TWI758030B - 無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法及其製品 - Google Patents

無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法及其製品 Download PDF

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TWI758030B
TWI758030B TW109145992A TW109145992A TWI758030B TW I758030 B TWI758030 B TW I758030B TW 109145992 A TW109145992 A TW 109145992A TW 109145992 A TW109145992 A TW 109145992A TW I758030 B TWI758030 B TW I758030B
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halogen
fiber
reinforced polymer
polymer composite
retardant thermoplastic
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TW109145992A
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TW202224899A (zh
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呂嘉陽
巫昇炎
蕭奕文
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科森複合材料股份有限公司
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Priority to TW109145992A priority Critical patent/TWI758030B/zh
Priority to CN202110820310.8A priority patent/CN114670504A/zh
Priority to US17/458,822 priority patent/US11691354B2/en
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Publication of TW202224899A publication Critical patent/TW202224899A/zh

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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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Abstract

一種無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，至少包括以下步驟：準備具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料的回收料；對所述回收料添加高分子基材原料並以低剪切力押出機押出成型；經滾輪熱壓成型獲得回收纖維芯層；準備由具有眾多孔隙之纖維材或織物所構成的補強層；將所述回收纖維芯層與所述補強層層疊熱壓複合成型，使所述回收纖維芯層的無鹵阻燃熱塑性纖維強化高分子複合材料滲入所述補強層的眾多孔隙中，以形成兩種材料層相互交聯的無鹵阻燃熱塑性編織型纖維強化高分子複合板。

Description

無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法及其製品
本發明是有關於一種無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法及其製品。
現今使用的以纖維補強的高分子複合材料（纖維複合材料，簡稱纖維複材）具有良好的力學性質，如高強度、低密度等，並廣泛應用於航太、鐵路、機械製造、建築等多個領域。其中，使纖維複材具有阻燃性，從而提高安全性和減少火災損失，是目前纖維複材的重要發展方向。
此外，隨著纖維複材被大量且多元應用於各領域，此類生產過程中所產生的餘廢料及結束生命週期的纖維複材產品，其回收問題已不容忽視。面對環境和立法的壓力以及逐漸提高的填埋費用，傳統掩埋及焚燒的處理方式勢必已面臨淘汰，如何將纖維複材廢棄物進行有效的回收與循環利用成為重要的課題。
本發明所要解決的技術問題在於：如何將纖維複合材料廢料進行有效的回收與循環利用，且回收利用再製之複合板仍具有良好的阻燃性及力學性質。
因此，本發明提供一種無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，包括至少包括以下步驟：步驟(A)，準備具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料的回收料；步驟(B)，於所述步驟(A)之後，對所述回收料添加高分子基材原料並以低剪切力押出機押出成型；步驟(C)，於所述步驟(B)之後，經滾輪熱壓成型獲得回收纖維芯層；步驟(D)，於所述步驟(C)之後，準備由具有眾多孔隙之纖維材或織物所構成的補強層；以及步驟(E)，於所述步驟(D)之後，將所述回收纖維芯層與所述補強層層疊熱壓複合成型，使所述回收纖維芯層的無鹵阻燃熱塑性纖維強化高分子複合材料滲入所述補強層的眾多孔隙中，以形成兩種材料層相互交聯的無鹵阻燃熱塑性編織型纖維強化高分子複合板。
於本發明的一實施例，所述步驟(A)中，具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料之廢料尺寸為20~40 mm。
於本發明的一實施例，所述步驟(B)中，高分子基材原料為熱塑性樹脂。
於本發明的一實施例，所述步驟(B)中，所述熱塑性樹脂為聚碳酸酯。
於本發明的一實施例，所述步驟(B)中，所述熱塑性樹脂為新料或回收料，且所述回收料不含無機纖維或無機粉體。
於本發明的一實施例，所述步驟(B)中，所述低剪切力押出機的螺桿轉速介於20~80 rpm，且押出溫度介於200~280℃。
於本發明的一實施例，所述步驟(B)中，所述低剪切力押出機的螺桿之螺距介於10~15 cm，且螺溝深度為20 mm。
於本發明的一實施例，所述步驟(C)中，所述滾輪熱壓成型的滾輪溫度介於50~200℃，且滾輪間隙介於0.5~2 mm。
於本發明的一實施例，所述步驟(C)中，所述回收纖維芯層的纖維長度介於5~20 mm，且厚度介於0.3~1.2 mm。
此外，本發明另提供一種無鹵阻燃熱塑性編織型纖維強化高分子複合板，包括：一回收纖維芯層以及至少一補強層。該回收纖維芯層係由回收而得之具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料之回收料所構成。該至少一補強層係由具有眾多孔隙之纖維材或織物所構成的網狀體，並具有一第一側與一相反該第一側的第二側。該回收纖維芯層與該至少一補強層相互層疊熱壓複合成型，使該回收纖維芯層的無鹵阻燃熱塑性編織型纖維強化高分子複合材料滲入該至少一補強層的眾多孔隙中，且該回收纖維芯層的至少一部分係包覆在該至少一補強層的該第一側上，以形成兩種材料層相互交聯的複合板。
基於上述，本發明所提供的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法及其製品藉由具有無鹵阻燃熱塑性高分子材料的回收料經一定加工程序後製成回收纖維芯層，並與補強層複合成型為板材，將纖維複合材料廢棄物進行有效地回收與循環利用。此外，回收纖維芯層的纖維長度介於5~20 mm，能夠具有優異的機械強度，並仍具阻燃等級UL94 V0 （1/32英吋試片厚度）。
為讓本發明的上述特徵和優點能更明顯易懂，下文特舉實施例，並配合所附圖式作詳細說明如下。
請參照圖1，本實施例的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，至少包括以下步驟：步驟(A)，準備具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料的回收料；步驟(B)，於所述步驟(A)之後，對所述回收料添加高分子基材原料並以低剪切力押出機押出成型；步驟(C)，於所述步驟(B)之後，經滾輪熱壓成型獲得回收纖維芯層；步驟(D)，於所述步驟(C)之後，準備由具有眾多孔隙之纖維材或織物所構成的補強層；以及步驟(E)，於所述步驟(D)之後，將所述回收纖維芯層與所述補強層層疊熱壓複合成型，使所述回收纖維芯層的無鹵阻燃熱塑性纖維強化高分子複合材料滲入所述補強層的眾多孔隙中，以形成兩種材料層（回收纖維芯層與補強層）相互交聯的無鹵阻燃熱塑性編織型纖維強化高分子複合板。
前述步驟(A)中，具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料之廢料能夠為板材，且尺寸為20~40 mm。
前述步驟(B)中，高分子基材原料能夠為熱塑性樹脂。進一步地，所述熱塑性樹脂能夠為聚碳酸酯（Polycarbonate, PC），且所述熱塑性樹脂能夠為新料（Virgin Resin）或回收料（Recycled Resin），且所述回收料不含無機纖維如：玻璃纖維、碳纖維等或無機粉體。所述低剪切力押出機的螺桿轉速能夠介於20~80 rpm，且押出溫度能夠介於200~280℃。低剪切力押出機的螺桿之螺距能夠介於10~15 cm，且螺溝深度能夠為20 mm。
前述步驟(C)中，所述滾輪熱壓成型的滾輪溫度能夠介於50~200℃，且滾輪間隙能夠介於0.5~2 mm。所述回收纖維芯層的纖維長度能夠介於5~20 mm，厚度能夠介於0.3~1.2 mm，且押出成型時與押出機方向平行，故其機械強度優於市售短纖維板材，且仍符合阻燃等級UL94 V0 （1/32英吋試片厚度）。此外，如圖2所示的回收纖維芯層實品外觀圖，因其高纖維含量而具有美觀的大理石紋路外觀。
前述步驟(D)中，補強層的補強材原材料結構：可分為補強材型態及補強材種類，其中補強材型態結構能夠為：編織纖維布（Woven Fabrics）、不織布（Non-Woven Fabrics）、單向纖維布（Uni-Direction Fabrics）、多軸多層織物（Multiaxial Multilayer Warp Knitting；MMWK or Non-crimp Fabrics）其中任一或其組合式所構成。至於補強材種類能夠為：石墨纖維、石墨烯纖維、碳纖維、玻璃纖維、陶瓷纖維、硼纖維、硼氮纖維、氮化矽纖維、礦鹽纖維，其中任一者或任二者以上互相編織或不織布型態或單一方向纖維布運用。
請參照圖3至圖5，為經前述製造方法步驟(A)～(E)所製成之無鹵阻燃熱塑性編織型纖維強化高分子複合板1，包括：回收纖維芯層10以及至少一補強層20。回收纖維芯層10能夠由回收而得之具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料之回收料經前述製造方法步驟(A)～(C)所構成。至少一補強層20能夠為前述製造方法步驟(D)所述由具有眾多孔隙之纖維材或織物所構成的網狀體，且至少一補強層20具有一第一側21與一相反第一側21的第二側22。如圖5所示，回收纖維芯層10與至少一補強層20能夠如前述製造方法步驟(E)相互層疊熱壓複合成型，使回收纖維芯層10的無鹵阻燃熱塑性編織型纖維強化高分子複合材料滲入至少一補強層20的眾多孔隙中，且回收纖維芯層10的至少一部分係包覆在至少一補強層20的第一側21上，以形成兩種材料層（回收纖維芯層10與補強層20）相互交聯的複合板。
於本實施例中，無鹵阻燃熱塑性編織型纖維強化高分子複合板1能夠由一層回收纖維芯層10以及兩層位於回收纖維芯層10之相反兩側的補強層20相互層疊熱壓複合成型，即兩層補強層20位於第一層及第三層，回收纖維芯層10位於第二層之三明治結構。可以理解地，回收纖維芯層10以及補強層20也能夠以不同之疊層搭配及以不同加工形態形成無鹵阻燃熱塑性編織型纖維強化高分子複合板1，並不侷限於本實施例所揭示之層數或層疊態樣。
綜上所述，本發明所提供的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法及其製品，藉由具有無鹵阻燃熱塑性高分子材料的回收料經一定加工程序後製成回收纖維芯層10，並與補強層20複合成型為板材，將纖維複合材料廢棄物進行有效地回收與循環利用。此外，回收纖維芯層10的纖維長度介於5~20 mm，能夠具有優異的機械強度，並仍具阻燃等級UL94 V0 （1/32英吋試片厚度）。
雖然本發明已以實施例揭露如上，然其並非用以限定本發明，任何所屬技術領域中具有通常知識者，在不脫離本發明的精神和範圍內，當可作些許的更動與潤飾，故本發明的保護範圍當視後附的申請專利範圍所界定者為準。
1:無鹵阻燃熱塑性編織型纖維強化高分子複合板 10:回收纖維芯層 20:補強層 21:第一側 22:第二側 A～E:步驟
圖1是使用本發明無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法的流程圖。 圖2是回收纖維芯層的實品外觀圖。 圖3是本發明無鹵阻燃熱塑性編織型纖維強化高分子複合板的外觀示意圖。 圖4是圖3所示無鹵阻燃熱塑性編織型纖維強化高分子複合板的爆炸示意圖。 圖5是圖3以一點鍊線圈選處的放大示意圖。
A~E:步驟

Claims (10)

  1. 一種無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，至少包括以下步驟：步驟(A)，準備具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料的回收料；步驟(B)，於所述步驟(A)之後，對所述回收料添加高分子基材原料並以低剪切力押出機押出成型；步驟(C)，於所述步驟(B)之後，經滾輪熱壓成型獲得回收纖維芯層；步驟(D)，於所述步驟(C)之後，準備由具有眾多孔隙之纖維材或織物所構成的補強層；以及步驟(E)，於所述步驟(D)之後，將所述回收纖維芯層與所述補強層層疊熱壓複合成型，使所述回收纖維芯層的無鹵阻燃熱塑性纖維強化高分子複合材料滲入所述補強層的眾多孔隙中，以形成兩種材料層相互交聯的複合板。
  2. 如請求項1所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(A)中，具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料之廢料尺寸為20~40mm。
  3. 如請求項1所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(B)中，高分子基材原料為熱塑性樹脂。
  4. 如請求項3所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(B)中，所述熱塑性樹脂為聚碳酸酯。
  5. 如請求項3所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(B)中，所述熱塑性樹脂為新料或回收料，且所述回收料不含無機纖維或無機粉體。
  6. 如請求項1所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(B)中，所述低剪切力押出機的螺桿轉速介於20~80rpm，且押出溫度介於200~280℃。
  7. 如請求項1所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(B)中，所述低剪切力押出機的螺桿之螺距介於10~15cm，且螺溝深度為20mm。
  8. 如請求項1所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(C)中，所述滾輪熱壓成型的滾輪溫度介於50~200℃，且滾輪間隙介於0.5~2mm。
  9. 如請求項1所述的無鹵阻燃熱塑性編織型纖維強化高分子複合板之製造方法，其中所述步驟(C)中，所述回收纖維芯層的纖維長度介於5~20mm，且厚度介於0.3~1.2mm。
  10. 一種無鹵阻燃熱塑性編織型纖維強化高分子複合板，其係以如請求項1至9中任一項之方法製造，包括：一回收纖維芯層，其係由回收而得之具有無鹵阻燃熱塑性編織型纖維強化高分子複合材料之回收料所構成；以及至少一補強層，其係由具有眾多孔隙之纖維材或織物所構成的網狀體，該至少一補強層具有一第一側與一相反該第一側的第二側；該回收纖維芯層與該至少一補強層相互層疊熱壓複合成型，使該回收纖維芯層的無鹵阻燃熱塑性編織型纖維強化高分子複合材料滲入該至少一補強層的眾多孔隙中，且該回收纖維芯層的至少一部分係包覆在該至少一補強層的該第一側上，以形成兩種材料層相互交聯的複合板。
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