CN116063779B

CN116063779B - Electric insulation thermoplastic composite material and preparation method and application thereof

Info

Publication number: CN116063779B
Application number: CN202111278008.0A
Authority: CN
Inventors: 张琦; 李长金; 徐凯; 邵清; 张师军; 高达利; 尹华; 权慧; 徐耀辉; 李�杰
Original assignee: Sinopec Beijing Research Institute of Chemical Industry; China Petroleum and Chemical Corp
Current assignee: Sinopec Beijing Research Institute of Chemical Industry; China Petroleum and Chemical Corp
Filing date: 2021-10-30
Publication date: 2024-11-19
Anticipated expiration: 2041-10-30

Abstract

The invention discloses an electric insulation thermoplastic composite material, a preparation method and application thereof. The electrically insulating thermoplastic composite comprises an inner layer material being a core layer comprising a fiber bundle, a first thermoplastic resin and a first auxiliary agent, and at least one outer layer material surrounding the core layer and being a resin layer comprising a second thermoplastic resin and a second auxiliary agent, wherein the fiber bundle extends continuously from one end of the core layer to the opposite end thereof, the first auxiliary agent and the second auxiliary agent each independently comprise a polypropylene grafted heterocyclic modified material comprising structural units derived from a copolymerized polypropylene and structural units derived from an alkenyl-containing heterocyclic monomer. The electric insulation thermoplastic composite material is designed based on a multi-component material system, so that the effect of performance synergy among all components can be achieved, and meanwhile, the electric insulation thermoplastic composite material has excellent electric insulation performance.

Description

Electric insulation thermoplastic composite material and preparation method and application thereof

Technical Field

The invention belongs to the field of polymer composite materials, and particularly relates to an electric insulation thermoplastic composite material, a preparation method and application thereof.

Background

Long fiber reinforced thermoplastic composites are one common thermoplastic composite that is one of the fastest growing materials in the composite market today. As semi-structural materials and structural materials, long fiber reinforced thermoplastic composites are developed for various fields of industry and civilian use, including fields of automobiles, appliances, entertainment, food processing, communications, electronic appliances, electric tools, gardening, and the like.

The fiber length of the long fiber reinforced thermoplastic material is equal to the particle length, the fiber orientation is highly uniform, and the long fiber reinforced thermoplastic material has the characteristics of low density, easiness in molding, high specific strength, high modulus, good fatigue resistance, no water absorption and the like. In addition, the material has the advantages of good dimensional stability, excellent impact resistance, chemical stability (salt resistance, oil resistance, fuel resistance and the like) and recycling. The polypropylene material is used as a polymer material with a simple structure, has better electrical insulation performance and higher melting point, but the mechanical properties of pure polypropylene are more brittle and catalytic especially under the low-temperature condition, and cannot meet the working requirements. The long fiber polypropylene material has obviously improved mechanical performance and electric insulating performance and has room for regulation and improvement. With the continuous improvement of the technical level of long fiber reinforced thermoplastic composite materials and the continuous expansion of application cases, materials are required to have excellent mechanical properties and processability, and also better electrical insulation properties. A great deal of literature and data currently indicate that doping nanoparticles for modification is an effective way to improve electrical insulation properties. However, the doping behavior of the nano particles is difficult to control in the actual preparation, so that the problem that the nano particles are easy to agglomerate and the insulation performance is reduced is caused, and the wide application of the nano particles in the actual engineering is limited.

For the problems, the prior art still does not meet the requirements of practical application far.

Disclosure of Invention

Aiming at the problems in the prior art, the invention provides an electric insulation thermoplastic composite material, a preparation method and application thereof, and the electric insulation thermoplastic composite material is based on a multi-component material system design, can achieve the effect of performance synergy among the components, and has excellent electric insulation performance. Furthermore, the electric insulation thermoplastic composite material can also greatly improve the fluidity of fibers in a resin melt, greatly improve the surface performance of the composite material and expand the application range.

In a first aspect the present invention provides an electrically insulating thermoplastic composite comprising an inner layer material being a core layer comprising a fibre bundle, a first thermoplastic resin and a first auxiliary agent, and at least one outer layer material surrounding the core layer and being a resin layer comprising a second thermoplastic resin and a second auxiliary agent, wherein the fibre bundle extends continuously from one end of the core layer to its opposite end, the first auxiliary agent and the second auxiliary agent each independently comprising a modified material of a polypropylene grafted heterocycle comprising structural units derived from a copolypropylene and structural units derived from an alkenyl-containing heterocyclic monomer.

The present inventors have found that an electrically insulating thermoplastic composite material having a continuous fiber-reinforced resin as a core layer (inner layer material) and a resin layer as an outer layer material wrapped outside the core layer is formed by impregnating a continuous fiber bundle with a first component comprising a first thermoplastic resin and a first auxiliary agent to form a core layer and uniformly wrapping a second component comprising a second thermoplastic resin outside the core layer, such thermoplastic composite material having excellent electrical insulation properties. In addition, by adjusting the properties and functions of the first thermoplastic resin in the core layer and the second thermoplastic resin in the resin layer, the electrically insulating thermoplastic composite can be made to have different properties and functions.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the outer layer material (resin layer) may substantially continuously encapsulate the inner layer material (core layer). Although not preferred, in the electrically insulating thermoplastic composite of the present invention, the outer layer material (resin layer) coats at least 80% of the inner layer material (core layer), for example, 80-99%,85-95% of the inner layer material (core layer).

In the present invention, the terms "one end" and/or "opposite end" are generally relative to the longitudinal direction of the electrically insulating thermoplastic composite.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the electrically insulating thermoplastic composite may be in the form of a bar, rod or pellet. Of course, the electrically insulating thermoplastic composite of the present invention may also be of other shapes, such as continuous filaments. In the present invention, the strip, rod or pellet-shaped electrically insulating thermoplastic composite may be cut from a continuous strand-shaped electrically insulating thermoplastic composite.

In some embodiments, the electrically insulating thermoplastic composite is in the form of a bar, rod, or pellet. The length (longitudinal dimension) of the strand-like, rod-like or particulate electrically insulating thermoplastic composite material may be from 5 to 30mm, preferably from 5 to 25mm, more preferably from 6 to 15mm.

In other embodiments, although not preferred, the electrically insulating thermoplastic composite may also have a relatively small length dimension. For example, the electrically insulating thermoplastic composite is in the form of particles, which may also have a particle size (length) of 2-5mm, preferably 3-4mm.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the present invention does not impose particular requirements on the cross-sectional shape of the electrically insulating thermoplastic composite. In some embodiments, the granular or rod-shaped electrically insulating thermoplastic composite is circular or quasi-circular in cross-section. In other embodiments, the granular or strip-shaped electrically insulating thermoplastic composite material may be rectangular or square in cross-section.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the amount of the first thermoplastic resin in the inner layer material is 1 to 90 parts by weight and the amount of the fiber bundles is 10 to 110 parts by weight.

In some embodiments, the amount of the first thermoplastic resin in the inner layer material may be 1 part by weight, 10 parts by weight, 20 parts by weight, 25 parts by weight, 30 parts by weight, 40 parts by weight, 45 parts by weight, 50 parts by weight, 55 parts by weight, 60 parts by weight, 70 parts by weight, 80 parts by weight, 90 parts by weight, or a range consisting thereof; and in some embodiments, the amount of the fiber bundles may be 1 part by weight, 10 parts by weight, 20 parts by weight, 25 parts by weight, 30 parts by weight, 40 parts by weight, 50 parts by weight, 60 parts by weight, 70 parts by weight, 80 parts by weight, 90 parts by weight, 100 parts by weight, 110 parts by weight, or a range consisting thereof.

In some preferred embodiments, the amount of the first thermoplastic resin in the inner layer material may be 20 to 70 parts by weight, preferably 20 to 55 parts by weight, more preferably 24 to 45 parts by weight; and/or the amount of the fiber bundles may be 20 to 110 parts by weight, more preferably 25 to 110 parts by weight.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the amount of the second thermoplastic resin in the outer layer material is from 1 to 110 parts by weight.

In some embodiments, the amount of the second thermoplastic resin in the outer layer material may be 1 part by weight, 10 parts by weight, 20 parts by weight, 30 parts by weight, 40 parts by weight, 45 parts by weight, 50 parts by weight, 60 parts by weight, 65 parts by weight, 70 parts by weight, 75 parts by weight, 80 parts by weight, 85 parts by weight, 90 parts by weight, 95 parts by weight, 100 parts by weight, 105 parts by weight, 110 parts by weight, or a range consisting of the same.

In some preferred embodiments, the amount of the second thermoplastic resin in the outer layer material may be 10 to 99 parts by weight, more preferably 10 to 90 parts by weight, and preferably 40 to 90 parts by weight.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the amount of the first thermoplastic resin in the inner layer material is 1 to 90 parts by weight, preferably 20 to 70 parts by weight, more preferably 20 to 55 parts by weight, still more preferably 24 to 45 parts by weight; and/or the amount of the fiber bundles is 10 to 99 parts by weight, preferably 20 to 80 parts by weight, more preferably 25 to 50 parts by weight.

According to further embodiments of the electrically insulating thermoplastic composite according to the invention, the amount of the first thermoplastic resin in the inner layer material is 50-70 parts by weight, more preferably 50-60 parts by weight; and/or the amount of the fiber bundles is 90 to 110 parts by weight, preferably 100 to 110 parts by weight; and/or the amount of the second thermoplastic resin in the outer layer material is 90 to 110 parts by weight, more preferably 95 to 105 parts by weight.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the weight ratio of the fiber bundles to the first thermoplastic resin in the inner layer material is 0.25-6:1. For example, in the inner layer material, the weight ratio of the fiber bundles to the first thermoplastic resin is 0.25:1、0.3:1、0.35:1、0.4:1、0.45:1、0.5:1、0.55:1、0.6:1、0.65:1、0.7:1、0.8:1、0.9:1、1:1、1.2:1、1.5:1、1.7:1、1.8:1、1.9:1、2:1、2.5:1、3:1、3.5:1、4:1、4.5:1、5:1、6:1 or a range consisting of them.

In some preferred embodiments, the weight ratio of the fiber bundles to the first thermoplastic resin in the inner layer material may be 0.35-4.5:1, preferably 1.7-4.5:1.

The invention also limits the dosage of the first auxiliary agent and the second auxiliary agent, so as to realize the function of the relevant auxiliary agents.

In various embodiments of the present invention, the number of layers of the outer layer material is not limited, and the outer layer material may be one or more layers. When the outer layer material is a plurality of layers, the plurality of layers may be formed of one outer layer material or may be formed of a plurality of outer layer materials.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin and the second thermoplastic resin are the same or different and are each independently selected from at least one of polypropylene, polyethylene, polystyrene, polyvinyl chloride, polyacrylonitrile-butadiene-styrene copolymer, polyacrylonitrile-styrene copolymer, polyoxymethylene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polymethyl methacrylate, polycarbonate, polyphenylene oxide, polyurethane, polyetheretherketone, and polyphenylene sulfide, and alloy polymers thereof.

According to a preferred embodiment of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin and the second thermoplastic resin are each independently selected from at least one of polypropylene, polyethylene, polyamide (also known as nylon), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene sulfide, polyurethane and Polyetheretherketone (PEEK).

According to a preferred embodiment of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin and the second thermoplastic resin are each independently selected from at least one of homo-polypropylene, co-polypropylene, a mixture of homo-polypropylene and co-polypropylene, nylon 6 (PA 6), nylon 66 (PA 66), a mixture of nylon 6 and nylon 66.

According to other embodiments of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin and the second thermoplastic resin may also be selected from thermoplastic polyurethane elastomers (TPU) and/or high temperature nylons (PPA).

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin has a melt flow rate of 60 to 8000g/10min at 230 ℃ and a load of 2.16 kg. For example, the melt flow rate of the first thermoplastic resin at 230 ℃ and a load of 2.16kg may be 60g/10min、100g/10min、200g/10min、450g/10min、500g/10min、1000g/10min、1500g/10min、2000g/10min、3000g/10min、4000g/10min、5000g/10min、6000g/10min、7000g/10min、7500g/10min、8000g/10min or a range consisting thereof.

In some preferred embodiments, the melt flow rate of the first thermoplastic resin at 230℃and a load of 2.16kg may be in the range of 100 to 8000g/10min, preferably 1000 to 7500g/10min, more preferably 1900 to 7500g/10min.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the second thermoplastic resin has a melt flow rate of 0.1 to 8000g/10min at 230 ℃ and a load of 2.16 kg. For example, the melt flow rate of the second thermoplastic resin at 230 ℃ and a load of 2.16kg may be 0.1g/10min、1g/10min、1.5g/10min、3g/10min、10g/10min、20g/10min、30g/10min、40g/10min、45g/10min、50g/10min、55g/10min、60g/10min、70g/10min、80g/10min、90g/10min、100g/10min、450g/10min、500g/10min、800g/10min、1000g/10min、1500g/10min、1900g/10min、2500g/10min、3000g/10min、4000g/10min、5000g/10min、6000g/10min、7000g/10min、8000g/10min or a range consisting thereof.

In some preferred embodiments, the melt flow rate of the second thermoplastic resin at 230℃and a load of 2.16kg may be 3-55g/10min or 450-8000g/10min, preferably 3-45g/10min or 1900-8000g/10min.

In various embodiments of the present invention, the melt flow rates of the first thermoplastic resin and the second thermoplastic resin are not particularly limited, and may be selected according to desired properties.

In particular, the inventors have found that electrically insulating thermoplastic composites having high surface quality properties and high overall properties can be prepared according to the parameters of the present application (e.g., melt flow rate). For example, the melt flow rate of the first thermoplastic resin is higher than the melt flow rate of the second thermoplastic resin, thereby allowing the electrically insulating thermoplastic composite to have improved mechanical properties; conversely, a higher melt flow rate of the second thermoplastic resin than the first thermoplastic resin may result in an electrically insulating thermoplastic composite having improved gloss.

According to some preferred embodiments of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin has a melt flow rate of 60-450g/10min, e.g. 60-200g/10min, at 230 ℃ and a load of 2.16kg, and the second thermoplastic resin has a melt flow rate of 3-55g/10min or 450-8000g/10min, at 230 ℃ and a load of 2.16 kg. In some embodiments, the first thermoplastic resin has a melt flow rate of 60 to 450g/10min at 230℃and a load of 2.16kg, and the second thermoplastic resin has a melt flow rate of 800 to 8000g/10min at 230℃and a load of 2.16 kg.

According to further preferred embodiments of the electrically insulating thermoplastic composite according to the invention, the first thermoplastic resin has a melt flow rate of more than 450g/10min, in particular more than 450g/10min at 230 ℃ and a load of 2.16kg, and the second thermoplastic resin has a melt flow rate of less than 100g/10min, preferably 1.5-55g/10min, more preferably 3-50g/10min at 230 ℃ and a load of 2.16 kg.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the weight ratio of the second thermoplastic resin to the first thermoplastic resin is from 0.05 to 12.5:1. For example, the weight ratio of the second thermoplastic resin to the first thermoplastic resin may be 0.05:1、0.1:1、0.14:1、0.15:1、0.18:1、0.2:1、0.25:1、0.3:1、0.5:1、0.8:1、1:1、1.2:1、1.3:1、1.4:1、1.7:1、2:1、2.5:1、3:1、3.5:1、4:1、5:1、8:1、10:1、12.5:1 or a range consisting of them.

In some preferred embodiments, the weight ratio of the second thermoplastic resin to the first thermoplastic resin may be 0.1-4:1, preferably 0.14-3.5:1.

According to a preferred embodiment of the electrically insulating thermoplastic composite according to the invention, the weight ratio of the second thermoplastic resin to the first thermoplastic resin is less than 0.25:1, preferably less than 0.18:1, more preferably less than 0.15:1, when the melt flow rate of the second thermoplastic resin is 800-8000g/10min at 230 ℃ and a load of 2.16 kg.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, when the first thermoplastic resin and the second thermoplastic resin are selected from at least one of nylon 6, nylon 66, a mixture of nylon 6 and nylon 66, the selected nylon 6 and nylon 66 have a viscosity of 1.8-3.5. The viscosity of the nylon in the present invention is the relative viscosity measured according to the Engler viscosimetry GB/T266-88.

According to a specific embodiment of the electrically insulating thermoplastic composite of the present invention, the first thermoplastic resin and the second thermoplastic resin are self-made or commercially available.

For example, polypropylene resin available from China petrochemical company and having a brand name of PPB-M100-GH, polypropylene resin available from China petrochemical company and having a brand name of M60RHC, nylon 6 available from China petrochemical company and having a brand name of PA6-BL3200H may be used as the first thermoplastic resin.

For example, a polypropylene resin with a brand of PPB-M100-GH, a brand of PPH-T03, a brand of M50RH, a brand of K8303, a brand of PF1500, a brand of PPH-Y450, a brand of PA6-BL3200H, or a brand of PA6-BL3200H, respectively, may be used as the second thermoplastic resin.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the fiber bundles are selected from at least one of glass fibers, carbon fibers, basalt fibers, aramid fibers, stainless steel fibers, synthetic resin fibers, and mineral fibers.

According to a preferred embodiment of the electrically insulating thermoplastic composite according to the invention, the glass fibers are continuous glass fibers and/or fixed length glass fibers.

The fiber bundles suitable for use in the present invention may be alkali-free glass fibers available from the company Eurasian glass fiber, inc. under the designation SE4805, alkali-free glass fibers available from the company Severe International composite materials, inc. under the designation ER4301H, carbon fibers available from the company Dongli, japan under the designation T700SC, basalt fibers available from the company Paeonia river gold basalt fiber, inc.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, in a transverse cross section of the electrically insulating thermoplastic composite, a core layer and a resin layer are sequentially present from inside to outside; the fiber bundles are oriented in a longitudinal direction of the electrically insulating thermoplastic composite. Preferably, the length of the fiber bundles in the present invention is substantially the same as the length (longitudinal dimension) of the electrically insulating thermoplastic composite material, whereby the fiber bundles extend continuously from one end in the longitudinal direction of the core layer to the opposite end in the longitudinal direction.

In some preferred embodiments, the fiber bundles may be subjected to a dispersion treatment. Such a dispersion treatment method is known in the art, and the present invention is not particularly limited thereto.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the inner layer material is free of staple fibers, in particular non-oriented staple fibers.

In some embodiments, the inner layer material is comprised of fiber bundles, a first thermoplastic resin, and a first aid.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the outer layer material is free of fibers. In some preferred embodiments, the outer layer material consists of a second thermoplastic resin and a second auxiliary agent.

According to further embodiments of the electrically insulating thermoplastic composite according to the invention, the outer layer material contains fibres, for example short fibres.

In some embodiments, the weight ratio of the fibers to the second thermoplastic resin in the outer layer material is from 1 to 50:100, preferably from 5 to 50:100, more preferably from 20 to 45:100.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the first and second auxiliary agents each independently comprise 2-30 parts by weight of an electrically insulating modifier, preferably each independently comprise 5-25 parts by weight of an electrically insulating modifier, based on 100 parts by weight of the first and second thermoplastic resins, respectively.

According to still further embodiments of the thermoplastic composite of the present invention, the electrical insulation modifier is a polypropylene grafted heterocyclic modified material. The modified polypropylene grafted heterocycle material comprises structural units derived from copolymerized polypropylene and structural units derived from alkenyl-containing heterocycle monomers; the content of the structural unit which is derived from the heterocyclic monomer containing alkenyl and is in a grafted state in the modified material of the polypropylene grafted heterocycle is 0.5 to 6 weight percent, preferably 0.5 to 4 weight percent based on the weight of the modified material of the polypropylene grafted heterocycle; the copolymer polypropylene has the following characteristics: the comonomer content is 0.5 to 40mol%, preferably 0.5 to 30mol%, more preferably 4 to 25mol%; a xylene solubles content of 2-80 wt%; the comonomer content in the solubles is 10-70 wt%; the intrinsic viscosity ratio of the soluble substance to the polypropylene is 0.3-5.

The melt flow rate of the polypropylene grafted heterocycle modified material under the load of 2.16kg at 230 ℃ is 0.01-30g/10min, preferably 0.05-20g/10min, more preferably 0.1-10g/10min, and even more preferably 0.2-8g/10min;

The heterocyclic monomer containing alkenyl group may be any heterocyclic compound containing alkenyl group capable of undergoing polymerization by free radical, and may be at least one selected from imidazole containing alkenyl group substituent, pyrazole containing alkenyl group substituent, carbazole containing alkenyl group substituent, pyrrolidone containing alkenyl group substituent, pyridine or pyridine salt containing alkenyl group substituent, piperidine containing alkenyl group substituent, caprolactam containing alkenyl group substituent, pyrazine containing alkenyl group substituent, thiazole containing alkenyl group substituent, purine containing alkenyl group substituent, morpholine containing alkenyl group substituent and oxazoline containing alkenyl group substituent. Preferably, the heterocyclic monomer containing alkenyl is a heterocyclic monomer containing mono alkenyl.

Specifically, the alkenyl-containing heterocyclic monomer may be selected from: at least one of 1-vinylimidazole, 2-methyl-1-vinylimidazole, N-allylimidazole, 1-vinylpyrazole, 3-methyl-1-vinylpyrazole, vinylcarbazole, N-vinylpyrrolidone, 2-vinylpyridine, 3-vinylpyridine, 4-vinylpyridine, 2-methyl-5-vinylpyridine, vinylpyridine N-oxide, vinylpyridine salt, vinylpiperidine, N-vinylcaprolactam, 2-vinylpyrazine, N-vinylpiperazine, 4-methyl-5-vinylthiazole, N-vinylpurine, vinylmorpholine and vinyloxazoline.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the first and second auxiliary agents each independently comprise at least one of 0.5 to 15 parts by weight of a compatibilizer, 0.05 to 3 parts by weight of an antioxidant, and 0.05 to 2.5 parts by weight of a lubricant, based on 100 parts by weight of the first and second thermoplastic resins, respectively. Preferably, the first auxiliary and the second auxiliary each independently comprise at least one of 1 to 15 parts by weight, preferably 1 to 6 parts by weight, more preferably 3 to 6 parts by weight of a compatibilizer, 0.1 to 1 part by weight, preferably 0.1 to 0.5 part by weight of an antioxidant, and 0.5 to 2.5 parts by weight of a lubricant.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the compatibilizing agent is selected from at least one of polar monomer grafted modified polymers. Preferably, the polar monomer is selected from at least one of maleic anhydride, maleic anhydride derivatives, acrylic acid and acrylic ester derivatives. Preferably, the polymer is selected from at least one of polyethylene, polypropylene, ethylene-alpha-olefin copolymer and propylene-alpha-olefin (alpha-olefin other than propylene) copolymer.

According to a specific embodiment of the electrically insulating thermoplastic composite of the present invention, a maleic anhydride grafted polypropylene (PP-g-MAH) available from the company of the plastics industry, company of the general Li Lang, under the trade designation BONDYRAM 1001, a maleic anhydride grafted ethylene-octene copolymer (POE-g-MAH) available from the company of the science and technology, company of the Shanghai, under the trade designation CMG9805, a titanate coupling agent available from the company of the Nanjing dado photo-chemical industry, under the trade designation NDZ12, or an aluminate coupling agent available from the company of the Nanj dado chemical industry, under the trade designation XHY-501, may be used as the compatibilizing agent.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the antioxidant is selected from at least one of pentaerythritol tetrakis [ β - (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (antioxidant 1010), tris [2, 4-di-tert-butylphenyl ] phosphite (antioxidant 168), n-stearyl β - (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (antioxidant 1076), 2' -methylenebis (4-methyl-6-tert-butylphenol) (antioxidant 2246), 1, 3-tris (2-methyl-4-hydroxy-5-tert-butylphenyl) butane (antioxidant CA) and bis (2, 4-di-tert-butylphenol) pentaerythritol diphosphite (antioxidant 626).

According to embodiments of the electrically insulating thermoplastic composite of the present invention, antioxidants 1010 and/or 168 available from basf corporation may be used as the antioxidants.

According to some embodiments of the electrically insulating thermoplastic composite of the present invention, the lubricant is selected from at least one of ethylene bis stearamide, calcium stearate, polyethylene wax, pentaerythritol stearate, silicone, polyethylene glycol and a fluorine-containing resin.

According to a specific embodiment of the electrically insulating thermoplastic composite according to the invention, oxidized polyethylene wax commercially available from the auspicious coatings group under the trade designation XH-201 may be used as the lubricant.

In various embodiments of the present invention, the first auxiliary agent may further include at least one of a slipping agent, an antistatic agent, and a plasticizer, and/or the second auxiliary agent may further include at least one of a slipping agent, an antistatic agent, a plasticizer, a nucleating agent, a light stabilizer, a heat stabilizer, a color master, an antistatic agent, and a filler, and the specific kinds and amounts of the auxiliary agents are not limited, and may have a wide selection range.

In a second aspect, the present invention provides a method of preparing an electrically insulating thermoplastic composite, the method comprising the steps of:

Step A, mixing and melting a first thermoplastic resin and a first auxiliary agent to obtain a first component melt;

step B, carrying out first impregnation treatment on the continuous fiber bundles and the first component melt to form a filiform core layer product;

step C, mixing and melting the second thermoplastic resin and the second auxiliary agent to obtain a second component melt;

And D, carrying out second impregnation treatment on the filiform core layer product and the second component melt to form a resin layer for continuously wrapping the core layer.

According to some embodiments of the preparation method of the present invention, the preparation method may be performed continuously on-line to obtain a continuous filamentous product, which may be stored directly, used, or cut into a strip, rod or pellet product having a certain length.

According to some embodiments of the preparation method of the present invention, the mixing conditions of step a include: the temperature is 40-60deg.C, and the time is 0.5-20min, preferably 1-10min, more preferably 3-5min.

According to some embodiments of the preparation method of the present invention, the melting temperature in step a is 200-380 ℃. In the present invention, the melting time may have a wide selection range with the aim of enabling the first thermoplastic resin and the first auxiliary agent to be sufficiently melted to obtain a melt.

According to some embodiments of the preparation method of the present invention, preferably, in step B, the continuous fibers are further subjected to a dispersion treatment and a preheating treatment, preferably at a temperature of 80 to 250 ℃, before the continuous fibers are subjected to the first impregnation treatment with the first component melt. The dispersion treatment process in the present invention employs a fiber dispersion treatment process conventional in the art.

According to some embodiments of the preparation method of the present invention, the mixing conditions of step C comprise: the temperature is 40-60deg.C, and the time is 0.5-20min, preferably 1-10min, more preferably 3-5min.

According to some embodiments of the preparation method of the present invention, the melting temperature in step C is 200-380 ℃. In the present invention, the melting time may have a wide selection range for the purpose of sufficiently melting the second thermoplastic resin and the optional second auxiliary agent.

According to some embodiments of the preparation method of the present invention, the first impregnation treatment in step B may be performed in a first impregnation die, the first impregnation die being an adjustable impregnation die, the first impregnation die comprising a fiber inlet, a fiber outlet and a melt runner, at least one first godet being provided in a die cavity of the first impregnation die; the first godet is movable between the fiber inlet and the fiber outlet; and/or the first godet is movable in a direction perpendicular to the line connecting the fiber inlet and the fiber outlet.

According to some embodiments of the preparation method of the present invention, the first impregnation treatment in step B may be performed in a second impregnation die, the second impregnation die being a combined impregnation die, the second impregnation die comprising a first module, an intermediate module and a second module connected in sequence, the first module being provided with a fiber inlet and a first module flow channel, the second module being provided with a fiber outlet and a second module flow channel, the intermediate module being provided with an intermediate module flow channel; after the first module, the middle module and the second module are connected in sequence, the first module flow channel, the middle module flow channel and the second module flow channel are communicated to form a combined flow channel for the fiber to pass through.

According to some embodiments of the preparation method of the present invention, the first impregnation treatment in step B may also be performed in a third impregnation die, the third impregnation die being a strongly turbulent impregnation die, the third impregnation die comprising a fiber inlet channel, an impregnation outlet and a melt-slit runner, the fiber inlet channel, the impregnation outlet and the melt-slit runner all communicating with a die cavity inside the third impregnation die; the second godet is arranged in a die cavity of the third impregnation die and comprises at least one driving godet, and the driving godet is driven to rotate by a driving device.

The first, second and third impregnation dies used in the present invention are described in chinese patent applications CN 202011193483.3, 202011191450.5 and 202011199839.4, the entire contents of which are incorporated herein by reference.

It should be noted that the first impregnation die, the second impregnation die and the third impregnation die according to the present invention can be applied to any existing manufacturing system and manufacturing technology of an electrically insulating thermoplastic composite material, and in particular, can be applied to any existing manufacturing system and manufacturing technology of a continuous fiber reinforced intumescent flame retardant thermoplastic composite material.

According to some embodiments of the preparation method of the present invention, the second impregnation treatment in step D may be performed in a forming mold. The forming die consists of a core part, a jacket and a jacket mouth template. The core is positioned inside the jacket and forms a cavity with the jacket, and the resin melt can enter the cavity from the bottom or the top or both sides of the jacket. The core part can move back and forth in the outer sleeve, and the pressure of the melt in the cavity is determined by adjusting the size of the formed cavity space. The pressure of the melt in the cavity can also be adjusted by the angle between the core and the jacket.

The working principle of the forming die is as follows: the material strip of the inner layer impregnating material is formed after passing through the impregnating mould, and is guided to pass through a hole in the middle of the core part, then the forming of the composite structure of the inner layer material and the outer layer material is realized in a cavity which is formed by the core part and the outer sleeve and is full of mixed melt, and finally the composite structure is led out through the outer sleeve mouth template.

According to some embodiments of the preparation method of the present invention, step D further comprises, after step D, pulling out, bracing, cooling, drying, and pelletizing the resulting electrically insulating thermoplastic composite. The technological conditions of the pulling, bracing, cooling, drying and granulating treatment are not particularly limited, and the process conditions are within a wide selection range, so that the electric insulation thermoplastic composite material meeting the requirements of different specifications can be obtained.

According to some embodiments of the method of manufacturing of the present invention, the amount of the first thermoplastic resin in the inner layer material is 1 to 90 parts by weight and the amount of the fiber bundles is 10 to 110 parts by weight.

In some preferred embodiments, the amount of the first thermoplastic resin in the inner layer material may be 20 to 70 parts by weight, preferably 20 to 55 parts by weight, more preferably 24 to 45 parts by weight; and/or the amount of the fiber bundles may be 20 to 110 parts by weight, preferably 25 to 110 parts by weight.

According to some embodiments of the method of manufacturing of the present invention, the second thermoplastic resin is used in an amount of 1 to 110 parts by weight in the outer layer material.

In some preferred embodiments, the amount of the second thermoplastic resin in the outer layer material may be 10 to 90 parts by weight, preferably 40 to 90 parts by weight.

According to some embodiments of the preparation method of the present invention, the amount of the first thermoplastic resin in the inner layer material is 1 to 90 parts by weight, preferably 20 to 70 parts by weight, more preferably 20 to 55 parts by weight, still more preferably 24 to 45 parts by weight; and/or the amount of the fiber bundles is 10 to 99 parts by weight, preferably 20 to 80 parts by weight, more preferably 25 to 50 parts by weight.

According to further embodiments of the preparation method of the present invention, the amount of the first thermoplastic resin in the inner layer material is 50 to 70 parts by weight, more preferably 50 to 60 parts by weight; and/or the amount of the fiber bundles is 90 to 110 parts by weight, preferably 100 to 110 parts by weight; and/or the amount of the second thermoplastic resin in the outer layer material is 90 to 110 parts by weight, more preferably 95 to 105 parts by weight.

According to some embodiments of the method of manufacture of the invention, the weight ratio of the fibers to the first thermoplastic resin in the inner layer material is 0.25-6:1. For example, in the inner layer material, the weight ratio of the fiber bundles to the first thermoplastic resin is 0.25:1、0.3:1、0.35:1、0.4:1、0.45:1、0.5:1、0.55:1、0.6:1、0.65:1、0.7:1、0.8:1、0.9:1、1:1、1.2:1、1.5:1、1.7:1、1.8:1、1.9:1、2:1、2.5:1、3:1、3.5:1、4:1、4.5:1、5:1、6:1 or a range consisting of them.

In some preferred embodiments, the weight ratio of the fiber bundles to the first thermoplastic resin in the inner layer material may be 0.35-4.5:1, preferably 0.43-4.5:1.

According to some embodiments of the preparation method of the present invention, the first thermoplastic resin and the second thermoplastic resin are the same or different and are each independently selected from at least one of polypropylene, polyethylene, polystyrene, polyvinyl chloride, polyacrylonitrile-butadiene-styrene copolymer, polyacrylonitrile-styrene copolymer, polyoxymethylene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polymethyl methacrylate, polycarbonate, polyphenylene oxide, polyurethane, polyether ether ketone, and polyphenylene sulfide, and alloy polymers thereof.

According to a preferred embodiment of the production method of the present invention, the first thermoplastic resin and the second thermoplastic resin are each independently selected from at least one of polypropylene, polyethylene, polyamide (also called nylon), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene sulfide, polyurethane, and Polyetheretherketone (PEEK).

According to a preferred embodiment of the production method of the present invention, the first thermoplastic resin and the second thermoplastic resin are each independently selected from at least one of homo-polypropylene, co-polypropylene, a mixture of homo-polypropylene and co-polypropylene, nylon 6 (PA 6), nylon 66 (PA 66), a mixture of nylon 6 and nylon 66.

According to other embodiments of the preparation method of the present invention, the first and second thermoplastic resins may also be selected from thermoplastic polyurethane elastomers (TPU) and/or high temperature nylons (PPA).

According to some embodiments of the preparation method of the present invention, the first thermoplastic resin has a melt flow rate of 60 to 8000g/10min at 230℃and a load of 2.16 kg. For example, the melt flow rate of the first thermoplastic resin at 230 ℃ and a load of 2.16kg may be 60g/10min、100g/10min、200g/10min、450g/10min、500g/10min、1000g/10min、1500g/10min、2000g/10min、3000g/10min、4000g/10min、5000g/10min、6000g/10min、7000g/10min、7500g/10min、8000g/10min or a range consisting thereof.

According to some embodiments of the preparation method of the present invention, the second thermoplastic resin has a melt flow rate of 0.1 to 8000g/10min at 230℃and a load of 2.16 kg. For example, the melt flow rate of the second thermoplastic resin at 230 ℃ and a load of 2.16kg may be 0.1g/10min、1g/10min、1.5g/10min、3g/10min、10g/10min、20g/10min、30g/10min、40g/10min、45g/10min、50g/10min、55g/10min、60g/10min、70g/10min、80g/10min、90g/10min、100g/10min、450g/10min、500g/10min、800g/10min、1000g/10min、1500g/10min、1900g/10min、2500g/10min、3000g/10min、4000g/10min、5000g/10min、6000g/10min、7000g/10min、8000g/10min or a range consisting thereof.

In the different embodiments of the present application, the melt flow rates of the first thermoplastic resin and the second thermoplastic resin are not particularly limited, and may be selected according to desired properties. In particular, the inventors have found that electrically insulating thermoplastic composites having high surface quality properties and high overall properties can be produced under the production conditions (e.g. melt flow rate) according to the application. For example, the melt flow rate of the first thermoplastic resin is higher than the melt flow rate of the second thermoplastic resin, thereby allowing the electrically insulating thermoplastic composite to have improved mechanical properties; conversely, a higher melt flow rate of the second thermoplastic resin than the first thermoplastic resin may result in an electrically insulating thermoplastic composite having improved gloss.

According to some preferred embodiments of the preparation method of the present invention, the first thermoplastic resin has a melt flow rate of 60 to 450g/10min, for example, 60 to 200g/10min, at 230℃and a load of 2.16kg, and the second thermoplastic resin has a melt flow rate of 3 to 55g/10min or 450 to 8000g/10min, at 230℃and a load of 2.16 kg. In some embodiments, the first thermoplastic resin has a melt flow rate of 60 to 450g/10min at 230℃and a load of 2.16kg, and the second thermoplastic resin has a melt flow rate of 800 to 8000g/10min at 230℃and a load of 2.16 kg.

According to further preferred embodiments of the preparation method of the present invention, the melt flow rate of the first thermoplastic resin at 230℃and a load of 2.16kg is above 450g/10min, in particular above 450g/10min, and the melt flow rate of the second thermoplastic resin at 230℃and a load of 2.16kg is less than 100g/10min, preferably between 1.5 and 55g/10min, more preferably between 3 and 50g/10min.

According to some embodiments of the method of preparation of the present invention, the weight ratio of the second thermoplastic resin to the first thermoplastic resin is 0.05-12.5:1. For example, the weight ratio of the second thermoplastic resin to the first thermoplastic resin may be 0.05:1、0.1:1、0.14:1、0.15:1、0.18:1、0.2:1、0.25:1、0.3:1、0.5:1、0.8:1、1:1、1.2:1、1.3:1、1.4:1、1.7:1、2:1、2.5:1、3:1、3.5:1、4:1、5:1、8:1、10:1、12.5:1 or a range consisting of them.

In some preferred embodiments, the weight ratio of the second thermoplastic resin to the first thermoplastic resin may be 0.14-4:1, preferably 0.14-3.5:1.

According to a preferred embodiment of the preparation method of the present invention, when the melt flow rate of the second thermoplastic resin is 800-8000g/10min at 230 ℃ and a load of 2.16kg, the weight ratio of the second thermoplastic resin to the first thermoplastic resin is less than 0.25:1, preferably less than 0.18:1, more preferably less than 0.15:1.

According to some embodiments of the preparation method of the present invention, when the first thermoplastic resin and the second thermoplastic resin are selected from at least one of nylon 6, nylon 66, a mixture of nylon 6 and nylon 66, the selected nylon 6 and nylon 66 have a viscosity of 1.8 to 3.5.

According to a specific embodiment of the preparation method of the present invention, the first thermoplastic resin and the second thermoplastic resin may be self-made or commercially available.

According to some embodiments of the method of producing the present invention, the fiber bundle is selected from at least one of glass fiber, carbon fiber, basalt fiber, aromatic polyamide fiber, stainless steel fiber, synthetic resin fiber, and mineral fiber.

According to a preferred embodiment of the preparation method of the invention, the glass fibers are continuous glass fibers and/or fixed length glass fibers.

According to some embodiments of the preparation method of the present invention, the first auxiliary agent and the second auxiliary agent each independently include at least one of 0.5 to 15 parts by weight of a compatibilizer, 0.05 to 3 parts by weight of an antioxidant, and 0.05 to 2.5 parts by weight of a lubricant, based on 100 parts by weight of the first thermoplastic resin and the second thermoplastic resin, respectively. Preferably, the first auxiliary and the second auxiliary each independently comprise at least one of 1to 15 parts by weight, preferably 1to 6 parts by weight, more preferably 3 to 6 parts by weight of a compatibilizer, 0.1 to 1 part by weight, preferably 0.1 to 0.5 part by weight of an antioxidant, and 0.5 to 2.5 parts by weight of a lubricant.

According to some embodiments of the method of preparation of the present invention, the compatibilizing agent is selected from at least one of polar monomer graft modified polymers. Preferably, the polar monomer is selected from at least one of maleic anhydride, maleic anhydride derivatives, acrylic acid and acrylic ester derivatives. Preferably, the polymer is selected from at least one of polyethylene, polypropylene, ethylene-alpha-olefin copolymer and propylene-alpha-olefin (alpha-olefin other than propylene).

According to some embodiments of the method of preparing the present invention, the lubricant is selected from at least one of ethylene bis stearamide, calcium stearate, polyethylene wax, pentaerythritol stearate, silicone, polyethylene glycol and fluorine-containing resin.

In various embodiments of the present invention, the first auxiliary agent may further include at least one of a slipping agent, an antistatic agent, and a plasticizer, and the second auxiliary agent may further include at least one of a slipping agent, an antistatic agent, a plasticizer, a nucleating agent, a light stabilizer, a flame retardant, a heat stabilizer, a masterbatch, an antistatic agent, and a filler, and the specific kinds and amounts of the several auxiliary agents are not limited and may be selected within a wide range.

In some embodiments of the present invention, the method of preparation of the present invention is performed in an electrically insulating thermoplastic composite manufacturing system as shown in fig. 2 or 3, the specific structure and manner of connection of which is described in the detailed description section.

The third aspect of the invention provides an application of the electric insulation thermoplastic composite material prepared by the preparation method in the fields of automobile industry, mechanical manufacturing, electronic and electric appliances, chemical environmental protection, aerospace communication and building industry, preferably in large-sized automobile parts and/or high-precision electronic and electric elements, and more preferably in an automobile front end module and/or an all-plastic tail door inner plate. But is not limited thereto.

The invention has the beneficial effects that:

1. The electrical insulation thermoplastic composite material prepared by the invention has a core layer and an outer layer composite structure, the composite system design based on the materials can realize the performance synergistic effect between different components between the inner layer material and the outer layer material, can effectively improve the processability of the electrical insulation thermoplastic composite material and the lubricity between fibers and a resin matrix during injection molding, and promote the fluidity of the fibers in a resin matrix melt, thereby improving the bonding state between the fibers and the resin matrix melt, reducing the separation state between the fibers and the resin matrix melt, improving the fluidity of the whole material system, greatly improving the comprehensive performance and the surface quality of the prepared electrical insulation thermoplastic composite material, simultaneously reducing the requirement of the injection molding process, expanding the application range of the electrical insulation thermoplastic composite material, and having wide application prospect and economic significance.

2. The electric insulation thermoplastic composite material has the advantages of low cost, short injection molding period, high dimensional stability of a finished product, high material strength and good electric insulation property, does not need secondary mixing when in use, can be added with functional materials into the first component and/or the second component, particularly the second component (resin layer), and has wide applicability. Further, the outer layer material of the electric insulation thermoplastic composite material provided by the invention can be free of fibers, has the advantage of good surface quality performance, has no floating fibers on the surface, and has improved glossiness.

Drawings

The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate the invention and together with the description serve to explain, without limitation, the invention. In the drawings:

FIG. 1 is a schematic illustration of the structure of an electrically insulating thermoplastic composite in accordance with one embodiment of the present invention;

FIG. 2 is a schematic diagram of an electrically insulating thermoplastic composite manufacturing system in accordance with one embodiment of the present invention;

FIG. 3 is a schematic diagram of an electrical insulation thermoplastic composite manufacturing system in accordance with another embodiment of the present invention;

FIG. 4 is a cross-sectional view of a first impregnation die in an embodiment of the invention;

FIG. 5 is a cross-sectional view of a second impregnation die in an embodiment of the invention;

FIG. 6 is a cross-sectional view of a third impregnation die in an embodiment of the invention;

FIG. 7 is a schematic illustration of a second impregnation process in an embodiment of the invention;

Fig. 8 is a cross-sectional view of a molding die used in the second dipping treatment according to an embodiment of the present invention.

Reference numerals illustrate:

0-1, core layer; 0-2, fiber bundles; 0-3, a resin layer;

1. A fiber frame and a fiber guiding device; 2. a fiber pretreatment device; 3. a first impregnation die; 4. melting, plasticizing and feeding device; 5. a forming die; 6. a cooling water tank; 7. a dryer; 8. a traction machine; 9. a granulator; 10. a collection box;

A300, a first impregnation die head; a1, a fiber inlet; a2, a second chute; a3, a melt runner; a4, a first chute; a5, an upper die cover; a6, a fiber outlet; a7, impregnating the die body; a8, a first godet;

B300, a second impregnation die head; b1, fiber inlet; b2, a melt runner; b3, a first module; b31, a first module runner; b4, combining the flow channels; b5, standardized joints; b6, an intermediate module; b61, middle module flow channels; b7, a second module; b71, a second module runner; b8, fiber outlet;

C300, a third impregnation die head; c1, a melt crack runner; c2, dipping the outer body of the die; c3, fiber inlet channel; c4, an active godet; c5, a driven godet; c6, an immersion outlet;

4-1, an extruder I;4-2, an extruder II;

5-1, core; 5-2, a jacket; 5-3, coating the mouth template; 5-4, material strips; 5-5, a second resin inlet.

Detailed Description

In order that the invention may be more readily understood, the invention will be described in detail below with reference to the following examples, which are given by way of illustration only and are not limiting of the scope of application of the invention.

The test method and the equipment used in the test are as follows:

(1) The tensile strength test was carried out according to ISO527-2, the tensile speed being 5mm/min.

(2) The bending strength test was carried out according to ISO178, the bending speed being 2mm/min.

(3) Notched impact strength tests were carried out according to the ISO179 standard.

(4) The surface gloss test was measured according to ISO2813 standard.

The sources of part of the reagents used in the invention are as follows:

(1) PPB-M100-GH, melt flow rate of 100g/10min, test conditions of 230 ℃,2.16Kg load conditions, produced by China petrochemical company, yangzi petrochemical Co.

(2) PF1500, melt flow rate 1500g/10min, manufactured by Hunan Cheng Jin New Material Co.

(3) PPH-Y450, melt flow rate 450g/10min, manufactured by China petrochemical Shijia refining division.

(4) BL3200H, viscosity 1.8, produced by China petrochemical Baling company.

(5) SE4805 alkali-free glass fiber having a diameter of 17 μm and a linear density of 2400tex, manufactured by the company euros corning (shanghai) glass fiber limited.

(6) ER4301H, alkali-free glass fiber, diameter 17 μm, linear density 2400tex, manufactured by Chongqing International composite Co., ltd.

(7) T700SC, carbon fiber, tow 1200-50C, manufactured by east Asia, japan.

(8) Basalt fiber, with a single fiber diameter of 12 μm, manufactured by the company of basalt fiber, inc. of Goujiang Jinshi.

(9) The PP-g-MAH brand is BONDYRAM to 1001, manufactured by general Li Lang plastics industries, inc.

(10) POE-g-MAH is designated CMG9805, manufactured by Shanghai, highway technology Co., ltd.

(11) NDZ12, manufactured by the company of the Nanjing dawn chemical industry group.

(12) XHY-501, manufactured by Nanjing UpXYPAN chemical Co., ltd.

(13) Antioxidant 1010, manufactured by basf corporation.

(14) Antioxidant 168, manufactured by basf corporation.

(15) The melt flow rate of polypropylene-g-vinylimidazole at 230 ℃ under 2.16kg load is 7.98g/10min, the vinylimidazole content of the structural unit in the grafted state is 3.45%, and the monomer grafting efficiency is 46%.

(16) XH-201, produced by the auspicious coatings group.

The invention is further described below with reference to the accompanying drawings.

Fig. 1 shows the structure of an electrically insulating thermoplastic composite of the present invention. As shown in FIG. 1, the cross section of the electric insulation thermoplastic composite material of the present invention is circular, and comprises a core layer 0-1 and a resin layer 0-3 in sequence from inside to outside, wherein fiber bundles 0-2 oriented along the longitudinal direction are distributed in the core layer 0-1, and the fiber bundles 0-2 are uniformly dispersed in the core layer 0-1.

As shown in fig. 2 and 3, the manufacturing system of the present invention includes a fiber frame and a fiber guiding device 1, a fiber pretreatment device 2, a first impregnation die 3, a melt plasticizing feeding device 4, a molding die 5, a cooling water tank 6, a dryer 7, a tractor 8, a pelletizer 9, a collecting box 10, and an electric control system (not shown in the drawings) which are connected in this order.

In the manufacturing system, the forming mold 5 is used for forming the composite material with the inner and outer layer composite structure, and the structure of the forming mold is shown in fig. 8.

In the manufacturing system, a first impregnation die 3 is used for impregnating the fibers with the resin melt.

As shown in fig. 4, in one embodiment, the first impregnation die is an impregnation device with an adjustable godet position, and includes a first impregnation die head a300, where the first impregnation die head a300 includes an impregnation die body A7, a fiber inlet A1, a fiber outlet A6, and a melt runner A3. At least one first godet A8 is arranged in the die cavity, wherein the first godet A8 can move between the fiber inlet A1 and the fiber outlet A6, or the first godet A8 can move along the direction perpendicular to the connecting line of the fiber inlet A1 and the fiber outlet A6; more alternatively, the first godet A8 is movable both between the fiber inlet A1 and the fiber outlet A6 and in a direction perpendicular to the line connecting the fiber inlet A1 and the fiber outlet A6.

Taking a rectangular first dipping die head a300 as an example, a plurality of first godet rollers A8 are disposed in the first dipping die head a300, and the axial direction of each first godet roller A8 is the width direction of the first dipping die head a300, so that each first godet roller A8 can move along the length direction of the first dipping die head a300 and also can move along the height direction, thereby changing the position of the first godet roller A8 in the first dipping die head a 300.

It will be appreciated that the axial direction of the first godet A8 may also be the length direction of the first impregnation die a300, where each first godet A8 may be movable in the width direction of the first impregnation die a300 or in the height direction of the first impregnation die a300, thereby changing the position of the first godet A8 within the first impregnation die a 300.

Since the fiber (fiber bundle) needs to sequentially bypass the first godet A8 in the cavity when traveling in the cavity of the first impregnation die head a300, the traveling path of the fiber in the cavity can be changed by changing the position (horizontal position, longitudinal position, etc.) of the first godet A8 in the first impregnation die head a300, so that when the impregnation condition required for the fiber is changed, it is only necessary to adjust the position of the first godet A8 in the first impregnation die head a300 without changing a new die, thereby improving the production efficiency and the continuity of production. And meanwhile, the number of the first impregnation die heads A300 can be reduced, and the production cost is saved.

Specifically, the inventive concept of the present invention is to achieve the purpose of adjusting the position of the first godet A8 by grooving on the inner wall of the cavity of the first impregnation die head a 300.

A first chute A4 is provided on a first inner wall of the first impregnation die head a300, the first chute A4 extending between the fiber inlet A1 and the fiber outlet A6 (i.e., in the X-axis direction shown in fig. 4), and the first godet A8 moves along the first chute A4 to change its horizontal position within the first impregnation die head a 300.

Further, a second chute A2 is further provided on the first inner wall of the first impregnation die head a300, the second chute extends in a direction perpendicular to the first chute A4 (i.e., in the Y-axis direction shown in fig. 4), and the first godet A8 moves along the second chute A2 to change the vertical position thereof in the die head.

The first chute A4 and the second chute A2 may be in communication. Thereby, the first godet A8 can be arbitrarily moved in the longitudinal direction or the transverse direction, so that its position is changed.

The cross sections of the first chute A4 and the second chute A2 may be trapezoidal, circular, arc-shaped, rectangular or the like, which is not limited in the present invention.

Both ends of the first godet A8 are provided with adjusting devices (not shown in the figure), and the adjusting devices are used for adjusting the axial length of the first godet A8, wherein the minimum axial length of the first godet A8 is smaller than the interval between the first inner wall and the second inner wall, and the maximum axial length of the first godet A8 is larger than the interval between the first inner wall and the second inner wall.

In another embodiment of the present invention, as shown in fig. 5, the second impregnation die is a combination impregnation die, including a second impregnation die head B300, and the second impregnation die head B300 includes a first module B3, an intermediate module B6, and a second module B7 connected in sequence. The first module B3 is provided with a fiber inlet B1 and a first module flow channel B31, the second module B7 is provided with a fiber outlet B8 and a second module flow channel B71, and the middle module B6 is provided with a middle module flow channel B61.

After the first module B3, the middle module B6 and the second module B7 are sequentially connected, the first module flow channel B31, the middle module flow channel B61 and the second module flow channel B71 are communicated to form a combined flow channel B4 for passing the fibers, wherein the number of the middle modules B6 is at least one. I.e. the first module B3 is the head module and the second module B7 is the tail module, with one or more intermediate modules B6 in between. Note that these intermediate modules B6 are also connected in sequence.

That is, the number of intermediate modules B6 may be increased or decreased as needed, so that when the impregnation requirement conditions are changed, different intermediate modules B6 are selected to be combined to form the combined second impregnation die head B300, thereby improving the continuity of production and the production efficiency, and saving the cost of additional die opening.

Furthermore, by selecting different intermediate modules B6, the shape parameters (such as curvature, etc.) of the formed combined runner B4 can be changed, so that the flow paths of the fibers and the melt can be changed, the impregnation angle and the fiber tension of the fibers in different stations of the die can be changed, the aim of adjusting and optimizing the whole impregnation process of the fibers is finally achieved, and the adaptability of the second impregnation die head B300 to different resin matrixes and fibers is improved.

The first module B3, the middle module B6 and the second module B7 are placed in a die frame, and are in tight contact with each other under the constraint action of the die frame, so that the tightness of the formed combined flow channel B4 is ensured.

As shown in fig. 5, an embodiment with 2 intermediate modules B6 is shown. In the embodiment shown in fig. 5, the downstream end of the first module flow path B31 is connected to the upstream end of one of the intermediate module flow paths B61, the two intermediate module flow paths B61 are connected to each other, and the downstream section of the other intermediate module flow path B61 is connected to the upstream end of the second intermediate module flow path B71, thereby forming a combined flow path B4 extending from the fiber inlet B1 to the fiber outlet B8.

It will be appreciated that by selecting different intermediate modules B6, different combined flow paths B4 can be obtained.

As shown in fig. 5, the downstream end of the first module flow path B31, the upstream end of the second module flow path B71, and both ends of the intermediate module flow path B61 are all located in the same plane, and a standardized joint B5 is configured. In other words, the junctions of the first module flow path B31, the intermediate module flow path B61, and the second module flow path B71 are connected by the standardized joint B5. Because standardized tabs B5 are all located in the same plane and standardized tabs B5 are all identical in shape and size, a modular connection between different modules is facilitated.

In still another embodiment of the present invention, as shown in fig. 6, the third impregnation die is a strong turbulence impregnation die, and includes a third impregnation die head C300, wherein the third impregnation die head C300 includes an impregnation die outer body C2, a fiber inlet channel C3, an impregnation outlet C6, and a melt-gap runner C1 are disposed on the impregnation die outer body C2, and the fiber inlet channel C3, the impregnation outlet C6, and the melt-gap runner C1 are all in communication with a mold cavity inside the impregnation die outer body C2.

Wherein, the die cavity of the dipping outer die body C2 is internally provided with a second godet, the second godet comprises at least one active godet C4, and the active godet C4 is driven to rotate by a driving device (not shown in the figure). Because the rotation of the active godet C4 is driven by the driving device, but not by the traction of the fiber, when the fiber passes through the active godet C4, the active godet C4 which actively rotates is helpful for reducing the traction tension of the fiber and the friction between the fiber and the active godet C4, thereby reducing the breaking quantity of the fiber, ensuring the integrity of the fiber, avoiding the situation that the fiber is broken, and improving the mechanical property of the material. Preferably, the second godet further comprises at least one driven godet C5, the driven godet C5 being driven by the fibers passing through the driving godet C4; or the driven godet C5 is connected with the driving godet C4 through a belt mechanism, a gear mechanism or a chain mechanism. As shown in fig. 6, an example is shown with one driving godet C4 and 2 driven godets C5, where the 2 driven godets C5 are arranged one above the other to extend the impregnation path of the fibers passing through them. The heights of the driving godet C4 and the driven godet C5 in the die cavity can be the same or different.

Further, the driving device may be a motor, a hydraulic mechanism, a reduction gearbox, or the like, which can drive the active godet C4 to rotate.

According to the travelling speed v1 of the fibers entering the die cavity of the dipping outer die body C2, the tangential speed v2 of the corresponding active godet C4 can be selected, for example, the tangential speed v2 of the active godet C4 is the same as the travelling speed v1 of the fibers, that is, v1=v2, so that the purpose of reducing the breakage and abrasion of the fibers is achieved, and therefore, the integrity of the fibers can be ensured, the dipping degree of the fibers is promoted, the dipping time is shortened, and the production efficiency is improved.

As shown in fig. 2, the melt plasticizing feeding device 4 is composed of a twin-screw extruder for melt plasticizing the material. The double-screw extruder is a homodromous double-screw extruder, the screw diameter is 25mm-95mm, and the length-diameter ratio is 36:1-65:1. When the melt plasticizing feeding device 4 consists of one extruder 4, the melt plasticized in the extruder is split by a melt distributor and respectively enters the dipping mold and the forming mold, and the flow rates of the melt plasticizing feeding device and the forming mold are controlled by using melt flow control valves.

As shown in fig. 3, when the melt plasticizing feeding device 4 is composed of two extruders 4-1 and 4-2, melt of the respective melt plasticization is fed into the impregnation die and the molding die through the extruder I4-1 and the extruder II 4-2, respectively. In this embodiment, the melt plasticizing feeding device is composed of two extruders, namely, an extruder I4-1 and an extruder II 4-2, and the melt of the melt plasticizing feeding device is fed into the first dipping mold 3 and the forming mold 5 through the extruder I4-1 and the extruder II 4-2, respectively. Extruder I4-1 and extruder II 4-2 may be fed with the same or different materials, and thus composite materials may be prepared with the same or different materials for the inner and outer layers.

The fiber pretreatment device 2 is composed of a tension roller and a hot drying channel in a combined mode, and the combined mode enables the tension applied to the fiber when the fiber enters the hot drying channel to be released to a certain extent, so that the fiber pretreatment device is suitable for the fiber with different strength, and the fiber with smaller strength is prevented from breaking before entering a dipping die head. The surface of the tension roller in the fiber pretreatment device 2 is subjected to surface ceramic plating treatment to improve the surface roughness so as to reduce friction to the fiber.

In the manufacturing system, a fiber frame and a fiber guiding device 1 are used for guiding out and untwisting fibers, the device is provided with an automatic control untwisting device, is linked with a tractor 8, and is respectively and electrically connected with an electric control system (such as a PLC control device).

In the manufacturing system, the cooling water tank 6, the dryer 7, the tractor 8, the granulator 9, and the collection box 10 are conventional devices or apparatuses known to those skilled in the art, and will not be described herein.

Fig. 7 shows a schematic view of the second dipping treatment using the forming die, and fig. 8 shows a sectional view of the forming die used in the second dipping treatment.

In one embodiment, as shown in FIG. 8, the molding die 5 is composed of a core 5-1, a jacket 5-2, and a jacket mouth template 5-3. The core 5-1 is located inside the jacket 5-2 and forms a cavity with the jacket 5-2, and the resin melt can enter the cavity from the bottom or top or both sides of the jacket 5-2. The core 5-1 can move back and forth in the jacket 5-2, and the pressure of the melt in the cavity is determined by adjusting the size of the cavity space formed. The pressure of the melt in the cavity can also be adjusted by the angle between the core 5-1 and the jacket 5-2. The working principle of the forming die 5 is as follows: the material strip of the inner layer impregnating material is formed after passing through the impregnating mould 3, is guided through a hole in the middle of the core part 5-1, then the forming of the composite structure of the inner layer material and the outer layer material is realized in a cavity filled with mixed melt and formed by the core part 5-1 and the outer sleeve 5-2, and finally the material strip is guided out through the outer sleeve mouth template 5-3.

As shown in fig. 7, the strand 5-4 is fed into a cavity formed by a core (not shown) and a jacket 5-2 and filled with a second component melt, which is fed into the cavity from a second resin inlet 5-5.

In the following examples and comparative examples, an electrically insulating thermoplastic composite was prepared using the manufacturing system shown in fig. 3, wherein the first impregnation treatment was a first impregnation die shown in fig. 4, and the second impregnation treatment was a forming die shown in fig. 8.

[ Example 1]

(1) Dried 50 parts by weight of PPB-M100-GH polypropylene resin (melt flow rate: 100g/10 min), 5 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight BONDYRAM parts by weight 1001, 0.1 part by weight of antioxidant 1010, 0.5 parts by weight XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes to obtain a first component melt, and fed into a first impregnation die.

(2) 30 Parts by weight of glass fiber SE4805 enters a first dipping mold under the action of a tractor, is soaked and dispersed with the first component melt to form a material strip, and is used as an inner layer material.

(3) Dried 49 parts by weight of PPH-Y450 polypropylene resin (melt flow rate: 450g/10 min), 5 parts by weight of polypropylene-g-vinylimidazole, 2.5 parts by weight BONDYRAM parts by weight 1001, 0.1 part by weight of antioxidant 1010, and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes as an outer layer material, and fed into a twin-screw extruder connected to a molding die to obtain a second component melt.

(4) The inner layer material enters into the forming die under the action of the tractor, is guided to pass through the hole in the middle of the core, is formed in the cavity filled with the second component melt by the core and the jacket, realizes the forming of the inner and outer layer material composite structure, and is finally led out through the die outlet.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die opening die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount defined in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 61.1mm. The glass fiber SE4805 was 20.6 wt% in the composite material.

(6) And (3) injection molding the polypropylene composite material prepared by the method into standard sample bars, and performing performance test. The test results are shown in Table 1.

[ Example 2]

(1) Weighing 20 parts by weight of dried self-made high-flow polypropylene (with a melt flow rate of 1000g/10 min), 2 parts by weight of polypropylene-g-vinylimidazole, 0.6 part by weight BONDYRAM part by weight 1001, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight XH-201, stirring in a high-speed mixer at 50 ℃ for 3min to obtain a first component melt, and feeding the first component melt into a first impregnation die.

(2) 50 Parts by weight of glass fiber SE4805 enters a first dipping mold under the action of a tractor, is soaked and dispersed with melt to form a material strip, and is used as an inner layer material.

(3) Dried 59 parts by weight of PPH-T03 polypropylene resin (melt flow rate 3g/10 min), 10 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight BONDYRAM 1001, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes as an outer layer material, and fed into a twin-screw extruder connected to a molding die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount limited in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 15mm. In the composite material, the glass fiber SE4805 accounts for 34.3 weight percent.

[ Example 3]

(1) Dried 20 parts by weight of self-made high-flow polypropylene (melt flow rate 7500g/10 min), 6 parts by weight of polypropylene-g-vinylimidazole, 0.6 parts by weight BONDYRAM parts by weight 1001, 0.1 parts by weight of antioxidant 1010, and 0.5 parts by weight XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3min to obtain a first component melt, and fed into a first impregnation die.

(2) 80 Parts by weight of glass fiber SE4805 enters a first dipping mold under the action of a tractor, is soaked and dispersed with melt to form a material strip, and is used as an inner layer material.

(3) Dried 69 parts by weight of K8303 polypropylene resin (melt flow rate 1.5g/10 min), 20 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight BONDYRAM parts by weight 1001, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes as an outer layer material, and fed into a twin-screw extruder connected to a molding die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die opening die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount defined in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 18mm. In the composite material, the glass fiber SE4805 accounts for 40 weight percent.

[ Example 4]

(1) 70 Parts by weight of dried PPB-M100-GH (melt flow rate 100g/10 min), 20 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight BONDYRAM parts by weight 1001, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes to obtain a first component melt, and fed into a first impregnation die.

(2) 25 Parts by weight of glass fiber SE4805 enters a first dipping mold under the action of a tractor, is soaked and dispersed with melt to form a material strip, and is used as an inner layer material.

(3) Weighing 10 parts by weight of dried self-made high-flow polypropylene (melt flow rate 1900g/10 min), 3 parts by weight of polypropylene-g-vinylimidazole, 0.5 part by weight BONDYRAM part by weight 1001, 0.05 part by weight of antioxidant 1010 and 0.25 part by weight of XH-201, stirring in a high-speed mixer for 3min at 50 ℃ to obtain an outer layer material, and feeding the outer layer material into a double-screw extruder connected with a forming die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount limited in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 5mm. The glass fiber SE4805 was 18.9 wt% in the composite material.

[ Example 5]

(1) Dried 57 parts by weight of M60RHC polypropylene resin (melt flow rate 60g/10 min), 17 parts by weight of polypropylene-g-vinylimidazole, 2.5 parts by weight BONDYRAM parts by weight 1001, 0.5 parts by weight NDZ12, 0.1 parts by weight of antioxidant 168, 0.25 parts by weight XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3min to obtain a first component melt, and fed into a first impregnation die.

(2) 40 Parts by weight of glass fiber SE4805 enters a first dipping mold under the action of a tractor, is soaked and dispersed with melt to form a material strip, and is used as an inner layer material.

(3) Dry 97 parts by weight of M50RH polypropylene resin (melt flow rate 50g/10 min), 25 parts of polypropylene-g-vinylimidazole, 4 parts by weight BONDYRAM parts by weight 1001, 0.8 parts by weight NDZ12, 0.1 parts by weight antioxidant 168, 0.8 parts by weight XH-201 were weighed, stirred in a high speed mixer at 50 ℃ for 3min as an outer layer material, and fed into a twin screw extruder connected to a forming die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die opening die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount limited in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 10mm. The glass fiber SE4805 was 16.3 wt% in the composite material.

[ Example 6]

(1) Dry 57 parts by weight of PA6-BL3200H, 17 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight of CMG9805, 0.1 part by weight of antioxidant 1010, 0.5 parts by weight of XH-201 were weighed, stirred in a high speed mixer at 50 ℃ for 3min to obtain a first component melt, and fed into a first impregnation die.

(2) ER4301H enters a first impregnation die under the action of a tractor, is infiltrated and dispersed with the first component melt to form a material strip, and is used as an inner layer material.

(3) Weighing 72 parts by weight of dried PA6-BL3200H, 25 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight of CMG9805, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201, stirring in a high-speed mixer for 3min at 50 ℃ to obtain an outer layer material, and feeding the outer layer material into a double-screw extruder connected with a forming die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die opening die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount limited in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 12mm. In the composite, ER4301H was 40% by weight.

(6) And (3) injection molding the long glass fiber reinforced PA6 composite material prepared by the method into standard sample bars, and performing performance test. The test results are shown in Table 1.

[ Example 7]

(1) Dried 57 parts by weight of PPB-M100-GH, 17 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight BONDYRAM parts by weight 1001, 0.5 part by weight of XHY-501, 0.1 part by weight of antioxidant 1010, and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes to obtain a first component melt, and fed into a first impregnation die.

(2) The continuous basalt fiber enters a first impregnation die under the action of a tractor, is soaked and dispersed with the first component melt to form a material strip, and is used as an inner layer material.

(3) Dried 72 parts by weight of PPB-M100-GH, 25 parts by weight of polypropylene-g-vinylimidazole, 3 parts by weight BONDYRAM parts by weight of 1001, 0.5 part by weight of XHY-501, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201 are weighed, stirred in a high-speed mixer at 50 ℃ for 3 minutes to serve as an outer layer material, and fed into a double-screw extruder connected with a forming die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die opening die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount limited in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 12mm. In the composite material, the continuous basalt fiber accounts for 40 weight percent.

(6) And (3) injection molding the basalt fiber reinforced PP composite material prepared by the method into standard sample bars, and performing performance test. The test results are shown in Table 1.

[ Example 8]

The procedure is as in example 1, except that: 70 parts by weight of PPB-M100-GH are weighed in the step (1), and 85 parts by weight of PPH-Y450 are weighed in the step (3). And performance testing is carried out on the prepared composite material, and the test results are shown in table 1. The glass fiber SE4805 was 14.8 wt% in the composite material.

[ Example 9]

The procedure is as in example 1, except that: 45 parts by weight of PPB-M100-GH, 2.5 parts by weight BONDYRAM parts by weight 1001, 0.08 part by weight of antioxidant 1010 and 0.4 part by weight of XH-201 are weighed in the step (1), and 65 parts by weight of PPH-Y450 are weighed in the step (3). And performance testing is carried out on the prepared composite material, and the test results are shown in table 1. The glass fiber SE4805 was 19% by weight in the composite material.

[ Example 10]

The procedure is as in example 1, except that: in the step (1), 25 parts by weight of PPB-M100-GH, 1.5 parts by weight BONDYRAM parts by weight 1001, 0.05 part by weight of antioxidant 1010 and 0.25 part by weight of XH-201 are weighed, and in the step (3), 45 parts by weight of PPH-Y450 are weighed. And performance testing is carried out on the prepared composite material, and the test results are shown in table 1. The glass fiber SE4805 was 25.6 wt% in the composite material.

[ Example 11]

The procedure is as in example 1, except that: 55 parts by weight of PPB-M100-GH are weighed in the step (1), and 70 parts by weight of PPH-Y450 are weighed in the step (3). And performance testing is carried out on the prepared composite material, and the test results are shown in table 1. In the composite material, the glass fiber SE4805 accounts for 17.4 weight percent.

[ Example 12]

(3) The dried 49 parts by weight of M60RHC polypropylene resin (melt flow rate: 60g/10 min), 5 parts by weight of polypropylene-g-vinylimidazole, 20 parts by weight of short glass fiber with a length of 3mm cut from glass fiber SE4805, 2.5 parts by weight BONDYRAM parts by weight 1001, 0.1 part by weight of antioxidant 1010, and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes as an outer layer material, and fed into a twin-screw extruder connected with a molding die to obtain a second component melt.

(5) The extrusion amount of the extruder for the outer layer material and the diameter of the die opening die outlet are adjusted to adjust the coating amount of the outer layer material, so that the outer layer material is coated according to the amount limited in the step (3), and the rotating speed of a cutter of the granulator is adjusted, so that the granulating length of the prepared electric insulation thermoplastic composite material is controlled to be 6.1mm. In the composite material, the glass fiber SE4805 accounts for 30 weight percent.

Comparative example 1

(1) Dried 57 parts by weight of PPB-M100-GH, 3 parts by weight BONDYRAM parts by weight of 1001, 0.1 part by weight of antioxidant 1010, and 0.5 part by weight of XH-201 were weighed, stirred in a high-speed mixer at 50℃for 3 minutes to obtain a melt, and fed into an impregnation die.

(2) And the SE4805 enters the dipping mold under the action of the tractor and is soaked and dispersed with the melt, the content of the SE4805 in the composite material is regulated by selecting the size (6 mm) of a sizing die plate of the dipping mold, the content of the SE4805 is controlled to be 22 weight percent, and the rotating speed of a cutter of a granulator is regulated, so that the granulating length of the prepared polypropylene composite material is controlled to be 12mm.

(3) And (3) injection molding the polypropylene composite material prepared by the method into standard sample bars, and performing performance test. The test results are shown in Table 1.

Comparative example 2

(1) Weighing 50 parts by weight of dried PPB-M100-GH polypropylene resin (melt flow rate is 100g/10 min), 30 parts by weight of short glass fiber with a length of 3mm cut by glass fiber SE4805, 3 parts by weight BONDYRAM 1001, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201, and stirring in a high-speed mixer at 50 ℃ for 3min to obtain an inner layer resin;

(2) Weighing 49 parts by weight of dried M60RHC polypropylene resin (with a melt flow rate of 60g/10 min), 20 parts by weight of short glass fiber with a length of 3mm cut by glass fiber SE4805, 3 parts by weight BONDYRAM parts by weight 1001, 0.1 part by weight of antioxidant 1010 and 0.5 part by weight of XH-201, and stirring in a high-speed mixer at 50 ℃ for 3min to obtain an outer layer material;

(3) Respectively adding the inner layer material into a No. 1 extruder, adding the outer layer material into a No. 2 extruder, extruding the raw materials by two extruders simultaneously, and extruding by a die head with an inner and outer layer structure to obtain a continuous wire material with an inner layer of a resin layer containing short glass fibers and an outer layer of a resin layer containing short glass fibers, and granulating to obtain the raw material of the comparative example. The performance test is shown in Table 1.

TABLE 1

Note that: in Table 1, D1 and D2 are comparative example 1 and comparative example 2, respectively, and S1 to S12 are examples 1 to 12.

By comparing examples 1-5 and examples 8-12 with comparative examples 1-2, the tensile strength, bending strength, notched impact strength of the simply supported beams and surface glossiness of the long glass fiber reinforced polypropylene material prepared by the invention are all obviously higher than those of the material prepared by comparative example 1, and the surface quality of the product is higher.

According to the embodiments 6-7 of the invention, the preparation method provided by the invention is not only suitable for long glass fiber reinforced polypropylene composite materials, but also suitable for continuous glass fiber reinforced PA6 and continuous basalt fiber reinforced polypropylene preparation.

Further, as can be seen from the data of table 1, the thermoplastic composite material of the present invention has excellent electrical insulation properties, and the melt flow rate of the thermoplastic resin of the inner layer material and the outer layer material is selected so that the prepared composite material has a desired surface gloss.

The preparation method disclosed by the invention is simple to operate, can realize online continuous production, can ensure higher productivity and lower energy consumption, and is suitable for industrial production and application.

What has been described above is merely a preferred example of the present invention. It should be noted that other equivalent modifications and improvements will occur to those skilled in the art, and are intended to be within the scope of the present invention, as a matter of common general knowledge in the art, in light of the technical teaching provided by the present invention.

Claims

1. An electrically insulating thermoplastic composite comprising an inner layer material which is a core layer comprising a fiber bundle, a first thermoplastic resin and a first auxiliary agent, and at least one outer layer material which encapsulates the core layer and is a resin layer comprising a second thermoplastic resin and a second auxiliary agent, wherein the fiber bundle extends continuously from one end of the core layer to the opposite end thereof, the first auxiliary agent and the second auxiliary agent each independently comprise a modified material of a polypropylene grafted heterocycle comprising structural units derived from a copolymerized polypropylene and structural units derived from an alkenyl-containing heterocyclic monomer;

on the transverse section of the electric insulation thermoplastic composite material, a core layer and a resin layer are sequentially arranged from inside to outside; the first thermoplastic resin and the second thermoplastic resin are the same in kind;

The first thermoplastic resin has a melt flow rate of 60-8000g/10min at 230 ℃ and a load of 2.16 kg;

The second thermoplastic resin has a melt flow rate of 0.1 to 8000g/10min at 230 ℃ under a load of 2.16 kg;

the first thermoplastic resin has a higher melt flow rate than the second thermoplastic resin;

or, the melt flow rate of the second thermoplastic resin is higher than the melt flow rate of the first thermoplastic resin;

In the inner layer material, the amount of the first thermoplastic resin is 1 to 90 parts by weight; the amount of the fiber bundles is 10-110 parts by weight;

The amount of the second thermoplastic resin in the outer layer material is 1 to 110 parts by weight.

2. An electrically insulating thermoplastic composite according to claim 1, characterized in that the electrically insulating thermoplastic composite is in the form of strips, rods or granules.

3. An electrically insulating thermoplastic composite according to claim 2, characterized in that the length of the strand, rod or pellet thermo-oxidative ageing resistant thermoplastic composite is 5-30mm.

4. An electrically insulating thermoplastic composite according to claim 3, characterized in that the length of the strand, rod or pellet thermo-oxidative ageing resistant thermoplastic composite is 5-25mm.

5. An electrically insulating thermoplastic composite according to claim 4, wherein the length of the thermoplastic composite being resistant to thermo-oxidative aging in the form of strips, rods or particles is 6-15mm.

6. The electrically insulating thermoplastic composite of claim 1, wherein the weight ratio of the fiber bundles to the first thermoplastic resin in the inner layer material is 0.25-6:1.

7. The electrically insulating thermoplastic composite material according to claim 6, wherein the amount of the first thermoplastic resin in the inner layer material is 20 to 70 parts by weight; and/or the number of the groups of groups,

The weight ratio of the fiber bundles to the first thermoplastic resin in the inner layer material is 0.35-4.5:1; and/or, in the outer layer material, the amount of the second thermoplastic resin is 10 to 99 parts by weight.

8. The electrically insulating thermoplastic composite material according to claim 7, wherein the amount of the first thermoplastic resin in the inner layer material is 20 to 55 parts by weight; and/or the number of the groups of groups,

The weight ratio of the fiber bundles to the first thermoplastic resin in the inner layer material is 0.43-4.5:1; and/or, in the outer layer material, the amount of the second thermoplastic resin is 40 to 90 parts by weight.

9. The electrically insulating thermoplastic composite material of claim 8, wherein the amount of the first thermoplastic resin in the inner layer material is 24-45 parts by weight.

10. The electrically insulating thermoplastic composite material of claim 6, wherein the amount of fiber bundles is 20-110 parts by weight.

11. An electrically insulating thermoplastic composite as in claim 10, wherein the amount of said fiber bundles is from 25 to 110 parts by weight.

12. The electrically insulating thermoplastic composite material according to claim 6, wherein the amount of the first thermoplastic resin in the inner layer material is 1 to 90 parts by weight; and/or the amount of the fiber bundles is 10 to 99 parts by weight, or

In the inner layer material, the amount of the first thermoplastic resin is 50 to 70 parts by weight; and/or the amount of the fiber bundles is 90-110 parts by weight; and/or, in the outer layer material, the amount of the second thermoplastic resin is 90 to 110 parts by weight.

13. The electrically insulating thermoplastic composite material according to claim 12, wherein the amount of the first thermoplastic resin in the inner layer material is 20 to 70 parts by weight; and/or the amount of the fiber bundles is 20 to 80 parts by weight, or

In the inner layer material, the amount of the first thermoplastic resin is 50 to 60 parts by weight; and/or the amount of the fiber bundles is 100-110 parts by weight; and/or, the amount of the second thermoplastic resin in the outer layer material is 95 to 105 parts by weight.

14. The electrically insulating thermoplastic composite material according to claim 13, wherein the amount of the first thermoplastic resin in the inner layer material is 20 to 55 parts by weight; and/or the amount of the fiber bundles is 25 to 50 parts by weight.

15. The electrically insulating thermoplastic composite material of claim 14, wherein the amount of the first thermoplastic resin in the inner layer material is 24-45 parts by weight.

16. An electrically insulating thermoplastic composite as in any one of claims 1-15, wherein the inner layer material is free of non-oriented staple fibers.

17. The electrically insulating thermoplastic composite of claim 16, wherein the inner layer material is comprised of fiber bundles, a first thermoplastic resin, and a first aid.

18. The electrically insulating thermoplastic composite material according to any one of claims 1-15, wherein the outer layer material is free of fibers; or the outer layer material contains fibers.

19. The electrically insulating thermoplastic composite material of claim 18, wherein the outer layer material consists of a second thermoplastic resin and a second auxiliary agent; or the outer layer material contains short fibers.

20. The electrically insulating thermoplastic composite material of claim 19, wherein the weight ratio of the fibers to the second thermoplastic resin in the outer layer material is 1-50:100.

21. An electrically insulating thermoplastic composite material according to claim 20, wherein the weight ratio of the fibres to the second thermoplastic resin in the outer layer material is from 5 to 50:100.

22. An electrically insulating thermoplastic composite material according to claim 21, wherein the weight ratio of the fibres to the second thermoplastic resin in the outer layer material is 20-45:100.

23. The electrically insulating thermoplastic composite of claim 1, wherein the first and second thermoplastic resins are selected from at least one of polypropylene, polyethylene, polystyrene, polyvinyl chloride, polyacrylonitrile-butadiene-styrene copolymer, polyacrylonitrile-styrene copolymer, polyoxymethylene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polymethyl methacrylate, and alloy polymers thereof; and/or the number of the groups of groups,

The fiber bundles are selected from at least one of carbon fibers, stainless steel fibers, synthetic resin fibers, and mineral fibers.

24. The electrically insulating thermoplastic composite material of claim 23, wherein the first thermoplastic resin and the second thermoplastic resin are selected from the group consisting of polypropylene, polyethylene, polyamide, polyethylene terephthalate, polybutylene terephthalate; and/or the number of the groups of groups,

The fiber bundles are selected from at least one of glass fibers, basalt fibers and aromatic polyamide fibers.

25. The electrically insulating thermoplastic composite of claim 24, wherein the first thermoplastic resin and the second thermoplastic resin are selected from at least one of a homo-polypropylene, a co-polypropylene, a mixture of homo-polypropylene and co-polypropylene, nylon 6, nylon 66, a mixture of nylon 6 and nylon 66.

26. The electrically insulating thermoplastic composite material of claim 1, wherein the first thermoplastic resin has a melt flow rate of 100-8000g/10min at 230 ℃ and a load of 2.16 kg; the second thermoplastic resin has a melt flow rate of 3-55g/10min or 450-8000g/10min at 230 ℃ and a load of 2.16 kg.

27. The electrically insulating thermoplastic composite of claim 26, wherein the first thermoplastic resin has a melt flow rate of 1000-7500g/10min at 230 ℃ and a load of 2.16kg or the second thermoplastic resin has a melt flow rate of 3-45g/10min at 230 ℃ and a load of 2.16 kg.

28. An electrically insulating thermoplastic composite according to claim 27, characterized in that the first thermoplastic resin has a melt flow rate of 1900-7500g/10min at 230 ℃ and a load of 2.16 kg.

29. An electrically insulating thermoplastic composite according to claim 26, wherein the first thermoplastic resin has a melt flow rate of 60-450g/10min at 230 ℃ and a load of 2.16kg and the second thermoplastic resin has a melt flow rate of 3-55g/10min or 450-8000g/10min at 230 ℃ and a load of 2.16 kg.

30. An electrically insulating thermoplastic composite according to claim 29, characterized in that the first thermoplastic resin has a melt flow rate of 60-200g/10min at 230 ℃ and a load of 2.16 kg.

31. The electrically insulating thermoplastic composite of claim 30, wherein the first thermoplastic resin has a melt flow rate of 60-450g/10min at 230 ℃ and a load of 2.16kg, and the second thermoplastic resin has a melt flow rate of 800-8000g/10min at 230 ℃ and a load of 2.16 kg; or (b)

The first thermoplastic resin has a melt flow rate of 450g/10min or more at 230 ℃ and a load of 2.16 kg; the second thermoplastic resin has a melt flow rate of less than 100g/10min at 230 ℃ and a load of 2.16 kg; and/or the weight ratio of the second thermoplastic resin to the first thermoplastic resin is 0.05-12.5:1.

32. The electrically insulating thermoplastic composite of claim 31, wherein the first thermoplastic resin has a melt flow rate greater than 450g/10min at 230 ℃ and a load of 2.16 kg.

33. An electrically insulating thermoplastic composite according to claim 32, characterized in that the melt flow rate of the second thermoplastic resin is 1.5-55g/10min at 230 ℃ and a load of 2.16 kg.

34. An electrically insulating thermoplastic composite according to claim 33, characterized in that the melt flow rate of the second thermoplastic resin is 3-50g/10min at 230 ℃ and a load of 2.16 kg.

35. The electrically insulating thermoplastic composite of claim 34, wherein the weight ratio of the second thermoplastic resin to the first thermoplastic resin is from 0.1 to 4:1.

36. An electrically insulating thermoplastic composite material according to claim 35, wherein the weight ratio of the second thermoplastic resin to the first thermoplastic resin is from 0.14 to 3.5:1.

37. The electrically insulating thermoplastic composite of claim 26, wherein the weight ratio of the second thermoplastic resin to the first thermoplastic resin is less than 0.25:1 when the melt flow rate of the second thermoplastic resin is 800-8000g/10min at 230 ℃ and a load of 2.16 kg; and/or the number of the groups of groups,

When the first thermoplastic resin and the second thermoplastic resin are selected from at least one of nylon 6, nylon 66, a mixture of nylon 6 and nylon 66, the viscosity of nylon 6 and nylon 66 is 1.8 to 3.5.

38. The electrically insulating thermoplastic composite of claim 37, wherein the weight ratio of the second thermoplastic resin to the first thermoplastic resin is less than 0.18:1.

39. The electrically insulating thermoplastic composite of claim 38, wherein the weight ratio of the second thermoplastic resin to the first thermoplastic resin is less than 0.15:1.

40. The electrically insulating thermoplastic composite according to claim 1, wherein the content of structural units in the modified polypropylene-grafted heterocycle derived from an alkenyl-containing heterocyclic monomer in the grafted state is from 0.5 to 6% by weight, based on the weight of the modified polypropylene-grafted heterocycle;

and/or the melt flow rate of the polypropylene grafted heterocycle modified material at 230 ℃ under a load of 2.16kg is 0.01-30g/10min;

And/or, the first auxiliary agent and the second auxiliary agent each independently comprise 2-30 parts by weight of a polypropylene grafted heterocycle modifying material based on 100 parts by weight of the first thermoplastic resin and the second thermoplastic resin, respectively.

41. An electrically insulating thermoplastic composite according to claim 40, wherein the modified polypropylene-grafted heterocycle comprises from 0.5 to 4% by weight of structural units derived from an alkenyl-containing heterocyclic monomer in the grafted state, based on the weight of the modified polypropylene-grafted heterocycle; and/or

The heterocyclic monomer containing alkenyl is selected from at least one of imidazole containing alkenyl substituent, pyrazole containing alkenyl substituent, carbazole containing alkenyl substituent, pyrrolidone containing alkenyl substituent, pyridine or pyridine salt containing alkenyl substituent, piperidine containing alkenyl substituent, caprolactam containing alkenyl substituent, pyrazine containing alkenyl substituent, thiazole containing alkenyl substituent, purine containing alkenyl substituent, morpholine containing alkenyl substituent and oxazoline containing alkenyl substituent;

And/or the melt flow rate of the polypropylene grafted heterocycle modified material at 230 ℃ under a load of 2.16kg is 0.05-20g/10min;

And/or, the first auxiliary agent and the second auxiliary agent each independently comprise 5 to 25 parts by weight of a polypropylene grafted heterocycle modifying material based on 100 parts by weight of the first thermoplastic resin and the second thermoplastic resin, respectively.

42. An electrically insulating thermoplastic composite material according to claim 41, wherein said alkenyl-containing heterocyclic monomer is a mono-alkenyl-containing heterocyclic monomer;

and/or the melt flow rate of the polypropylene grafted heterocycle modified material under the load of 2.16kg at 230 ℃ is 0.1-10g/10min.

43. An electrically insulating thermoplastic composite in accordance with claim 42, wherein said alkenyl-containing heterocyclic monomer is selected from the group consisting of: at least one of 1-vinylimidazole, 2-methyl-1-vinylimidazole, N-allylimidazole, 1-vinylpyrazole, 3-methyl-1-vinylpyrazole, vinylcarbazole, N-vinylpyrrolidone, 2-vinylpyridine, 3-vinylpyridine, 4-vinylpyridine, 2-methyl-5-vinylpyridine, vinylpyridine N-oxide, vinylpyridine salt, vinylpiperidine, N-vinylcaprolactam, 2-vinylpyrazine, N-vinylpiperazine, 4-methyl-5-vinylthiazole, N-vinylpurine, vinylmorpholine and vinyloxazoline;

And/or the melt flow rate of the polypropylene grafted heterocycle modified material under the load of 2.16kg at 230 ℃ is 0.2-8g/10min.

44. An electrically insulating thermoplastic composite as in any one of claims 1-43, wherein the first and second adjuvants each independently comprise at least one of 0.5-15 parts by weight of a compatibilizer, 0.05-3 parts by weight of an antioxidant, and 0.05-2.5 parts by weight of a lubricant, based on 100 parts by weight of the first and second thermoplastic resins, respectively; and/or the number of the groups of groups,

The compatilizer is at least one of polar monomer grafted modified polymers; and/or the number of the groups of groups,

The antioxidant is at least one of pentaerythritol tetra [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate ], tris [2, 4-di-tert-butylphenyl ] phosphite, beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate, 2' -methylenebis (4-methyl-6-tert-butylphenol), 1, 3-tris (2-methyl-4-hydroxy-5-tert-butylphenyl) butane and bis (2, 4-di-tert-butylphenol) pentaerythritol diphosphite; and/or the number of the groups of groups,

The lubricant is at least one selected from ethylene bis stearamide, calcium stearate, polyethylene wax, pentaerythritol stearate, silicone, polyethylene glycol and fluorine-containing resin; and/or the number of the groups of groups,

The first auxiliary agent further comprises at least one of a slipping agent, an antistatic agent and a plasticizer; and/or the number of the groups of groups,

The second auxiliary agent further comprises at least one of a slipping agent, an antistatic agent, a plasticizer, a nucleating agent, a light stabilizer, a flame retardant, a heat stabilizer, a color masterbatch and a filler.

45. An electrically insulating thermoplastic composite as in claim 44, wherein said first and second adjuvants each independently comprise at least one of 1-15 parts by weight of a compatibilizer, 0.1-1 part by weight of an antioxidant, and 0.5-2.5 parts by weight of a lubricant, based on 100 parts by weight of the mass of said first and second thermoplastic resins, respectively; and/or the number of the groups of groups,

The polar monomer is at least one selected from maleic anhydride, maleic anhydride derivatives, acrylic acid and acrylic ester derivatives; and/or the polymer is selected from at least one of polyethylene, polypropylene, ethylene-alpha-octene copolymer and propylene-alpha-olefin copolymer.

46. An electrically insulating thermoplastic composite as in claim 45, wherein said first and second adjuvants each independently comprise at least one of 1-6 parts by weight of a compatibilizer, 0.1-0.5 parts by weight of an antioxidant, and 0.5-2.5 parts by weight of a lubricant, based on 100 parts by weight of the mass of said first and second thermoplastic resins, respectively.

47. An electrically insulating thermoplastic composite as in claim 46, wherein said first and second adjuvants each independently comprise at least one of 3-6 parts by weight of a compatibilizer, 0.1-0.5 parts by weight of an antioxidant, and 0.5-2.5 parts by weight of a lubricant, based on 100 parts by weight of the mass of said first and second thermoplastic resins, respectively.

48. A method of preparing an electrically insulating thermoplastic composite material according to any one of claims 1 to 47, comprising the steps of:

and D, carrying out second impregnation treatment on the filiform core layer product and the second component melt to form a resin layer wrapping the core layer.

49. The method of claim 48, wherein the mixing conditions of step A include: the temperature is 40-60 ℃ and the time is 0.5-20min; the melting temperature in the step A is 200-380 ℃; and/or the number of the groups of groups,

The mixing conditions of step C include: the temperature is 40-60 ℃ and the time is 0.5-20min; the melting temperature in step C is 200-380 ℃.

50. The method of claim 49, wherein the mixing conditions of step A include: the time is 1-10min; and/or, the mixing conditions of the step C comprise: the time is 1-10min.

51. The method of claim 50, wherein the mixing conditions of step A include: the time is 3-5min; and/or, the mixing conditions of the step C comprise: the time is 3-5min.

52. The method of any one of claims 48-51, wherein the first impregnation treatment in step B is performed in a first impregnation die, the first impregnation die being an adjustable impregnation die, the first impregnation die comprising a fiber inlet, a fiber outlet, and a melt runner, at least one first godet being disposed within a die cavity of the first impregnation die; the first godet is movable between the fiber inlet and the fiber outlet; and/or the first godet is movable in a direction perpendicular to the line connecting the fiber inlet and the fiber outlet.

53. The method of any one of claims 48-51, wherein the first impregnation treatment in step B is performed in a second impregnation die, the second impregnation die being a combined impregnation die, the second impregnation die comprising a first module, an intermediate module and a second module connected in sequence, the first module having a fiber inlet and a first module flow channel, the second module having a fiber outlet and a second module flow channel, the intermediate module having an intermediate module flow channel; after the first module, the middle module and the second module are connected in sequence, the first module flow channel, the middle module flow channel and the second module flow channel are communicated to form a combined flow channel for the fiber to pass through.

54. The method of any one of claims 48-51, wherein the first impregnation treatment in step B is performed in a third impregnation die, the third impregnation die being a high turbulence impregnation die, the third impregnation die comprising a fiber inlet channel, an impregnation outlet, and a melt nip flow channel, the fiber inlet channel, the impregnation outlet, and the melt nip flow channel each in communication with a die cavity inside the third impregnation die; the second godet is arranged in a die cavity of the third impregnation die and comprises at least one driving godet, and the driving godet is driven to rotate by a driving device.

55. Use of an electrically insulating thermoplastic composite according to any one of claims 1 to 47 or of an electrically insulating thermoplastic composite obtainable by a process according to any one of claims 48 to 54 in the automotive industry, in machine manufacture, in electronics, in chemical environmental protection, in space communication and in the construction industry.

56. The use according to claim 55, wherein the use is in large automotive parts and/or high precision electrical and electronic components.

57. The use according to claim 56, wherein the use is in an automotive front end module and/or an all plastic tailgate inner panel.