WO2022016764A1 - 一种热塑性轻质复合材料及其制备方法 - Google Patents

一种热塑性轻质复合材料及其制备方法 Download PDF

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WO2022016764A1
WO2022016764A1 PCT/CN2020/131528 CN2020131528W WO2022016764A1 WO 2022016764 A1 WO2022016764 A1 WO 2022016764A1 CN 2020131528 W CN2020131528 W CN 2020131528W WO 2022016764 A1 WO2022016764 A1 WO 2022016764A1
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thermoplastic
continuous fiber
composite material
fibers
resin layer
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PCT/CN2020/131528
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English (en)
French (fr)
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高峰
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汉达精密电子(昆山)有限公司
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
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    • B32B17/067—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of fibres or filaments
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Definitions

  • the invention relates to the technical field of composite materials, in particular to a thermoplastic lightweight composite material and a preparation method thereof.
  • the composite material Due to the excellent mechanical properties of the composite material, it can also be used in the casing of electronic and electrical equipment and information equipment such as notebook computers, tablet notebooks, mobile phones, portable information terminals, cameras, etc., and has played a role in thinning the casing and reducing the weight of the equipment. .
  • thermoplastic composite products used in electronic appliances, automobiles, sports equipment and other products are made of full carbon fiber, carbon fiber and glass fiber composite sheet for molding, and the density of thermoplastic full carbon fiber composite sheet is 1.40-1.60g/cm 3 , The density of carbon fiber and glass fiber composite sheet is 1.60-1.80g/cm 3 .
  • the modulus and rigidity are high enough, the weight of the product is still heavy, which is not in line with the current development direction of lightweight.
  • thermoplastic lightweight composite material it is necessary to develop a thermoplastic lightweight composite material and its preparation method to solve the above problems.
  • An object of the present invention is to provide a thermoplastic lightweight composite material, which can ensure that the composite material is light in weight and has high strength and high modulus.
  • thermoplastic lightweight composite material comprising:
  • thermoplastic resin at least two continuous fiber layers, each of which is composed of continuous fibers impregnated with thermoplastic resin
  • At least one composite resin layer which is hot-pressed and formed between the two continuous fiber layers, and the composite resin layer is composed of wood fibers and chopped carbon fibers impregnated with thermoplastic resin;
  • both ends of the at least two continuous fiber layers and the at least one composite resin layer are bent to form a U-shaped structure.
  • thermoplastic resin is one of polyethylene, polypropylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, polyester, polyoxymethylene, polyamide, and polyphenylene ether.
  • the continuous fibers in the continuous fiber layer are unidirectional carbon fibers or woven carbon fibers.
  • the continuous fibers in the continuous fiber layer are at least one of carbon fibers, glass fibers, and aramid fibers.
  • the number of single filaments in the fiber yarn bundle of the continuous fiber layer is 3000.
  • the density of the wood fiber is 0.6g/cm 3 -0.9g/cm 3
  • the length of the chopped carbon fiber is 0.2cm-3cm.
  • the continuous fiber layer and the composite resin layer are cut into a size of 350mm*255mm.
  • the thickness of the continuous fiber layer is 0.2 mm, and the thickness of the composite resin layer is 1 mm.
  • the present invention also provides a method for preparing a thermoplastic lightweight composite material, comprising the following steps:
  • S1 prepare at least two continuous fiber layers, each of which is composed of continuous fibers impregnated with thermoplastic resin;
  • S2 preparing at least one composite resin layer, the composite resin layer is composed of wood fibers and chopped carbon fibers impregnated with thermoplastic resin;
  • S3 Lay at least one composite resin layer between at least two continuous fiber layers to form a laminated material, and the at least two continuous fiber layers and both ends of the at least one composite resin layer are bent to form a U-shaped structure;
  • thermoplastic resin is one of polyethylene, polypropylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, polyester, polyoxymethylene, polyamide, and polyphenylene ether.
  • thermoplastic lightweight composite material of the present invention and the preparation method thereof, by using a composite resin layer of wood fiber and chopped carbon fiber impregnated with thermoplastic resin as an intermediate layer, and using continuous fiber layers impregnated with thermoplastic resin on both surface layers of the intermediate layer, have the following characteristics:
  • the density of the board after hot pressing can reach 0.9-1.2g/cm 3 , and the usage amount of carbon fiber, glass fiber, etc. can be reduced, and the cost can be reduced.
  • the preparation process is simple, the operation of alternately laying continuous fiber layers and composite resin layers is simple and convenient, and composite materials of different thicknesses can be formed; in addition, the whole process can be automated processing, the production cycle is short, and the operation efficiency is high.
  • FIG. 1 is a schematic structural diagram of the thermoplastic lightweight composite material provided by the present invention.
  • Fig. 2 is a flow chart of the preparation method of the thermoplastic lightweight composite material of the present invention.
  • FIG. 1 is a schematic structural diagram of the thermoplastic lightweight composite material provided by the present invention.
  • thermoplastic lightweight composite material 100 provided by the present invention includes:
  • each of the continuous fiber layers 110 is composed of continuous fibers impregnated with thermoplastic resin
  • At least one composite resin layer 120 which is hot-pressed and formed between the two continuous fiber layers 110, and the composite resin layer 120 is composed of wood fibers and chopped carbon fibers impregnated with thermoplastic resin;
  • both ends of the at least two continuous fiber layers and the at least one composite resin layer are bent to form a U-shaped structure.
  • thermoplastic resin is one of polyethylene, polypropylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, polyester, polyoxymethylene, polyamide, and polyphenylene ether.
  • the continuous fibers in the continuous fiber layer 110 are unidirectional carbon fibers or woven carbon fibers.
  • the continuous fibers in the continuous fiber layer 110 are at least one of carbon fibers, glass fibers, and aramid fibers.
  • the number of single filaments in the fiber yarn bundle of the continuous fiber layer 110 is 3000.
  • the density of the wood fiber is 0.6g/cm 3 -0.9g/cm 3
  • the length of the chopped carbon fiber is 0.2cm-3cm.
  • the continuous fiber layer 110 and the composite resin layer 120 are cut into a size of 350mm*255mm.
  • the thickness of the continuous fiber layer 110 is 0.2 mm, and the thickness of the composite resin layer 120 is 1 mm.
  • FIG. 2 is a flow chart of the method for preparing the thermoplastic lightweight composite material of the present invention.
  • each of the continuous fiber layers 110 is composed of continuous fibers impregnated with thermoplastic resin
  • S2 preparing at least one composite resin layer 120, the composite resin layer 120 is composed of wood fibers and chopped carbon fibers impregnated with thermoplastic resin;
  • S3 Lay at least one composite resin layer 120 between at least two continuous fiber layers 110 to form a laminate, and bend both ends of the at least two continuous fiber layers 110 and the at least one composite resin layer 120 to form a U-shaped structure;
  • thermoplastic resin in the steps S1 and S2 is one of polyethylene, polypropylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, polyester, polyoxymethylene, polyamide, and polyphenylene ether. kind.
  • the two carbon fiber layers 110 impregnated with thermoplastic resin and the composite resin layer 120 of wood fiber and chopped carbon fiber impregnated with thermoplastic resin are cut to a size of 350mm*255mm, wherein the number of filaments in the fiber bundle of the carbon fiber layer 110 is 3000 root, the density of the wood fiber is 0.6g/cm 3 -0.9g/cm 3 , and the length of the chopped carbon fiber is 0.2cm-3cm; according to the order of the carbon fiber layer 100, the composite resin layer 120 and the carbon fiber layer , and the two ends of the at least two continuous fiber layers 110 and the at least one composite resin layer 120 are bent to form a U-shaped structure, wherein the corresponding thicknesses of each stack are 0.2 mm (carbon fiber layer 110 ), 1 mm (composite resin layer 120 ) layer 120) and 0.2mm (carbon fiber layer 110); first heat the pressing mold of the hot press to 220°C, then send the stacked laminated material into the hot pressing mold and position it, and close the hot pressing mold Press
  • thermoplastic lightweight composite material and the preparation method thereof of the present invention are composed of a composite resin layer of wood fiber and chopped carbon fiber impregnated with thermoplastic resin as the middle layer, and two layers of the middle layer are used for the composite resin layer.
  • the surface layer uses a continuous fiber layer impregnated with thermoplastic resin, which has the following technical effects:
  • the density of the board after hot pressing can reach 0.9-1.2g/cm 3 , and the usage amount of carbon fiber, glass fiber, etc. can be reduced, and the cost can be reduced.
  • the preparation process is simple, the operation of alternately laying continuous fiber layers and composite resin layers is simple and convenient, and composite materials of different thicknesses can be formed; in addition, the whole process can be automated processing, the production cycle is short, and the operation efficiency is high.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及一种热塑性轻质复合材料及其制备方法，所述热塑性轻质复合材料包括：至少两连续纤维层，各所述连续纤维层由含浸热塑性树脂的连续纤维组成；至少一复合树脂层，其热压成型于所述两连续纤维层之间，所述复合树脂层由含浸热塑性树脂的木质纤维、短切碳纤维组成；其中，所述至少两连续纤维层与所述至少一复合树脂层的两端弯曲形成一U型结构。利用本发明的热塑性轻质复合材料及其制备方法，可使热压成型后的复合材料密度可以达到0.9-1.2g/cm3，并且具有高强度和高模量的性能，以及还可以减少碳纤维、玻璃纤维等的使用量，降低了成本。

Description

一种热塑性轻质复合材料及其制备方法 【技术领域】
本发明涉及复合材料技术领域，尤其涉及一种热塑性轻质复合材料及其制备方法。
【背景技术】
随着笔记电脑、平板笔记本、便携式电话、便携式信息终端或相机等电子电气设备、信息设备的发展，市场上强烈要求开发出薄型且轻质的产品。轻薄的产品要求构成产品的外壳或内部部件薄壁、轻质同时也要求高强度、高刚性。由于复合材料具有质量轻、高强度和高模量、抗化学腐蚀、耐疲劳、易于整体成型等优点，被广泛应用于制作军工、飞机、汽车、风电等产品上。由于复合材料优良的力学特性，所以也可以用于笔记本电脑、平板笔记本、便携式电话、便携式信息终端或相机等电子电气设备、信息设备的外壳，发挥了使外壳薄壁化、减轻设备重量等作用。
目前电子电器、汽车、运动器材等产品所用的热塑性复合材料制品大多使用全碳纤维、碳纤维与玻璃纤维混合的复合板材进行成型加工，而热塑性全碳纤维复合板材的密度为1.40-1.60g/cm 3，碳纤维与玻璃纤维混合的复合板材的密度为1.60-1.80g/cm 3，虽然模量和刚性够高，但产品的重量仍偏重，不符合当前轻质化的发展方向。
因此，有必要研发一种热塑性轻质复合材料及其制备方法，以解决上述问题。
【发明内容】
本发明的一个目的在于提供一种热塑性轻质复合材料，能够保证复合材料重量较轻的同时，具有高强度和高模量。
为了实现上述目的，本发明提供的一种热塑性轻质复合材料，包括：
至少两连续纤维层，各所述连续纤维层由含浸热塑性树脂的连续纤维组成；
至少一复合树脂层，其热压成型于所述两连续纤维层之间，所述复合树脂层由含浸热塑性树脂的木质纤维、短切碳纤维组成；
其中，所述至少两连续纤维层与所述至少一复合树脂层的两端弯曲形成一U型结构。
进一步的，所述热塑性树脂为聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚酯、聚甲醛、聚酰胺、聚苯醚其中的一种。
进一步的，所述连续纤维层中的连续纤维为单向碳纤维或者编织纹碳纤维。
进一步的，所述连续纤维层中的连续纤维为碳纤维、玻璃纤维、芳纶纤维中的至少一种。
进一步的，所述连续纤维层的纤维纱束中单丝数量为3000根。
进一步的，所述木质纤维的密度为0.6g/cm 3-0.9g/cm 3，所述短切碳纤维的长度为0.2cm-3cm。
进一步的，所述连续纤维层及所述复合树脂层裁切成350mm*255mm的尺寸。
进一步的，所述连续纤维层的厚度为0.2mm，所述复合树脂层的厚度为1mm。
本发明还提供一种热塑性轻质复合材料制备方法，包括以下步骤：
S1：制备至少两连续纤维层，各所述连续纤维层由含浸热塑性树脂的连续纤维组成；
S2：制备至少一复合树脂层，所述复合树脂层由含浸热塑性树脂的木质纤维、短切碳纤维组成；
S3：将至少一复合树脂层铺设于至少两连续纤维层之间，形成一叠层材料，并且所述至少两连续纤维层与所述至少一复合树脂层的两端弯曲形成一U型结构；
S4：热压机压合模具加热至预设温度后，将叠层材料放入模具内热压合至预设时间；
S5：热压合结束后开启冷却，冷却一定时间后取出叠层材料；
S6：对热压合后的叠层材料进行CNC加工修边；
S7：将修边后的叠层材料放入注塑模具内进行注塑成型；
S8：开模取出注塑成型后的产品。
进一步的，所述热塑性树脂为聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚酯、聚甲醛、聚酰胺、聚苯醚其中的一种。
本发明的热塑性轻质复合材料及其制备方法，通过由含浸热塑性树脂的木质纤维、短切碳纤维的复合树脂层作为中间层，并在中间层两表层使用含浸热塑性树脂的连续纤维层，具有以下技术效果：
1.通过在复合树脂层中混合木质纤维和短切碳纤维，热压成型后的板材密度可以达到0.9-1.2g/cm 3，还可以减少碳纤维、玻璃纤维等的使用量，降低了成本。
2.在复合树脂层两面裹覆连续纤维，使得材料具有高强度和高模量的性能。
3.制备工艺简单，连续纤维层及复合树脂层交替铺叠操作简单方便，且可以成型不同厚度的复合材料；另外，整个制程可以采用自动化加工方式，生产周期短，作业效率高。
【附图说明】
图1是本发明提供的热塑性轻质复合材料的结构示意图。
图2是本发明热塑性轻质复合材料制备方法的流程图。
【具体实施方式】
为对本发明的目的、技术功效及技术手段有进一步的了解，现结合附图详细说明如下。请参阅图1，图1是本发明提供的热塑性轻质复合材料的结构示意图。
本发明提供的一种热塑性轻质复合材料100，包括：
至少两连续纤维层110，各所述连续纤维层110由含浸热塑性树脂的连续纤维组成；
至少一复合树脂层120，其热压成型于所述两连续纤维层110之间，所述复合树脂层120由含浸热塑性树脂的木质纤维、短切碳纤维组成；
其中，所述至少两连续纤维层与所述至少一复合树脂层的两端弯曲形成一U型结构。
其中，所述热塑性树脂为聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚酯、聚甲醛、聚酰胺、聚苯醚其中的一种。
其中，所述连续纤维层110中的连续纤维为单向碳纤维或者编织纹碳纤维。
其中，所述连续纤维层110中的连续纤维为碳纤维、玻璃纤维、芳纶纤维中的至少一种。
其中，所述连续纤维层110的纤维纱束中单丝数量为3000根。
其中，所述木质纤维的密度为0.6g/cm 3-0.9g/cm 3，所述短切碳纤维的长度为0.2cm-3cm。
其中，所述连续纤维层110及所述复合树脂层120裁切成350mm*255mm的尺寸。
其中，所述连续纤维层110的厚度为0.2mm，所述复合树脂层120的厚度为1mm。
请参阅图2，图2是本发明热塑性轻质复合材料制备方法的流程图。
于本实施例中，本发明提供的一种热塑性轻质复合材料制备方法，包括以下步骤：
S1：制备至少两连续纤维层110，各所述连续纤维层110由含浸热塑性树脂的连续纤维组成；
S2：制备至少一复合树脂层120，所述复合树脂层120由含浸热塑性树脂的木质纤维、短切碳纤维组成；
S3：将至少一复合树脂层120铺设于至少两连续纤维层110之间，形成一叠层材料，并且，所述至少两连续纤维层110与所述至少一复合树脂层120的两端弯曲形成一U型结构；
S4：热压机压合模具加热至预设温度后，将叠层材料放入模具内热压合至预设时间；
S5：热压合结束后开启冷却，冷却一定时间后取出叠层材料；
S6：对热压合后的叠层材料进行CNC加工修边；
S7：将修边后的叠层材料放入注塑模具内进行注塑成型；
S8：开模取出注塑成型后的产品。
其中，所述步骤S1及步骤S2中的热塑性树脂为聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚酯、聚甲醛、聚酰胺、聚苯醚其中的一种。
下面将具体实施步骤说明如下：
将含浸热塑性树脂的两碳纤维层110以及含浸热塑性树脂的木质纤维、短切碳纤维的复合树脂层120裁切呈350mm*255mm的尺寸，其中所述碳纤维层110的纤维纱束中单丝数量为3000根，所述木质纤维的密度为0.6g/cm 3-0.9g/cm 3，所述短切碳纤维的长度为0.2cm-3cm；依照碳纤维层100、复合树脂层120及碳纤维层的顺序铺叠，并且所述至少两连续纤维层110与所述至少一复合树脂层120的两端弯曲形成一U型结构，其中各叠层对应的厚度分别为0.2mm(碳纤维层110)、1mm(复合树脂层120)及0.2mm(碳纤维层110)；先将热压机压合模具升温到220℃，再将铺叠好的叠层材料送入热压模具中并定位，并使热压模具合模加压，在220℃的温度下恒温保持2分钟热压成型；热压合结束后开启冷却，冷却至30℃时开模，取出成型后的叠层材料；将热压合后的叠层材料进行CNC加工修边，去除叠层材料上的毛刺；将去除毛刺完成后的叠层材料放入注塑模具内注塑成型；开模取出注塑成型后的产品。
综上所述，相较于现有技术，本发明的热塑性轻质复合材料及其制备方法，通过由含浸热塑性树脂的木质纤维、短切碳纤维的复合树脂层作为中间层，并在中间层两表层使用含浸热塑性树脂的连续纤维层，具有以下技术效果：
1.通过在复合树脂层中混合木质纤维和短切碳纤维，热压成型后的板材密度可以达到0.9-1.2g/cm 3，还可以减少碳纤维、玻璃纤维等的使用量，降低了成本。
2.在复合树脂层两面裹覆连续纤维，使得材料具有高强度和高模量的性能。
3.制备工艺简单，连续纤维层及复合树脂层交替铺叠操作简单方便，且可以成型不同厚度的复合材料；另外，整个制程可以采用自动化加工方式，生产周期短，作业效率高。
以上结合具体实施例描述了本发明的技术原理，这些描述只是为了解释本发明原理，不能以任何方式解释为对本发明保护范围的限制。基于此处解释，本领域技术人员不需要付出创造性的劳动即可联想到本发明的其它具体实施方式，这些方式都将落入本发明的保护范围之内。

Claims (10)

  1. 一种热塑性轻质复合材料，其特征在于，包括：
    至少两连续纤维层，各所述连续纤维层由含浸热塑性树脂的连续纤维组成；
    至少一复合树脂层，其热压成型于所述两连续纤维层之间，所述复合树脂层由含浸热塑性树脂的木质纤维、短切碳纤维组成；
    其中，所述至少两连续纤维层与所述至少一复合树脂层的两端弯曲形成一U型结构。
  2. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述步骤S1及步骤S2中的热塑性树脂为聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚酯、聚甲醛、聚酰胺、聚苯醚其中的一种。
  3. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述连续纤维层中的连续纤维为单向碳纤维或者编织纹碳纤维。
  4. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述连续纤维层中的连续纤维为碳纤维、玻璃纤维、芳纶纤维中的至少一种。
  5. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述连续纤维层的纤维纱束中单丝数量为3000根。
  6. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述木质纤维的密度为0.6g/cm 3-0.9g/cm 3，所述短切碳纤维的长度为0.2cm-3cm。
  7. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述连续纤维层及所述复合树脂层裁切成350mm*255mm的尺寸。
  8. 根据权利要求1所述的热塑性轻质复合材料，其特征在于，所述连续纤维层的厚度为0.2mm，所述复合树脂层的厚度为1mm。
  9. 一种热塑性轻质复合材料制备方法，其特征在于，包括以下步骤：
    S1：制备至少两连续纤维层，各所述连续纤维层由含浸热塑性树脂的连续纤维组成；
    S2：制备至少一复合树脂层，所述复合树脂层由含浸热塑性树脂的木质纤维、短切碳纤维组成；
    S3：将至少一复合树脂层铺设于至少两连续纤维层之间，形成一叠层材料，并且所述至少两连续纤维层与所述至少一复合树脂层的两端弯曲形成一U型结构；
    S4：热压机压合模具加热至预设温度后，将叠层材料放入模具内热压合至预设时间；
    S5：热压合结束后开启冷却，冷却一定时间后取出叠层材料；
    S6：对热压合后的叠层材料进行CNC加工修边；
    S7：将修边后的叠层材料放入注塑模具内进行注塑成型；
    S8：开模取出注塑成型后的产品。
  10. 根据权利要求9所述的热塑性轻质复合材料制备方法，其特征在于，所述步骤S1及步骤S2中的热塑性树脂为聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚酯、聚甲醛、聚酰胺、聚苯醚其中的一种。
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Publication number Priority date Publication date Assignee Title
CN115548533A (zh) * 2022-12-05 2022-12-30 北京维盛复合材料有限公司 一种电池箱体
CN115548533B (zh) * 2022-12-05 2023-03-24 北京维盛复合材料有限公司 一种电池箱体

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