TWI732619B - Composite material structure and a forming method thereof - Google Patents

Abstract

The composite material structure of the present invention includes a first fiber layer, at least one flow-guiding middle layer and a second fiber layer, that are sequentially overlapped from top to bottom. The forming method thereof is first to overlay a second mold, the first fiber layer, at least one flow-guiding middle layer and the second fiber layer on a surface of a first mold from top to bottom, and then to cover and seal it with a vacuum plastic film. After the air in the space between the vacuum plastic film and the first mold is evacuated, the vacuum pressure is used to allow liquid resin to flow up and down through the at least one guide middle layer to soak the first and second fiber layers, while to allow the liquid resin to flow in a direction from a first end to the second end, and to close a feeding end after the liquid resin completely soaks the first fiber layer, to solidify the at least one flow -guiding middle layer and the second fiber layer, and finally to solidify and form the liquid resin.

Description

Composite material structure and its forming method

This creation is about a composite material structure and its forming method, especially a kind of composite material structure that can have high-quality surfaces on both the inner and outer sides of the composite material structure, so that it can be used as a product shell user with special needs.

At present, there are technologies on the market to harden a plurality of overlapping resin-containing carbon fiber cloths by heating and pressing to form a product shell, so that it has sufficient strength and reduces the weight and thickness of the product. Among them, Vacuum Assistant Resin Transfer Molding (Vacuum Assistant Resin Transfer Molding for short VARTM) is a closed-mold forming technology, which is mainly to spread multiple layers of carbon fiber or glass fiber dry cloth on the surface of the mold, and add a layer of release paper on top of the dry cloth. A layer of diversion mesh and diversion tube is added on the top of the release paper, and then covered and sealed with a vacuum plastic film along the periphery of the mold, so that after the space between the vacuum plastic film and the mold is evacuated, the vacuum pressure is used to make the resin Pour down the guide mesh to soak the dry cloth, and close the flow channel after the resin is completely impregnated with glass fiber cloth or carbon fiber cloth, and finally wait for the resin to solidify and form.

However, although the above-mentioned forming technology can effectively manufacture composite materials containing fiber cloth for use as a product shell, the surface of the product in contact with the mold will be delicate or smooth. The surface in contact with the release paper will be relatively rough. As a result, for shells that require high-quality surfaces on both the inner and outer sides, the conventional VARTM technology obviously cannot achieve the desired effect. In view of this, in order to improve the above shortcomings, the creators have accumulated years of experience and continuous research and development improvements, so this creation came into being.

One purpose of this creation is to provide a composite material structure and its molding method, so as to solve the problem that the conventional VARTM molding technology cannot make the inner and outer surfaces of the composite material product have high-quality surfaces. One end of a diversion middle layer is poured into, and then the liquid resin flows up and down respectively to soak different fiber layers separately, so as to form a composite material structure with high-quality surfaces on both the inner and outer sides. It is used for products with special needs.

In order to achieve the purpose of the above creation, the composite material structure set up in this creation mainly includes a first fiber layer, at least one flow guiding middle layer, and a second fiber layer that overlap from top to bottom. The first fiber layer has upper and lower layers. Connected first gap, the second fiber layer has a second gap connected up and down, the first gap and the second gap are respectively filled with cured resin, and the cured resin covers the first fiber layer and the second fiber respectively Layer; at least one flow guiding middle layer includes a first end transversely and a second end opposite to the first end, and at least one flow guiding middle layer has a plurality of channels connecting the first end and the second end, and a plurality of channels The first gap and the second gap are respectively connected, the multiple channels are filled with hardened resin, and the hardened resin covers at least one flow guiding middle layer.

In implementation, the first fiber layer and the second fiber layer respectively include multiple layers of dry fiber cloth, and the flow-guiding middle layer is a fiber cloth of chaotic fibers.

The molding method of the composite material structure set up in this creation mainly includes the following steps: a. Laying the first fiber layer, at least one intermediate layer and the second fiber layer from top to bottom in order On the surface of the first mold, add a second mold on top of the first fiber layer, and then cover and seal on the second mold with a vacuum plastic film along the circumference of the first mold, and at the same time allow at least one of the guide middle layer The first end is connected to the feed end to infuse resin, and the second end of the at least one guide middle layer is connected to the suction end to extract air; and b. After the space between the vacuum plastic film and the first mold is evacuated, a vacuum is used The pressure allows the liquid resin to flow upwards and downwards through at least one intermediate layer to soak the first fiber layer and the second fiber layer, while allowing the liquid resin to flow from the first end to the second end, and wait until the liquid resin is completely After impregnating the first fiber layer, at least one guide middle layer, and the second fiber layer, the feeding end is closed, and finally the liquid resin is waited for to be solidified and formed.

When implemented, this creation further includes a step of coating a release agent on the opposite surfaces of the first mold and the second mold respectively.

In order to facilitate a more in-depth understanding of this creation, I will elaborate on the following:

1: Composite material structure

2: The first fiber layer

21: The first gap

3: Diversion middle layer

31: first end

32: second end

33: Channel

4: The second fiber layer

41: second gap

5: The first mold

51: Mould Cavity

6: The second mold

7: Vacuum plastic film

8: Feeding end

9: suction side

Figure 1 is a three-dimensional cross-sectional view of a preferred embodiment of creating a composite material structure.

Figure 2 is a three-dimensional exploded view of the components of this creation before they are combined.

Figure 3 is a schematic diagram of the state of use of the creative composite material structure during molding.

Figure 4 is a partial enlarged view of part A of Figure 3.

Please refer to Figure 1, which is a preferred embodiment of the creative composite material structure 1, which includes a first fiber layer 2, a flow guiding middle layer 3, and a second fiber layered sequentially from top to bottom. Layer 4. The first fiber layer 2 and the second fiber layer 4 respectively include a plurality of layers of carbon fiber dry cloth overlapped on top of each other, and each carbon fiber dry cloth is a combination of a plurality of carbon fibers woven or unidirectional fibers. In this way, the first fiber layer 2 has a first gap 21 connected up and down, and the second fiber layer 4 has a second gap 41 connected up and down; in implementation, the fiber dry cloth can also be a plurality of glass fibers or Kevlar fibers. , Aramid fiber or Basalt fiber woven or unidirectional fiber combination. The first gap 21 and the second gap 41 are respectively filled with cured resin, and the cured resin covers the first fiber layer 2 and the second fiber layer 4, respectively. The flow guiding middle layer 3 is a fiber cloth of chaotic fibers, one of its lateral sides is used as the first end 31, and the other side in the opposite direction is used as the second end 32. The chaotic fiber structure of the flow guiding middle layer 3 forms a plurality of The plurality of channels 33 communicate with the first end 31 and the second end 32, and the plurality of channels 33 respectively communicate upwardly with the first gap 21 and downwardly communicate with the second gap 41. The plurality of channels 33 are filled with hardened Resin, and the cured resin covers the flow guiding intermediate layer 3.

Please refer to Figures 2~4. The molding method of this creative composite structure 1 mainly includes the following steps:

a. Lay the first fiber layer 2, the flow-guiding middle layer 3 and the second fiber layer 4 from top to bottom sequentially on the surface of the first mold 5, and add a second mold on top of the first fiber layer 2 6. A vacuum plastic film 7 is used to cover and seal the second mold 6 along the circumference of the first mold 5. At the same time, the first end 31 of the flow guiding intermediate layer 3 is connected to a feeding end 8 to infuse the resin. The second end 32 of the flow middle layer 3 is connected to a suction end 9 to extract air.

b. After the space between the vacuum plastic film 7 and the first mold 5 is evacuated, the vacuum pressure is used to allow the liquid resin to flow up and down through the guide intermediate layer 3, and respectively pass through the first gap 21 and the second gap 41. To soak the first fiber layer 2 and the second fiber layer 4, while allowing the liquid resin to flow from the first end 31 of the guide middle layer 3 toward the second end 32 through the plurality of channels 33, and wait for the liquid resin After the first fiber layer 2, the guide middle layer 3 and the second fiber layer 4 are completely impregnated, the feed end 8 is closed, and finally the liquid resin is waited for to be solidified and formed.

Among them, the first mold 5 of this embodiment is a master mold, which has a cavity 51, the surface of the first mold 5 at the position of the cavity 51 is coated with a release agent for demolding use, and the second mold 6 is For the metal bending plate, the lower surface of the metal bending plate 6 corresponds to the surface of the first mold 5 at the position of the mold cavity 51, and the lower surface of the metal bending plate 6 is also coated with a release agent. In this way, after the liquid resin is solidified and formed, the composite material structure 1 created by this invention can be formed, and after the film is released, the upper surface of the first fiber layer 2 and the lower surface of the second fiber layer 4 can be high. The surface of quality. In implementation, the above-mentioned first mold 5 can also be a protruding male mold, and the second mold 6 is a female mold for forming a metal bending plate, which can also form the composite material structure 1 created by this invention; in addition, the above-mentioned second mold 6 is also It can be flat, curved, wavy, or other shapes of bent plates. In terms of materials, it can be PE, PP, or a metal plate with a Teflon-containing surface to form different product shells. The flow guiding middle layer 3 can also be set to two layers, with a fiberboard sandwiched in between, and the first ends 31 of several flow guiding middle layers 3 can also be filled with resin to form the composite material structure 1 created by this invention.

In summary, based on the content disclosed above, this creation can indeed achieve the expected purpose, providing a composite material structure that can be molded with high-quality surfaces on both the inner and outer sides, which can be used as a product shell with special needs. Its forming method is of great value for industrial use. Yan filed an invention patent application in accordance with the law.

Although this creation discloses a better specific embodiment for achieving the above-mentioned purpose, it is not intended to limit the structural features of this creation. Any person with ordinary knowledge in the technical field should know that under the technical spirit of this creation, any easy thinking The changes or modifications are all possible, and they are all covered by the scope of patent application for this creation.

1: Composite material structure

2: The first fiber layer

21: The first gap

3: Diversion middle layer

31: first end

32: second end

33: Channel

4: The second fiber layer

41: second gap

Claims (7)

A composite material structure includes a first fiber layer, at least one flow guiding middle layer, and a second fiber layer that are sequentially overlapped from top to bottom, wherein the first fiber layer has a first gap connected up and down, The second fiber layer has a second gap connected up and down. The first gap and the second gap are respectively filled with a cured resin, and the cured resin is made to cover the first fiber layer and the second gap respectively. Two fiber layers; the at least one flow guiding middle layer includes a first end transversely and a second end opposite to the first end, and the at least one flow guiding middle layer has a connection between the first end and the second end A plurality of channels at the end, the plurality of channels respectively communicate with the first gap and the second gap, the plurality of channels are filled with the cured resin, and the cured resin covers the at least one flow guiding middle layer. According to the composite material structure described in item 1 of the scope of the patent application, the first fiber layer and the second fiber layer respectively comprise a plurality of layers of dry fiber cloth, and the flow-guiding middle layer is a fiber cloth with random fibers. A method for forming a composite material structure as described in item 1 or 2 of the scope of the patent application, comprising the following steps: a. The first fiber layer, the at least one flow guiding middle layer and the second fiber layer are from top to bottom Sequentially overlay on the surface of a first mold, add a second mold on top of the first fiber layer, and cover and seal on the second mold with a vacuum plastic film along the circumference of the first mold , While allowing the first end of the at least one flow guiding middle layer to communicate with a feed end to infuse resin, and the second end of the at least one flow guiding middle layer to communicate with a suction end to extract air, wherein the second mold It is a plate; and b. After the space between the vacuum plastic film and the first mold is evacuated, the vacuum pressure is used to allow the liquid resin to flow up and down through the at least one guide middle layer, and respectively pass The first gap and the second gap are used to soak the first fiber layer and the second fiber layer, and When the liquid resin flows from the first end to the second end, the feed end is closed after the liquid resin is completely impregnated with the first fiber layer, the at least one flow guiding middle layer and the second fiber layer, Finally, wait for the liquid resin to solidify and form. The method for forming a composite material structure as described in item 3 of the scope of the patent application, wherein the second mold is a flat plate. The method for forming a composite material structure as described in item 3 of the scope of patent application, wherein the second mold is a bent plate. The method for forming a composite material structure as described in item 3 of the scope of patent application, wherein the second mold is a metal plate. As described in item 3 of the scope of patent application, the method for forming a composite material structure further includes a step of coating a release agent on the opposite surfaces of the first mold and the second mold, respectively.

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