TWI627055B - Low-density fiber reinforced plastic composite plate and method for manufacturing the same - Google Patents

Abstract

The invention discloses a method for manufacturing a low-density fiber-reinforced plastic composite board, comprising the following steps: Firstly, a fiber prepreg is provided, which comprises a first fiber cloth and a resin adhered to the first fiber cloth a composition comprising a resin matrix and a plurality of lightweight filler materials dispersed in the resin matrix; then, a second fiber cloth is laminated on the fiber prepreg; The fiber prepreg and the second fiber cloth are heat-pressed so that a part of the resin composition on the fiber prepreg is uniformly permeated to the second fiber cloth to be cured to form a surface layer. Thereby, the weight problem of the composite material sheet applied to the electronic product can be improved.

Description

Low-density fiber reinforced plastic composite board and manufacturing method thereof

The invention relates to a composite material board and a manufacturing method thereof, in particular to a low density fiber reinforced plastic composite board and a manufacturing method thereof.

The pursuit of light, thin and short trends in consumer electronics is on the one hand to increase usability and on the other hand to reduce material costs. Take consumer electronics such as notebook computers and mobile phones as an example. The outer casing has evolved from a metal casing such as stainless steel to a light metal casing such as aluminum, magnesium or aluminum-magnesium alloy and a light plastic casing. Considering the structural strength, it develops later. A fiber-reinforced plastic shell (such as a fiber-reinforced plastic composite shell).

Composite materials are often used in comparison with metal materials in the application of consumer electronics. The comparative items include flexural modulus, deformation, weight ratio, and corresponding thickness. For example, fiber reinforced plastic composites can be achieved. Light weight reduction, but when the thickness of the sheet is thin, its modulus of flexural modulus and compression deformation are weaker than that of metal materials. It can be seen that how to reduce the weight of the structure under better structural performance design is the key to the upgrade of composite products.

In the prior art, the fiber cloth to be stacked is impregnated with a thermosetting resin, pre-baked into a fiber prepreg, and then cut and stacked layer by layer into a sheet, and then subjected to hot press forming. However, the fiber cloth is pre-impregnated with resin, pre-baked, cut, or even stacked, and the fiber cloth weave is easily deformed by external force, and this situation may affect the appearance when it occurs on the outer surface, especially around the fiber cloth. It is easier to deform due to improper external force pulling. At this time, it is necessary to cut off the appearance of the sputum, which causes waste of materials.

The technical problem to be solved by the present invention is to provide a method for manufacturing a low-density fiber-reinforced plastic composite panel which can optimize the existing process and has a low density, high structural strength and appearance. Additive.

In order to solve the above technical problem, one of the technical solutions adopted by the present invention is to provide a method for manufacturing a low-density fiber-reinforced plastic composite panel, which comprises the steps of: providing a fiber prepreg, the fiber prepreg is The first fiber cloth is composed of a resin composition adhered to the first fiber cloth, wherein the resin composition comprises a resin matrix and a plurality of lightweight filler materials dispersed in the resin matrix. And the lightweight filler material comprises between 10 and 50% by weight of the resin matrix; a second fiber cloth is laminated on the fiber prepreg; and the fiber prepreg and the first The two fiber cloths are subjected to hot pressing so that a part of the resin composition on the fiber prepreg is uniformly permeated to the second fiber cloth to be cured to form a surface layer.

In order to solve the above technical problem, another technical solution adopted by the present invention is to provide a low density fiber reinforced plastic composite panel comprising a fiber prepreg, a first surface layer and a second surface layer, The fiber prepreg has an upper surface and a lower surface, the first surface layer is formed on the upper surface, and the second surface layer is formed on the lower surface; wherein the fiber prepreg, the fiber The first surface layer and the second surface layer each comprise a resin matrix and a plurality of lightweight filler materials dispersed in the resin matrix, and the lightweight filler material accounts for 10 to 50 in the resin matrix. Between weight%.

In an embodiment of the invention, the lightweight filler material comprises between 30 and 35 weight percent of the resin matrix.

In an embodiment of the invention, the lightweight filler material comprises hollow glass microspheres.

In an embodiment of the invention, the hollow glass microspheres have a particle size of between 10 and 80 μm.

In an embodiment of the invention, the hollow glass microspheres have a particle size of between 20 and 50 μm.

In an embodiment of the invention, the first fiber cloth and the second fiber cloth comprise unidirectional or bidirectional woven glass fibers, carbon fibers, polyester fibers or aromatic polyamide fibers.

In an embodiment of the invention, the resin matrix is thermoset or thermoplastic.

In an embodiment of the invention, the thermosetting resin matrix is selected from the group consisting of unsaturated polyester (UP), epoxy resin (Epoxy), phenolic resin (PF), urea plastic (UF), and neodymium plastic ( SI), polyurethane (PU), polyimine (PI) or a combination thereof.

In an embodiment of the invention, the thermoplastic resin matrix is selected from the group consisting of acrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS), polycarbonate (PC), and polyethylene ( PE), acrylonitrile-styrene copolymer (AS), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamine (PA), polyethylene terephthalate Butylene glycol ester (PBT), polyetheretherketone (PEEK), polyamidoximine (PEI) or a combination thereof.

The invention has the beneficial effects of the method for manufacturing the low-density fiber-reinforced plastic composite board provided by the embodiment of the invention, which provides a fiber prepreg which is provided by the first fiber cloth and adhered to the first fiber cloth. The high-content resin composition is formed, and the second fiber cloth is laminated on the fiber prepreg, and then hot pressed to uniformly permeate a part of the resin composition on the fiber prepreg to the second fiber cloth. The manufacturing process simplifies the cumbersome and time-consuming steps to optimize the existing process; in addition, it avoids the problem of skewing the fiber web due to the wet impregnation method.

In view of the above, since the resin composition used in the method of the present invention contains an appropriate amount of a light filler material (or further contains other filler materials), the amount of the resin used can be reduced to achieve cost reduction.

Furthermore, the low-density fiber-reinforced plastic composite panel produced by the method of the invention can have both low density and high structural strength, and can be surface-treated as required. To make a thin and high-quality appearance.

For a better understanding of the features and technical aspects of the present invention, reference should be made to the accompanying drawings.

1‧‧‧Low density fiber reinforced plastic composite board

10‧‧‧Fiber prepreg

11‧‧‧First fiber cloth

12‧‧‧ hollow glass beads

13‧‧‧Foam material

S1‧‧‧ upper surface

S2‧‧‧ lower surface

20a‧‧‧First surface layer

20b‧‧‧Second surface layer

21‧‧‧Second fiber cloth

30‧‧‧Surface decorative layer

40‧‧‧heterogenous material layer

1 is a flow chart showing a method of manufacturing a low density fiber reinforced plastic composite panel of the present invention.

2 to 7 are schematic views showing the manufacturing process of the low-density fiber-reinforced plastic composite panel of the present invention.

The following is a description of an embodiment of the present invention relating to a "method of manufacturing a low-density fiber-reinforced plastic composite panel" by a specific embodiment, and those skilled in the art can understand the advantages and effects of the present invention from the contents disclosed in the specification. The present invention may be carried out or applied in various other specific embodiments, and various modifications and changes can be made without departing from the spirit and scope of the invention. In addition, the drawings of the present invention are merely illustrative and are not intended to be construed in terms of actual dimensions. The following embodiments will further explain the related technical content of the present invention, but the disclosure is not intended to limit the technical scope of the present invention.

Referring to FIG. 1 , a preferred embodiment of the present invention provides a method for manufacturing a low-density fiber reinforced plastic composite panel. The main steps include: step S100, providing a fiber prepreg, which is adhered to the first fiber cloth. a resin composition on the first fiber cloth; in step S102, the second fiber cloth is laminated on the fiber prepreg; and in step S104, the fiber prepreg and the second fiber cloth are hot pressed to pre-impregnate the fiber. A portion of the resin composition on the cloth was uniformly infiltrated into the second fiber cloth.

Referring to FIG. 2 to FIG. 4, in step S100, the fiber prepreg 10 is obtained by impregnating the first fiber cloth 11 with a high-content resin composition and baking it to form a semi-cured state of the resin composition. Cut the inner fabric made for a specific size. The first fiber cloth 11 may be made of unidirectional or bidirectional woven glass fiber, carbon fiber, polyester fiber or aromatic polyamide fiber (Kevlar), but is not limited thereto; it should be noted that depending on the function or specification of the product It is desirable that the fiber prepreg 10 can comprise a plurality of first fiber sheets 11 laminated together to achieve a desired thickness.

The resin composition comprises a resin matrix and a lightweight filler material dispersed in the resin matrix, wherein the lightweight filler material is between 10 and 50% by weight, preferably between 30 and 35% by weight, in the resin composition; In the resin composition, one or two or more kinds of lightweight fillers may be contained, and since the resin composition contains a light filler, the amount of the resin matrix used can be reduced and the overall density can be lowered.

Further, in practical applications, as shown in FIG. 3, the hollow glass microbeads 12 can be used alone as a lightweight filler material in the resin composition, and the hollow glass microbeads 12 have a particle diameter of 10 to 80 μm. Preferably, between 20 and 50 μm; if the particle diameter of the hollow glass microspheres 12 is too large, the compatibility between the hollow glass microspheres 12 and the resin is poor, and the hollow glass microspheres 12 are also limited. If the particle diameter of the hollow glass microspheres 12 is too small, the problem of agglomeration of the hollow glass microbeads 12 is liable to occur. Alternatively, as shown in FIG. 4, the hollow glass microbeads 12 and the foamed material 13 may be simultaneously used as a lightweight filler in the resin composition, thereby improving the toughness of the sheet and maintaining the structural strength, and specific examples of the foamed material 13. These include, but are not limited to, polystyrene foam, polyvinyl chloride foam, and polyurethane foam. The resin matrix may be thermosetting or thermoplastic. Specifically, specific examples of the thermosetting resin matrix include, but are not limited to, unsaturated polyester (UP), epoxy resin (Epoxy), phenolic resin (PF), and urea plastic (UF). , silicone plastic (SI), polyurethane (PU) and polyimine (PI); in addition, specific examples of thermoplastic resin matrix include, but are not limited to, acrylonitrile-butadiene-styrene copolymer (ABS), poly Styrene (PS), polycarbonate (PC), polyethylene (PE), acrylonitrile-styrene copolymer (AS), polymethyl methacrylate (PMMA), polyethylene terephthalate ( PET), polyamine (PA), polybutylene terephthalate (PBT), polyetheretherketone (PEEK) and polyamidoximine (PEI).

In step S102, the upper surface S1 and the lower surface S2 of the fiber prepreg 10 are covered. A second fiber cloth 21 is combined. In practical applications, the first fiber cloth 11 and the second fiber cloth 21 may be made of the same or different materials. For example, the second fiber cloth 21 may also be unidirectional or bidirectionally woven glass. Made of fiber, carbon fiber, polyester fiber or aromatic polyamide fiber (Kevlar), but is not limited thereto.

In step S104, the second fiber cloth 21 / fiber prepreg 10 / second fiber cloth 21 three-layer structure semi-finished product can be placed in a molding die (not shown) and hot pressed under appropriate temperature and pressure; It is worth noting that since the fiber prepreg 10 has a high content of the resin composition, a part of the resin composition is pressed during the hot pressing process and uniformly penetrates along the thickness direction of the fiber prepreg 10. The second fiber cloth 21 is infiltrated into the upper layer and the lower layer, and the low-density fiber-reinforced plastic composite panel 1 is obtained after the resin composition is cured. The detailed operating conditions for hot press forming can be adjusted according to the process requirements, so it will not be described in detail here.

Furthermore, the low-density fiber-reinforced plastic composite panel 1 comprises a fiber prepreg 10, a first surface layer 20a and a second surface layer 20b. The fiber prepreg 10 has an opposite upper surface S1 and a lower surface S2. The first surface layer 20a is formed on the upper surface S1 which is formed by curing of the second fiber cloth 21 having the upper layer of the resin composition, and the second surface layer 20b is formed on the lower surface S2 which is composed of the resin composition The lower second fiber cloth 21 is formed by curing, wherein the fiber prepreg 10, the first surface layer 20a and the second surface layer 20b each comprise a resin matrix and a lightweight filler material dispersed in the resin matrix, and are lightly filled. The material is comprised between 10 and 50% by weight of the resin composition, preferably between 30 and 35% by weight.

Referring to FIGS. 5 to 7, in order to impart a high-quality appearance to the low-density fiber-reinforced plastic composite panel 1, after completion of step S104, step S106 may be further performed to perform post-processing. Specifically, as shown in FIG. 5, the post-processing used in step S106 may be spraying, adhering or heat transferring, whereby the first surface layer 20a or the second surface is used. A surface decorative layer 30 is formed on the layer 20b; or, as shown in FIG. 6, the post-processing used in step S106 may be a plastic injection molding technique, that is, an engineering plastic such as polyethylene or polypropylene. The olefin, the nylon 6 or the like or the fiber-containing plastic composite material is directly injected on the surface of the first surface layer 20a or the second surface layer 20b, thereby forming a heterogeneous material layer 40 on the first surface layer 20a or the second surface layer 20b; Alternatively, as shown in FIG. 7, the post-processing used in step S106 may be to form a low-density fiber-reinforced plastic composite panel 1 (including press forming, hot press forming, mold forming, vacuum forming, etc.). A low-density fiber-reinforced plastic composite panel 1 of a specific shape is processed using the demand.

[Advantageous Effects of Embodiments]

A method for manufacturing a low-density fiber-reinforced plastic composite panel provided by an embodiment of the present invention, which provides a fiber prepreg which is a first fiber cloth and a high-content resin composition adhered to the first fiber cloth. The second fiber cloth is laminated on the fiber prepreg, and then hot pressed to uniformly permeate a part of the resin composition on the fiber prepreg to the second fiber cloth, which can be complicated and complicated. The time-consuming steps are streamlined to optimize the existing process; in addition, the problem of skewing of the fiber web due to the wet impregnation method can be avoided.

In view of the above, since the resin composition used in the method of the present invention contains an appropriate amount of a light filler material (or further contains other filler materials), the amount of the resin used can be reduced to achieve cost reduction.

Furthermore, the low-density fiber-reinforced plastic composite panel produced by the method of the invention can have both low density and high structural strength, and due to the material type and texture density of the fiber cloth and the hollow glass beads or light mixed in the resin. The proportion of the filling material can be adjusted according to its use, so it can meet the requirements of different specifications; the low-density fiber-reinforced plastic composite board can be surface-treated as needed to make a light and high-quality appearance. Pieces.

The above disclosure is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Therefore, any equivalent technical changes made by using the present specification and the contents of the drawings are included in the application of the present invention. Within the scope of the patent.

Claims (19)

A method for manufacturing a low-density fiber-reinforced plastic composite panel, comprising the steps of: providing a fiber prepreg comprising a first fiber cloth and a resin adhered to the first fiber cloth a composition, wherein the resin composition comprises a resin matrix and a plurality of lightweight filler materials dispersed in the resin matrix, the lightweight filler material is hollow glass microspheres, and the lightweight filler material accounts for Between 10 and 50% by weight of the resin composition; laminating a second fiber cloth on the fiber prepreg; and hot pressing the fiber prepreg and the second fiber cloth A portion of the resin composition on the fiber prepreg is uniformly infiltrated into the second fiber cloth to be cured to form a surface layer. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 1, wherein the lightweight filler material accounts for between 30 and 35 wt% of the resin composition. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 1, wherein the hollow glass microspheres have a particle diameter of between 10 and 80 μm. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 3, wherein the hollow glass microspheres have a particle diameter of between 20 and 50 μm. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 1, wherein the first fiber cloth and the second fiber cloth both comprise unidirectional or bidirectional woven glass fiber, carbon fiber, polyester fiber or aromatic Polyamide fiber. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 1, wherein the resin matrix is thermosetting or thermoplastic. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 6, wherein the thermosetting resin matrix is selected from the group consisting of unsaturated polyester (UP), epoxy resin (Epoxy), and phenolic resin (PF). Urea plastic (UF), neodymium plastic (SI), polyurethane (PU), polyimine (PI) or a combination thereof. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 6, wherein the thermoplastic resin matrix is selected from the group consisting of acrylonitrile-butadiene-styrene copolymer (ABS) and polystyrene (PS). , polycarbonate (PC), polyethylene (PE), acrylonitrile-styrene copolymer (AS), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyfluorene Amine (PA), polybutylene terephthalate (PBT), polyetheretherketone (PEEK), polyamidoximine (PEI), or a combination thereof. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 1, further comprising: post-processing the surface layer. The method for manufacturing a low-density fiber-reinforced plastic composite panel according to claim 1, further comprising: forming a layer of a heterogeneous material on the surface layer. The method for producing a low-density fiber-reinforced plastic composite panel according to claim 1, further comprising: molding the fiber prepreg and the second fiber cloth after the hot pressing. A low density fiber reinforced plastic composite panel comprising: a fiber prepreg having opposite upper and lower surfaces; a first surface layer, the first surface layer being formed on An upper surface; and a second surface layer formed on the lower surface; wherein the fiber prepreg, the first surface layer and the second surface layer each comprise a resin a substrate and a plurality of lightweight filler materials dispersed in the resin matrix, the lightweight filler material being hollow glass microspheres, and the lightweight filler material is between 10 and 50% by weight of the resin composition . The low-density fiber-reinforced plastic composite panel according to claim 12, wherein the lightweight filler material accounts for between 30 and 35 wt% of the resin composition. The low-density fiber-reinforced plastic composite panel according to claim 12, wherein the hollow glass microspheres have a particle diameter of between 10 and 80 μm. The low-density fiber-reinforced plastic composite panel according to claim 14, wherein the hollow glass microspheres have a particle diameter of between 20 and 50 μm. The low-density fiber-reinforced plastic composite panel according to claim 12, wherein the first fiber cloth and the second fiber cloth both comprise unidirectional or bidirectional woven glass fiber, carbon fiber, polyester fiber or aromatic polyamide fiber. The low density fiber reinforced plastic composite panel according to claim 12, wherein the resin matrix is thermosetting or thermoplastic. The low-density fiber-reinforced plastic composite panel according to claim 17, wherein the thermosetting resin matrix is selected from the group consisting of unsaturated polyester (UP), epoxy resin (Epoxy), phenolic resin (PF), and urea plastic. (UF), silicone plastic (SI), polyurethane (PU), polyimine (PI) or a combination thereof. The low-density fiber-reinforced plastic composite panel according to claim 17, wherein the thermoplastic resin matrix is selected from the group consisting of acrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS), and polycarbonate. Ester (PC), polyethylene (PE), acrylonitrile-styrene copolymer (AS), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamine (PA) ), polyethylene terephthalate (PBT), polyetheretherketone (PEEK), polyamidimide (PEI) or a combination thereof.