed on at least one side of the thermosetting composite material body, and the welding part includes a thermoplastic material; and at least one metal layer, which is followed by the welding part and/or the thermosetting composite material body.

The present invention also provides a method for manufacturing a multi-material composite board, which includes: providing fibers and impregnating them with thermosetting resin to obtain a thermosetting composite material layer; using a single thermosetting composite material layer or stacking a plurality of thermosetting composite material layers, Forming a thermosetting composite material body; providing a welding material and a metal, applying the welding material to at least one surface of the at least one thermosetting composite material body, and then superimposing the metal on the welding material and/or the thermosetting composite material body, and A laminate is formed, wherein the welding material includes a thermoplastic material; and the laminate is joined by heating and pressing the laminate to obtain the multi-material composite board.

The present invention adjusts the properties of the obtained composite board by matching the thermosetting resin and the thermoplastic material together, so that the composite board takes into account the rigidity of the thermosetting resin and the ease of processing of the thermoplastic resin, thereby making the composite board suitable for various Processing process (including plastic injection molding, metal joint welding, glue pressing and other processing), so it can be widely used in various fields. In particular, the invention can solve the problems of long thermosetting resin molding time and poor strength and impregnation effect of thermoplastic materials. Therefore, the composite board obtained by the present invention can be widely used in consumer products such as sports shoes, protective gear, medical aids, etc., which can greatly reduce production costs and improve product performance.

The present invention can be more easily understood by referring to this detailed description and the examples included herein. Several specific details are set forth in order to provide a thorough understanding of the examples described herein. However, those of ordinary skill in the art should understand that the examples described herein can be practiced without these specific details. In other cases, methods, procedures and components have not been described in detail in order to avoid confusion about the relevant features described. Furthermore, the description is not to be regarded as limiting the scope of examples.

Unless otherwise stated in the text, in this specification (especially in the scope of patent applications described later), the use of "a", "the" and similar terms should be understood to include both singular and plural forms. In addition, for the sake of clarity, the dimensions of each element and area may be exaggerated in the drawings, but not shown in actual proportions.

It should be understood that any numerical range cited in this specification is intended to include all sub-ranges contained therein. For example, the range from "30 to 55" includes all sub-ranges between the stated minimum value 30 and the stated maximum value 55 (such as from 31 to 52, 33 to 49, or 42 to 51, etc.) and includes both values, That is, the range including the minimum value equal to or greater than 30 and the maximum value equal to or less than 55 is included. Because the range of values revealed is continuous, they contain every value between the minimum and maximum values. Unless otherwise stated, the various numerical ranges indicated in this specification are approximate values.

In addition, in this article, it is assumed that all numerical values are modified by the term "about", which means that, as expected by those skilled in the art, the purpose of measurement and operation and measurement and the accuracy of the measurement equipment used are of concern The quantity matching the quantity measures the change.

1 and 2, the present invention provides a multi-material composite board, which includes: at least one thermosetting composite material body (10), each thermosetting composite material body (10) includes at least one thermosetting composite material layer, each thermosetting composite The material layer includes fibers (12) impregnated with thermosetting resin (11); wherein each thermosetting composite material body (10) may include a single thermosetting composite material layer or be composed of a single thermosetting composite material layer; or, each thermosetting composite material body (10 ) May include or consist of a plurality of thermosetting composite material layers, the types of fibers and thermosetting resins used in each thermosetting composite material layer may be the same or different; and at least one welding part (20), which is provided On part or all of at least one side of the thermosetting composite material body (10), the welded portion (20) includes, consists essentially of, or consists of a thermoplastic material.

The invention provides a method for manufacturing the above-mentioned multi-material composite board, which comprises: providing fibers and impregnating them with thermosetting resin to obtain a thermosetting composite material layer; using a single thermosetting composite material layer or stacking a plurality of thermosetting composite material layers in a stacked configuration Stack to the required thickness to form a thermosetting composite material body, the thermosetting composite material layers can be stacked without the use of adhesives, and when a plurality of thermosetting composite material layers are used, the fibers and the fibers used in each thermosetting composite material layer and The types of thermosetting resins can be the same or different; provide a welding material and apply it to at least one part or all of at least one side of the above-mentioned thermosetting composite material body to form a laminate, wherein the welding material includes a thermoplastic material, or substantially Composed of a thermoplastic material or a thermoplastic material; and heating and pressurizing the laminate so that the fusion material and the thermosetting resin of the thermosetting composite body reach crosslinking or melting temperature to join the laminate, To obtain the multi-material composite board, the temperature and pressure of heating and pressing can be adjusted according to the type and content of the welding material and the thermosetting resin, wherein the cross-linking temperature and time of the resin depend on the glass transition temperature (Tg) of the resin, Therefore, the heating temperature must reach the Tg point, and the pressurized pressure is adjusted to the value that can achieve the adhesion effect according to different materials.

Referring to FIG. 3, the present invention further provides a multi-material composite board, which includes: at least one thermosetting composite material body (10), each thermosetting composite material body includes at least one thermosetting composite material layer, and each thermosetting composite material layer includes impregnation Fibers (12) of thermosetting resin (11); wherein each thermosetting composite material body (10) may comprise or consist of a single thermosetting composite material layer; or, each thermosetting composite material body (10) contains plural thermosetting materials The composite material layer may be composed of a plurality of thermosetting composite material layers, and the types of fibers and thermosetting resins used in each thermosetting composite material layer may be the same or different; at least one welding part (20), which is provided on the thermosetting composite material layer Part or all of at least one side of (10), the welded portion (20) includes a thermoplastic material, consists essentially of a thermoplastic material, or consists of a thermoplastic material; and at least one metal layer (30), which is followed by The welded portion (20) and/or the thermoset composite body (10).

In this embodiment, the multi-material composite board can be applied to carbon fiber reinforced steel pipes, carbon fiber high-pressure gas cylinders, etc. For example, the former can be attached to SS400 steel pipes to reinforce the strength of corroded steel pipes. After testing, the 6-inch (6'') steel pipe reinforcement The back pressure can reach about 210kg/cm ² .

The invention provides a method for manufacturing the above-mentioned multi-material composite board, which comprises: providing fibers and impregnating them with thermosetting resin to obtain a thermosetting composite material layer; using a single thermosetting composite material layer or stacking a plurality of thermosetting composite material layers in a stacked configuration Stack to the required thickness to form a thermosetting composite material body, the thermosetting composite material layers can be stacked without the use of adhesives, and when a plurality of thermosetting composite material layers are used, the fibers and the fibers used in each thermosetting composite material layer and The types of thermosetting resins can be the same or different; provide welding materials and metals, superimpose the welding materials on part or all of at least one side of the thermosetting composite material body, and then superimpose the metals on the welding materials and/or the thermosetting composites Forming a laminate on the body of the material, wherein the welded material includes a thermoplastic material, consists essentially of a thermoplastic material, or consists of a thermoplastic material; and heat and pressurize the laminate to make the welded material and the thermoset composite The thermosetting resin of the material body reaches the crosslinking or melting temperature to join the laminate to obtain the multi-material composite board, wherein the temperature and pressure of heating and pressurizing can be adjusted according to the type of the welding material and the thermosetting resin, wherein the resin The cross-linking temperature and time depends on the glass transition temperature (Tg) of the resin, so the heating temperature must reach the Tg point, and the pressure of the press is adjusted to the value that can achieve the adhesion effect according to different materials.

In the present invention, the fibers include, but are not limited to, carbon fibers, glass fibers, kevlar fibers, basalt fibers, high-strength polyester fibers, cotton and hemp, or other natural fibers or other fibers that can be applied in the field as needed.

In the present invention, the thermosetting resin is selected according to the required strength of the multi-material composite board. The thermosetting resin includes but is not limited to epoxy resin, phenolic resin, polyurethane (PU), polyethylene terephthalate ( PET) etc. or a combination thereof, for example, T700 carbon yarn is impregnated with 37wt.% epoxy resin, and its bending stress and modulus are about 900MPa and about 60Gpa, respectively.

In the present invention, the thermosetting resin accounts for more than about 45 wt.% of the thermosetting composite material layer, preferably about 45 wt.% to about 70 wt.%, and more preferably about 45 wt.% Up to about 60 wt.%, more preferably about 45 wt.% to about 55 wt.%; the fiber system occupies less than about 55 wt% of the thermosetting composite layer, preferably 30 wt.% to About 55 wt.%, preferably about 40 wt.% to about 55 wt.%, more preferably about 45 wt.% to about 55 wt.%. The fiber content of the multi-material composite board of the present invention is designed according to the use function, and does not require high fiber content (high fiber has the disadvantage of high rigidity). The use of materials needs to match the human body movement function in order to exert comfort and enhancement effects.

In the present invention, the thickness of the thermosetting composite material body is related to product design, so the thickness of the thermosetting composite material body is not limited.

In the present invention, the welding part/welding material includes a thermoplastic material, consists essentially of a thermoplastic material, or consists of a thermoplastic material.

In the present invention, the type of the thermoplastic material can be selected according to the adhesion effect with the subsequent processing materials, including but not limited to polycarbonate (PC), polypropylene (PP), polyamide (PA), polyurethane (PU) ), polyethylene terephthalate (PET), thermoplastic composite materials, etc. or a combination thereof, wherein the thermoplastic composite material (such as polycarbonate/acrylonitrile-butadiene-styrene copolymer (PC-ABS )) It can be a commercially available thermoplastic composite material, such as polycarbonate/acrylonitrile-butadiene-styrene copolymer (PC-ABS), in which the content, ratio and additives of each component are provided by each manufacturer Depending on the product.

In the present invention, the thickness of the welded portion or the thickness of the welded material applied to at least one of the above thermosetting composite material bodies can be controlled in the range of about 0.1 to about 5 mm, preferably in the range of about 0.25 mm to about 3.0 mm, and more It is preferably in the range of about 0.25 mm to about 1.0 mm.

In the present invention, the metal can be a variety of metal materials, which can be selected according to needs, such as but not limited to stainless steel, aluminum alloy, magnesium aluminum alloy or other metal materials, which can select the desired metal material according to its application, For example, 3C products can use magnesium aluminum alloy.

In one embodiment, the welded portion (20) can be disposed on opposite sides of a thermoset composite body (10) (as shown in FIGS. 1 and 3), which can be covered by different post-processing requirements or product requirements Part or all of the surface of the thermoset composite material body (10), so when the composite board includes a metal layer (30), the metal layer (30) may be only connected to the welded portion (20), or partially welded to the welded portion The portion (20) is next, and the portion is in contact with and/or next to the thermosetting composite body (10). In this embodiment, the thermosetting composite material body (10) can be combined with the metal layer (30) and cured, thereby exerting strength characteristics, and then attached to the welded portion (20) by post-processing, so the composite of the present invention The board exerts the characteristics of thermosetting and metal materials.

In another embodiment, the welding part (20) may be sandwiched between two thermosetting composite material bodies (10) (as shown in FIG. 4), but at least part of the welding part (20) is exposed to facilitate subsequent welding, The position, size and shape of the surface of the welding part (20) available for welding can be determined according to different designs (such as product types and requirements).

In the present invention, the multi-material composite board can be made into any shape according to different applications, such as, but not limited to, bar type and tube type. Example Example 1 ( Manufacturing method of reinforced bottom plate for bicycle shoe )

Carbon fiber is impregnated with epoxy resin to obtain a thermosetting composite body with an epoxy resin content of about 45wt.%, and then the thermosetting composite body is laminated with a 0.25mm polyurethane (PU) film to form a laminate And then put it into a vulcanizing machine (150°C temperature is maintained for 30 minutes) to cure and strengthen into a reinforced plate, cut and punch the obtained reinforced version into the shape required by the sole, and finally put it into the molding machine to make it strengthened Bottom plate.

After that, the reinforced bottom plate can complete the production of bicycle shoes according to the general shoe-making procedures. Example 2

Examples 2a to 2c provide the manufacture of multi-material composite boards for high-elastic badminton shoes, safety toe caps, 3C casings, etc., and the manufacturing method is roughly the same as that of Example 1, except that the thermosetting composite material layer and the material of the welding part And the thickness and other parameters. The parameters and the efficacy data of each example are shown in Table 1 below.

In addition, taking the 3C case as an example, the existing 3C case only uses thermosetting resin, and does not mix thermosetting resin and thermoplastic resin, and it needs to open the mold and press it one by one, which is inefficient. However, if the composite board of the present invention is used for production, it can be made into a large-area board, which is cut out and then processed by injection, so the speed can be greatly increased and the cost can be reduced. Moreover, the strength of the composite board of the present invention has the same material as the same material. The strength of the aluminum-magnesium alloy plate is the same (such as the amount of compressive deformation: the deformation of the load of 20kg is less than 5mm). Example 3 ( medical wheelchair )

Carbon fiber is impregnated with epoxy resin to obtain a thermosetting composite body with an epoxy resin content of about 45wt.%, and then a thermosetting composite body with a thickness of 1.0 mm, a 0.1 mm polyurethane (PU) film and carbon steel ( JIS- S20C ) superimposed to form a composite, and then heated and pressurized at a temperature of about 155°C and a pressure of about 12 kg/cm ² for about 30 minutes to join the composite to obtain the multi-material composite Finally, according to the required size, style and function, the medical wheelchair can be made. Detailed parameters and efficacy data are also shown in Table 1. Table 1

The technical features and advantages of the present disclosure have been summarized quite broadly above, so that the detailed description of the invention below can be better understood. Other technical features and advantages that constitute the subject of the patent application scope of the present disclosure will be described below. Those of ordinary skill in the technical field to which the present invention pertains should understand that the concepts and specific embodiments disclosed below can be easily used to modify or design other structures or processes to achieve the same purpose as the present invention. Those with ordinary knowledge in the technical field to which the present invention belongs should also understand that such equivalent structures and methods still belong to the spirit and scope of the present invention defined by the appended patent application scope.

10‧‧‧thermosetting composite body 11‧‧‧thermosetting resin 12‧‧‧fiber 20‧‧‧‧welding part 30‧‧‧metal layer

FIG. 1 is a side view of a multi-material composite board including a thermosetting composite material body and a welded portion of the present invention.

2 is a schematic diagram of the thermosetting composite material body of the present invention.

3 is a side view of an embodiment of a multi-material composite board including a thermosetting composite material body, a welded portion, and a metal layer according to the present invention.

FIG. 4 is a side view of another embodiment of a multi-material composite board including a thermosetting composite material body, a welded portion, and a metal layer according to the present invention.

10‧‧‧thermosetting composite body

11‧‧‧thermosetting resin

12‧‧‧ Fiber

20‧‧‧welding department

Claims (17)

A multi-material composite board, comprising: at least one thermosetting composite material body, each thermosetting composite material body including at least one thermosetting composite material layer, each thermosetting composite material layer including fibers impregnated with thermosetting resin; and at least one welding part, which is provided On at least one side of the thermosetting composite material body, the welded portion includes a thermoplastic material. A multi-material composite board, comprising: at least one thermosetting composite material body, each thermosetting composite material body including at least one thermosetting composite material layer, each thermosetting composite material layer including fibers impregnated with thermosetting resin; at least one welding portion, which is provided in At least one side of the thermosetting composite material body, the welding part includes a thermoplastic material; and at least one metal layer, which is followed by the welding part and/or the thermosetting composite material body. The multi-material composite board according to claim 1 or 2, wherein the fiber is selected from carbon fiber, glass fiber, kevlar fiber, basalt fiber, high-strength polyester fiber or cotton and linen. The multi-material composite board according to claim 1 or 2, wherein the thermosetting resin is selected from epoxy resin, phenol resin, polyurethane (PU), polyethylene terephthalate (PET), or a combination thereof. Multi-material composite board as claimed in claim 1 or 2, wherein the thermoplastic material is selected from polycarbonate (PC), polypropylene (PP), polyamide (PA), polyurethane (PU), polyethylene terephthalate Diester (PET), thermoplastic composite material or a combination thereof. The multi-material composite board according to claim 1 or 2, wherein the thermosetting resin accounts for about 45 wt.% to about 70 wt.% of the thermosetting composite material layer, and the fiber accounts for about 30 wt.% to about 70 wt.% of the thermosetting composite material layer 55wt.%. The multi-material composite board according to claim 1 or 2, wherein the thickness of the welded portion is in the range of about 0.1 to about 5 mm. The multi-material composite board according to claim 2, wherein the metal is stainless steel, aluminum alloy or magnesium aluminum alloy. A method for manufacturing a multi-material composite board, comprising: providing fibers and impregnating them with thermosetting resin to obtain a thermosetting composite material layer; using a single thermosetting composite material layer or stacking a plurality of thermosetting composite material layers to form a thermosetting material A composite material body; providing a welding material, applying it to at least one side of at least one of the above thermosetting composite material bodies to form a laminate, wherein the welding material includes a thermoplastic material; and heating and pressing the laminate to cause the laminate To join the multi-material composite board. A method for manufacturing a multi-material composite board, comprising: providing fibers and impregnating them with thermosetting resin to obtain a thermosetting composite material layer; using a single thermosetting composite material layer or stacking a plurality of thermosetting composite material layers to form a thermosetting material Composite material body; providing a welding material and a metal, applying the welding material to at least one side of the at least one thermosetting composite material body, and then laminating the metal on the welding material and/or the thermosetting composite material body to form a laminate , Wherein the welding material includes a thermoplastic material; and the laminate is joined by heating and pressing the laminate to obtain the multi-material composite board. The method according to claim 9 or 10, wherein the pressurization of the laminate by heating causes the fusion bonding material and the thermosetting resin of the thermosetting composite body to reach a crosslinking or melting temperature to join the laminate. The method of claim 9 or 10, wherein the fiber is selected from carbon fiber, glass fiber, kevlar fiber, basalt fiber, high-strength polyester fiber, or cotton and linen. The method of claim 9 or 10, wherein the thermosetting resin is selected from epoxy resin, phenol resin, polyurethane (PU), polyethylene terephthalate (PET), or a combination thereof. The method of claim 9 or 10, wherein the thermoplastic material is selected from polycarbonate (PC), polypropylene (PP), polyamide (PA), polyurethane (PU), and polyethylene terephthalate ( PET), thermoplastic composite materials or a combination thereof. The method of claim 9 or 10, wherein the thermosetting resin accounts for about 45 wt.% to about 70 wt.% of the thermosetting composite material layer, and the fiber accounts for about 30 wt.% to about 55 wt.% of the thermosetting composite material layer . The method of claim 9 or 10, wherein the fusion-bonding material is applied to at least one of the above-mentioned thermosetting composite material bodies in a thickness ranging from about 0.1 to about 5 mm. The method of claim 10, wherein the metal is stainless steel, aluminum alloy, or magnesium aluminum alloy.

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