TWI773595B - A production method of a fiber composite material - Google Patents
A production method of a fiber composite material Download PDFInfo
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- TWI773595B TWI773595B TW110143227A TW110143227A TWI773595B TW I773595 B TWI773595 B TW I773595B TW 110143227 A TW110143227 A TW 110143227A TW 110143227 A TW110143227 A TW 110143227A TW I773595 B TWI773595 B TW I773595B
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Abstract
Description
本發明係有關於一種纖維複合材成品的製造方法。The present invention relates to a manufacturing method of a fiber composite material product.
碳纖維複合材憑藉其高強度、耐磨、耐腐蝕、耐高溫等多種性能 優勢,被廣泛的應用於多個領域。目前市面上碳纖維材品都是以碳纖維預浸材進行加工成形,所謂的碳纖維預浸材主要是以環氧樹脂之熱固性樹脂對碳纖維布先進行預浸為碳纖維預浸布,之後再將該碳纖維預浸布適型後加熱固化成型。Carbon fiber composite materials are widely used in many fields due to their high strength, wear resistance, corrosion resistance, high temperature resistance and other performance advantages. At present, carbon fiber products on the market are processed and formed by carbon fiber prepreg. The so-called carbon fiber prepreg mainly uses epoxy resin and thermosetting resin to pre-impregnate carbon fiber cloth into carbon fiber prepreg cloth, and then use the carbon fiber The prepreg is heated and cured after being shaped.
然而, 碳纖維預浸材因為選用的熱固環氧樹脂的特性,需要低溫保存且保存的期限有限的缺點,且在製造上還需事先將其軟化後才能進行加工塑形,導致具有加工流程繁多及生產成本高等問題。However, due to the characteristics of the selected thermosetting epoxy resin, the carbon fiber prepreg needs to be stored at low temperature and has a limited storage period, and it needs to be softened in advance before being processed and shaped, resulting in numerous processing procedures. and high production costs.
因此,有必要提供一種新穎且具有進步性之纖維複合材成品及其 製作方法,以解決上述之問題。Therefore, it is necessary to provide a novel and progressive fiber composite product and its manufacturing method to solve the above problems.
本發明之主要目的在於提供一種纖維複合材成品及其製作方法, 步驟簡單且可高效製造出三維的纖維複合材成品。The main purpose of the present invention is to provide a fiber composite material product and a manufacturing method thereof. The steps are simple and the three-dimensional fiber composite material product can be efficiently manufactured.
為達成上述目的,本發明提供一種纖維複合材成品之製造方法, 其包括以下步驟: 步驟1:提供一纖維乾布,該纖維乾布為可變形且未含浸任何樹脂的乾布狀態; 步驟2:置放該纖維乾布於一模具中,該模具包括一公模具及一母模具,該公模具設有一凸模,該母模具設有對應該凸模之一模穴,該纖維乾布於該模具中受力變形形成一三維結構,該纖維乾布在該模具中所形成的該三維結構上下不與該公模具的該凸模與該母模具之該模穴接觸,而維持於懸空的狀態;以及 步驟3:以射出成型的方式射入熱融之一樹脂材料至該模具之該間隙內一體結合於該纖維乾布並成型一三維之纖維複合材成品。 In order to achieve the above object, the present invention provides a manufacturing method of a fiber composite material product, which comprises the following steps: Step 1: Provide a dry fiber cloth that is deformable and not impregnated with any resin; Step 2: place the fiber dry cloth in a mold, the mold includes a male mold and a female mold, the male mold is provided with a punch, the female mold is provided with a cavity corresponding to the punch, the fiber dry cloth is A three-dimensional structure is formed by force and deformation in the mold, and the three-dimensional structure formed by the dry fiber cloth in the mold is not in contact with the cavity of the male mold and the female mold, but is maintained in a suspended state. ;as well as Step 3: inject a hot-melted resin material into the gap of the mold by means of injection molding, and integrate with the fiber dry cloth to form a three-dimensional fiber composite product.
其中,進一步該三維之纖維複合材成品包含超出該凸模與該模穴所框列範圍之一餘料,將該餘料除去。Wherein, further, the three-dimensional fiber composite material product contains a surplus material beyond the range framed by the punch and the mold cavity, and the surplus material is removed.
其中,該纖維乾布於該模具中受力變形是受地心引力鋪設或吸力變形於該凸模或該模穴以形成該三維結構。Wherein, the fiber dry cloth is deformed by force in the mold by being laid on the punch or the mold cavity by gravity or suction deformation to form the three-dimensional structure.
其中,該凸模與該模穴的表面分別延伸出適型的數個凸肋,即可用以支撐該纖維乾布維持於懸空的狀態以形成該三維結構。Wherein, the surfaces of the punch and the cavity are respectively extended with several convex ribs of suitable shape, which can be used to support the dry fiber cloth and maintain the suspended state to form the three-dimensional structure.
其中,該纖維乾布以多層層疊於該模具中,且每層的該纖維乾布的編織方法、排列方法或密度皆不同。Wherein, the dry fiber cloth is laminated in the mold in multiple layers, and the weaving method, arrangement method or density of the dry fiber cloth of each layer is different.
其中,該纖維乾布包含碳纖維乾布、玻璃纖維乾布、克維拉纖維乾布或聚酯纖維乾布。Wherein, the fiber dry cloth includes carbon fiber dry cloth, glass fiber dry cloth, Kevlar fiber dry cloth or polyester fiber dry cloth.
其中,該樹脂材料包括熱塑性聚氨酯(Thermoplastic polyurethane, TPU)、聚丙烯(Polypropylene, PP)、LCP塑膠原料(Liquid crystal polymer)、聚芳醚酮(polyetherketoneketone, PAEK) 、聚碳酸酯(Polycarbonate, PC)、聚碸(Polysulfone, PSU)或聚醚醚酮(poly-ether-ether-ketone, PEEK)。Wherein, the resin material includes thermoplastic polyurethane (Thermoplastic polyurethane, TPU), polypropylene (Polypropylene, PP), LCP plastic material (Liquid crystal polymer), polyaryletherketone (polyetherketoneketone, PAEK), polycarbonate (Polycarbonate, PC) , Polysulfone (Polysulfone, PSU) or polyether-ether-ketone (poly-ether-ether-ketone, PEEK).
其中,該射出成型的射壓範圍為30.00Mpa至300.00Mpa,達到以該樹脂材料厚度小於等於1.00mm進行射出。Wherein, the injection pressure range of the injection molding is 30.00Mpa to 300.00Mpa, so that the thickness of the resin material is less than or equal to 1.00mm for injection.
其中,該射出成型的射壓範圍為60.00Mpa至80.00Mpa,達到以該樹脂材料厚度小於等於0.50mm進行射出。Wherein, the injection pressure range of the injection molding is 60.00Mpa to 80.00Mpa, so that the thickness of the resin material is less than or equal to 0.50mm for injection.
為達成上述目的,本發明另提供一種使用如上述的方法製造之纖 維複合材成品,包括:一纖維層,其係該纖維乾布製成;及至少一樹脂層,各 該樹脂層一體連接於該纖維層,各該樹脂層係該熱融之樹脂材料固化成型;其 中,該纖維層與各該樹脂層係共構一預定立體結構。In order to achieve the above object, the present invention further provides a fiber composite product manufactured by the above method, comprising: a fiber layer, which is made of the fiber dry cloth; and at least one resin layer, each of which is integrally connected to the Fiber layers, each resin layer is formed by curing the hot-melting resin material; wherein, the fiber layer and each resin layer together form a predetermined three-dimensional structure.
本發明藉由直接使用纖維乾布取代既有的含浸材料,即可改善既有纖維預浸材因為選用的樹脂特性,需要低溫保存且保存的期限有限的缺點,且在製造上還需事先將其軟化後才能進行加工塑形,導致具有加工流程繁多及生產成本高等問題。By directly replacing the existing impregnating material with the fiber dry cloth, the present invention can improve the shortcomings of the existing fiber prepreg material, which needs to be stored at low temperature and has a limited storage period due to the selected resin characteristics, and also needs to be prepared in advance in manufacturing. It can only be processed and shaped after softening, which leads to the problems of numerous processing processes and high production costs.
進一步地,利用將纖維乾布懸空於該模具容置空間內部並兩面射出,達到高效率的樹脂分佈狀態與高品質的纖維複合材成品。Further, the fiber dry cloth is suspended in the mold accommodating space and injected from both sides, so as to achieve a high-efficiency resin distribution state and a high-quality fiber composite product.
為了更清楚地說明本發明實施例的技術方案,下面將對實施例描述中所需要使用的附圖作簡單的介紹。顯而易見地,下面描述中的附圖僅僅是本發明的一些示例或實施例,對於本領域的普通技術人員來講,在不付出創造性勞動的前提下,還可以根據這些附圖將本發明應用於其它類似情景。除非從語言環境中顯而易見或另做說明,圖中相同標號代表相同結構或操作。In order to illustrate the technical solutions of the embodiments of the present invention more clearly, the following briefly introduces the accompanying drawings that need to be used in the description of the embodiments. Obviously, the accompanying drawings in the following description are only some examples or embodiments of the present invention. For those of ordinary skill in the art, the present invention can also be applied to the present invention according to these drawings without any creative effort. other similar situations. Unless obvious from the locale or otherwise specified, the same reference numbers in the figures represent the same structure or operation.
如本發明和請求項書中所示,除非上下文明確提示例外情形,“一”、“一個”、“一種”和/或“該”等詞並非特指單數,也可包括複數。一般說來,術語“包括”與“包含”僅提示包括已明確標識的步驟和元素,而這些步驟和元素不構成一個排它性的羅列,方法或者設備也可能包含其它的步驟或元素。As shown in this specification and the claims, unless the context clearly dictates otherwise, the words "a", "an", "an" and/or "the" are not intended to be specific in the singular and may include the plural. Generally speaking, the terms "comprising" and "comprising" only imply that the clearly identified steps and elements are included, and these steps and elements do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.
請參考圖1,其顯示本發明之一較佳實施例,本發明之纖維複 合材成品之製造方法,包括以下步驟。Please refer to FIG. 1, which shows a preferred embodiment of the present invention, the manufacturing method of the fiber composite material product of the present invention, including the following steps.
步驟S1):提供一纖維乾布10,該纖維乾布10為可變形且未含浸任何樹脂的乾布狀態。該纖維乾布10可直接透過外力包含但不限於壓力、地心引力、吸力等產生形變。於本實施例中該纖維乾布10可以是碳纖維乾布、玻璃纖維乾布、克維拉(Kevlar)纖維乾布或聚酯纖維(Polyester)乾布;Step S1): providing a
步驟S2):請一併同時參考圖2~4A,置放該纖維乾布10 於一模具20中,該模具20包括一公模具22及一母模具23,該公模具22設有一凸模 24,該母模具23設有對應該凸模24之一模穴25,該纖維乾布10於該模具20中受力變形形成一三維結構12,舉例說明,該纖維乾布10可鋪設變形(或受地心引力變形、吸力)於該凸模24或該模穴25以形成該三維結構12,或該纖維乾布10亦可置於該公模具22及該母模具23之間並受該公模具22下壓而變形但不限於此,於該公模具22及該母模具23合模時,該三維結構12與該凸模24及該模穴25之間分別形成一間隙21,重要的是該纖維乾布10在該模具20中所形成的該三維結構12上下不與該公模具22的該凸模 24與該母模具23之該模穴25接觸,而維持於懸空的狀態,如此可選擇讓該樹脂材料30一體結合於該纖維乾布10的雙側包覆;及Step S2): Please refer to FIGS. 2 to 4A together, and place the fiber
進一步地,一併參考圖4B,本發明使該三維結構12上下不與該公模具22的該凸模 24與該母模具23之該模穴25接觸並形成該間隙21的另一方法可以是該凸模24與該模穴25的表面分別延伸出適型的數個凸肋28,即可用以支撐該纖維乾布10維持於懸空的狀態。Further, referring to FIG. 4B , another method of the present invention to prevent the three-
進一步地,本發明其它較佳實施例是該纖維乾布10以多層層疊於該模具10中,且可能的每層的該纖維乾布10的編織方法、排列方法與密度可能不同,達到不同的成品特性。Further, another preferred embodiment of the present invention is that the
步驟S3:如圖5~7所示,以射出成型的方式射入熱融之一樹脂材料30至該模具20之該間隙21內一體結合於該纖維乾布10並成型一三維之纖維複合材成品1。具體地說,該樹脂材料30可於該公模具22的一公模澆道26與該母模具23的一母模澆道27注入兩側之該間隙21;也就是說,僅以該模具20及簡化的加工步驟成型該三維之纖維複合材成品1,具有高製造效率且低製造成本的優點。如此,三維之該纖維複合材成品1基本可分類似三明治結構之中間層該纖維乾布10與兩外側之該樹脂材料。Step S3 : as shown in FIGS. 5 to 7 , inject a hot-melted
步驟S4 (可選地):若該三維之纖維複合材成品1包含超出該凸模24與該模穴25所框列範圍之一餘料1’’,則可適應性的採取切割手段將該餘料1’’部分除去。Step S4 (optional): If the three-dimensional fiber
具體地說,如圖7、8所示,該纖維乾布10初始係由複數纖維乾絲束11彼此相互編織而成,令該複數纖維乾絲束11定位。該複數纖維乾絲束11包括複數未含浸的碳纖維乾絲束或複數未含浸的玻璃纖維乾絲束或該複數碳纖維乾絲束及該複數玻璃纖維乾絲束。接著透過本發明前述製程步驟射出該樹脂材料30一體結合於複數該纖維乾絲束11,故該纖維乾布10與固化成型之該樹脂材料30之間具有高結合強度,且該樹脂材料30可以融入該纖維乾布10兩側面的該複數纖維乾絲束11間形成高度含浸的狀態,增加該三維之纖維複合材成品1的結構強度與耐久性,不易產生樹脂纖維分層的問題。Specifically, as shown in FIGS. 7 and 8 , the
該樹脂材料30一體熔接於該纖維乾布10,且該樹脂材料30包覆該 纖維乾布10,以簡易的步驟製造該三維之纖維複合材成品1且該樹脂材料30及該 纖維乾布10結合強度高;該樹脂材料30固化與該纖維乾布10相互結合共構一預定立體結構40,該預定立體結構40係對應該凸模24及該模穴25的結構;進一步說明,圖7係裁切掉纖維複合材成品1之該餘料1’’的部分之纖維複合材成品 1’。The
該樹脂材料30包括選自熱塑性聚氨酯(Thermoplastic polyurethane, TPU)、聚丙烯(Polypropylene, PP)、LCP塑膠原料(Liquid crystal polymer)、聚芳醚 酮(polyetherketoneketone, PAEK) 、聚碳酸酯(Polycarbonate, PC)、聚碸(Polysulfone, PSU)及聚醚醚酮(poly-ether-ether-ketone, PEEK)所組成之群組之 一材料,該射出成型的射壓範圍為30.00Mpa至300.00Mpa,可達到以樹脂材料30 厚度小於等於1.00mm進行充填。較佳地,該樹脂材料為聚丙烯(Polypropylene, PP),該射出成型的射壓範圍為60.00Mpa至80.00Mpa,故射出壓力中等利於充填且可達到以該樹脂材料30厚度小於等於0.50mm完全充填。The
進一步地,如圖8所示本發明提供一種使用如上所述的方法製造之纖維複合材成品, 包括:一纖維層13及至少一樹脂層14。該纖維層13係該纖維乾布10製成;至少一樹脂層14,各該樹脂層 14一體連接於該纖維層13,各該樹脂層14係該熱融之樹脂材料30固化成型,於本實施例中各該樹脂層14係熔接於該纖維層13之表面;其中,該纖維層13與各該樹脂層14係共構該預定立體結構40。Further, as shown in FIG. 8 , the present invention provides a fiber composite product manufactured by the above-mentioned method, comprising: a
綜上,本發明之纖維複合材成品及其製造方法,其係以纖維乾布 置放於該模具中,注入熱融之樹脂材料至該模具內,令該樹脂材料一體結合於 該纖維乾布並共同成型該三維纖維複合材成品,以簡化加工步驟,具有高製造 效率且成本低。To sum up, the finished fiber composite material of the present invention and the manufacturing method thereof are arranged by placing the fiber dry cloth in the mold, and injecting a hot-melt resin material into the mold, so that the resin material is integrally combined with the fiber dry cloth and together. The finished product of the three-dimensional fiber composite material is formed to simplify the processing steps, with high manufacturing efficiency and low cost.
以上一些實施例中使用了描述成分、屬性數量的數字,應當理解的是,此類用於實施例描述的數字,在一些示例中使用了修飾詞“大約”、“近似”或“大體上”來修飾。除非另外說明,“大約”、“近似”或“大體上”表明所述數字允許有±20%的變化。相應地,在一些實施例中,說明書和請求項中使用的數值參數均為 近似值,該近似值根據個別實施例所需特點可以發生改變。在一些實施例中,數值參數應考慮規定的有效數位並採用一般位數保留的方法。儘管本發明一些實施例中用於確認其範圍廣度的數值域和參數為近似值,在具體實施例中,此類數值的設定在可行範圍內盡可能精確。In some of the above embodiments, numbers describing the quantity of components and attributes are used, and it should be understood that such numbers used for the description of the embodiments use the modifiers "about", "approximately" or "substantially" in some examples to modify. Unless stated otherwise, "about", "approximately" or "substantially" means that a variation of ±20% is allowed for the stated number. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximations that may vary depending upon the desired characteristics of individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and use a general digit reservation method. Notwithstanding that the numerical fields and parameters used in some embodiments of the invention to confirm the breadth of their ranges are approximations, in particular embodiments such numerical values are set as precisely as practicable.
S1~S4:步驟
1, 1’:纖維複合材成品
1’’:餘料
10:纖維乾布
11:纖維乾絲束
12:三維結構
13:纖維層
14:樹脂層
20:模具
21:間隙
22:公模具
23:母模具
24:凸模
25:模穴
26, 27:澆道
28:凸肋
30:樹脂材料
40:預定立體結構
S1~S4:
本發明將以示例性實施例的方式進一步說明,這些示例性實施例將通過附圖進行詳細描述。這些實施例並非限制性的,在這些實施例中,相同的編號表示相同的結構,其中: 圖1為本發明一較佳實施例之製造流程之方塊圖。 圖2 為本發明的纖維乾布一較佳實施例示意圖。 圖3為本發明該模具與該纖維乾布一較佳實施例之一剖面圖。 圖4A、圖4B、圖5為本發明該模具數個較佳實施例剖面圖。 圖6為本發明該模具完成該纖維複合材料成品之較佳實施例示意圖。 圖7為本發明一較佳實施例之纖維複合材成品。 圖8為圖7之局部放大圖。 The present invention will be further illustrated by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These examples are not limiting, and in these examples, the same numbers refer to the same structures, wherein: FIG. 1 is a block diagram of a manufacturing process of a preferred embodiment of the present invention. Figure 2 is a schematic diagram of a preferred embodiment of the fiber dry cloth of the present invention. 3 is a cross-sectional view of a preferred embodiment of the mold and the fiber dry cloth of the present invention. 4A, 4B, and 5 are cross-sectional views of several preferred embodiments of the mold of the present invention. FIG. 6 is a schematic diagram of a preferred embodiment of the mold of the present invention to complete the finished fiber composite material. FIG. 7 is a finished fiber composite material according to a preferred embodiment of the present invention. FIG. 8 is a partial enlarged view of FIG. 7 .
S1-S4:步驟 S1-S4: Steps
Claims (8)
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Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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CN201136315Y (en) * | 2007-12-12 | 2008-10-22 | 黄春樱 | Structure for composite wood combining plastic material |
TWM415799U (en) * | 2011-04-18 | 2011-11-11 | Liang-An Wei | Structure of composite plastic molding body |
CN102470583A (en) * | 2010-03-26 | 2012-05-23 | 三菱重工塑胶科技有限公司 | Method for manufacturing a fiber-reinforced composite material |
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Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN201136315Y (en) * | 2007-12-12 | 2008-10-22 | 黄春樱 | Structure for composite wood combining plastic material |
CN102470583A (en) * | 2010-03-26 | 2012-05-23 | 三菱重工塑胶科技有限公司 | Method for manufacturing a fiber-reinforced composite material |
TWM415799U (en) * | 2011-04-18 | 2011-11-11 | Liang-An Wei | Structure of composite plastic molding body |
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