CN112440488A

CN112440488A - Method for producing composite material

Info

Publication number: CN112440488A
Application number: CN201910795553.3A
Authority: CN
Inventors: 邱绍祯; 骆长定; 黄世煜
Original assignee: Kezhan Materials Technology Co ltd
Current assignee: Kezhan Materials Technology Co ltd
Priority date: 2019-08-27
Filing date: 2019-08-27
Publication date: 2021-03-05

Abstract

The invention relates to a manufacturing method of a composite material, which comprises the following steps: (1) providing a thermoplastic prepreg, which comprises a first fiber layer pre-coated with a thermoplastic resin, wherein the first fiber layer comprises at least one layer body with the thickness not more than 0.1 millimeter, and fibers of at least partial blocks of the at least one layer body are arranged in the same direction; (2) providing a thermosetting prepreg material which comprises a second fiber layer which is pre-impregnated and coated with uncured thermosetting resin; (3) thermo-compression bonding the thermoplastic prepreg and the thermosetting prepreg, and forming a non-smooth bonding interface between the thermoplastic prepreg and the thermosetting prepreg; (4) cooling and solidifying to form the composite material.

Description

Method for producing composite material

Technical Field

The invention relates to a manufacturing method of a composite material.

Background

The known thermosetting composite material usually has a rough outer surface after being cured, and in order to make the outer surface have a smooth and glossy appearance, the thermosetting composite material needs to be subjected to a plurality of grinding and polishing operations, and the processing process is complicated and costly. In addition, the known composite material needs to be provided with an adhesive material between the two layers for mutual connection, but the difference in properties between the materials and the insufficient adhesive strength have the problem of easy peeling, and the overall thickness and weight of the composite material are increased, which has the disadvantage of being greatly improved.

Therefore, there is a need for a novel and advanced method for manufacturing a composite material to solve the above problems.

Disclosure of Invention

The invention mainly aims to provide a manufacturing method of a composite material, which has simple steps and good structural strength.

To achieve the above object, the present invention provides a method for manufacturing a composite material, comprising the steps of: (1) providing a thermoplastic prepreg, which comprises a first fiber layer pre-coated with a thermoplastic resin, wherein the first fiber layer comprises at least one layer body with the thickness not more than 0.1 millimeter, and fibers of at least partial blocks of the at least one layer body are arranged in the same direction; (2) providing a thermosetting prepreg material which comprises a second fiber layer which is pre-impregnated and coated with uncured thermosetting resin; (3) thermo-compression bonding the thermoplastic prepreg and the thermosetting prepreg, and forming a non-smooth bonding interface between the thermoplastic prepreg and the thermosetting prepreg; (4) cooling and solidifying to form the composite material.

Further, the heating temperature in the step (3) is between 100 and 300 ℃.

Further, the heating temperature is not lower than a curing temperature of the thermosetting resin, and the curing temperature of the thermosetting resin is higher than a Glass transition temperature (Tg) of the thermoplastic resin.

Further, the pressure applied in step (3) is between 1 and 50 bar.

Further, the thermoplastic prepreg is hot-pressed to form a thermoplastic plate before step (3).

Furthermore, the first fiber layer and the second fiber layer respectively comprise at least one of polymer fibers, Kevlar fibers, carbon fibers, glass fibers, basalt fibers, quartz fibers and natural fibers.

Furthermore, the number of the at least one layer is a plurality of layers, and the fiber arrangement direction of each layer is different from the fiber arrangement direction of at least one of the plurality of layers.

Furthermore, the number of the at least one layer is a plurality of layers, the plurality of layers includes a surface layer and at least one unidirectional fiber layer which are mutually laminated, and the fiber arrangement direction of the at least one unidirectional fiber layer includes at least one of 0 °, ± 15 °, ± 17 °, ± 22 °, ± 30 °, ± 45 °, ± 60 °, ± 75 °, and 90 ° relative to a reference line of the thermosetting prepreg.

Furthermore, at least one layer body is formed by weaving a plurality of unidirectional fiber belts, and the fiber arrangement directions of the adjacent unidirectional fiber belts are mutually vertical.

Further, in the step (1), the layers are respectively pre-impregnated with the thermoplastic resin to have a porosity of not more than 1%.

The invention has the beneficial effects that:

the invention provides a manufacturing method of a composite material, which has simple steps and good structural strength.

Drawings

FIG. 1 is a flow chart of a first preferred embodiment of the present invention.

Fig. 2 is an exploded view of the composite material according to the first preferred embodiment of the present invention.

FIG. 3 is a cross-sectional view of a composite material according to a first preferred embodiment of the present invention.

Fig. 4 is an exploded view of a composite material according to a second preferred embodiment of the present invention.

Fig. 5 is an exploded view of a composite material according to a third preferred embodiment of the present invention.

Reference numerals

1-4: a step of; 10: a thermoplastic prepreg; 11: a first fibrous layer; 111,111a,111 b: a layer body; 112,112 a: a unidirectional fiber layer; 113,113 a: skin layer 114,114 a: a unidirectional fiber tape; 20: thermosetting prepreg material; 21: a second fibrous layer; 30: non-smooth following interface; l: a reference line.

Detailed Description

The following description is given by way of example only, and is not intended to limit the scope of the invention.

Referring to fig. 1 to 3, which show a first preferred embodiment of the present invention, the method for manufacturing the composite material of the present invention includes the following steps: (1) providing a thermoplastic prepreg 10, which comprises a first fiber layer 11 pre-impregnated with a thermoplastic resin, wherein the first fiber layer 11 comprises at least one layer 111 with a thickness of not more than 0.1 mm, and fibers of at least partial blocks of the at least one layer 111 are arranged in the same direction; (2) providing a thermosetting prepreg 20 including a second fiber layer 21 pre-impregnated with an uncured thermosetting resin; (3) thermo-compression bonding the thermoplastic prepreg 10 and the thermosetting prepreg 20, and forming a non-smooth bonding interface 30 between the thermoplastic prepreg 10 and the thermosetting prepreg 20; (4) cooling and solidifying to form the composite material. Therefore, the manufacturing method of the composite material is simple, and the thermoplastic composite material and the thermosetting composite material can be connected without adding an adhesive material.

In the step (1), the layers 111 are preferably pre-impregnated with the thermoplastic resin respectively until the porosity is not greater than 1%, and then are stacked to form the thermoplastic pre-preg 10, so that the thermoplastic resin can be uniformly infiltrated into the at least one layer 111, and the thermal compression molding is easy, the porosity after molding is low, the structural strength is good, and the appearance is smooth. In other embodiments, the layers may be laminated and then pre-impregnated with the thermoplastic resin. The heating temperature in the step (3) is between 100 and 300 ℃, and the appropriate heating temperature can be adjusted according to the selected material. The heating temperature is not lower than a curing temperature of the thermosetting resin, and the curing temperature of the thermosetting resin is higher than a Glass transition temperature (Tg) of the thermoplastic resin. Therefore, when heated, the thermoplastic resin and the uncured thermosetting resin can be at least partially mixed with each other between the thermoplastic prepreg 10 and the thermosetting prepreg 20, and further integrally mixed to form the non-smooth bonding interface 30 (referring to the mutually mixed region, as shown in fig. 3), and the bonding strength after curing is good. The pressure applied in step (3) is between 1 and 50bar, which can be adjusted as required to increase the bonding strength and achieve the shaping effect.

The thermoplastic resin can be selected from non-crystalline polymers or semi-crystalline polymers, and has high toughness, short curing period and easy repeated processing. Non-crystalline polymers such as, but not limited to, poly (methyl methacrylate), PMMA, Polycarbonate (PC), polysulfone (polysulfonone), and the like; examples of the semi-crystalline polymer include, but are not limited to, polypropylene (PP), polyethylene terephthalate (PET), Polyamide (PA), and the like. The thickness of the thermoplastic prepreg 10 and the thermosetting prepreg 20 can be adjusted by changing the fiber volume fraction or the resin content, so as to meet different product requirements. In other embodiments, the thermoplastic prepreg can be further hot-pressed into a thermoplastic plate before step (3) for easy handling. The thermoplastic resin provides the composite with a smooth, glossy appearance without the need for additional abrasive processing.

In detail, the first fiber layer 11 and the second fiber layer 21 respectively include at least one of polymer fibers, kevlar fibers, carbon fibers, glass fibers, basalt fibers, quartz fibers, and natural fibers. Preferably, the number of the at least one layer 111 is a plurality of layers, and the fiber arrangement direction of each layer 111 is different from the fiber arrangement direction of at least one of the plurality of layers 111, so as to increase the structural strength of the composite material. The plurality of layers 111 includes a surface layer 113 and at least one unidirectional fiber layer 112 laminated to each other, and the fiber arrangement direction of the at least one unidirectional fiber layer 112 includes at least one of 0 °, ± 15 °, ± 17 °, ± 22 °, ± 30 °, ± 45 °, ± 60 °, ± 75 °, and 90 ° with respect to a reference line L of the thermosetting prepreg 20. In this embodiment, the plurality of layers 111 includes four unidirectional fiber layers 112 stacked on each other, and the surface layer 113 is the uppermost layer of the four unidirectional fiber layers 112; relative to the reference line L, the fiber arrangement directions of the four unidirectional fiber layers 112 are +45 °, -45 °, 0 °, and 90 ° in order toward the thermosetting prepreg 20, and the fibers of the unidirectional fiber layers 112 are densely arranged, so that voids can be effectively prevented from being generated when the composite material is bonded. In other embodiments, the number of the layers, the number of the at least one unidirectional fiber layer, and the fiber arrangement direction of each layer can be adjusted according to the product requirements.

In the second preferred embodiment of the present invention, the plurality of layers 111a includes the surface layer 113a and four unidirectional fiber layers 112a laminated to each other. The surface layer 113a is a woven layer, which provides more diversified appearances; with respect to the reference line L, the fiber arrangement direction of the four unidirectional fiber layers 112a is 0 °, 90 °, and 0 ° in order from the surface layer 113a toward the thermosetting prepreg 20, which can provide appropriate structural strength, as shown in fig. 4.

In the third preferred embodiment of the present invention, at least one layer 111b is formed by weaving a plurality of unidirectional fiber tapes 114,114a, and the fiber arrangement directions of two adjacent unidirectional fiber tapes 114,114a are perpendicular to each other, such as but not limited to plain weave, twill weave, etc. Therefore, the composite material has the advantages of special appearance, thin thickness, light weight and the like. However, the fiber arrangement directions of two adjacent unidirectional fiber belts can be configured to other angles; the first fibrous layer may also comprise a plurality of such layers, as shown in fig. 5.

Claims

1. A method of manufacturing a composite material, comprising the steps of:

(1) providing a thermoplastic prepreg, which comprises a first fiber layer pre-coated with a thermoplastic resin, wherein the first fiber layer comprises at least one layer body with the thickness not more than 0.1 millimeter, and fibers of at least partial blocks of the at least one layer body are arranged in the same direction;

(2) providing a thermosetting prepreg material which comprises a second fiber layer which is pre-impregnated and coated with uncured thermosetting resin;

(3) thermo-compression bonding the thermoplastic prepreg and the thermosetting prepreg, and forming a non-smooth bonding interface between the thermoplastic prepreg and the thermosetting prepreg;

(4) cooling and solidifying to form the composite material.

2. The method of claim 1, wherein the heating temperature in step (3) is between 100 and 300 ℃.

3. The method of claim 2, wherein the heating temperature is not lower than a curing temperature of the thermosetting resin, and the curing temperature of the thermosetting resin is higher than a glass transition temperature of the thermoplastic resin.

4. A method of manufacturing a composite material as claimed in claim 1, wherein the pressure applied in step (3) is between 1 and 50 bar.

5. The method of claim 1, wherein the thermoplastic prepreg is further thermoformed into a thermoplastic sheet before step (3).

6. The method of claim 1, wherein the first fiber layer and the second fiber layer each comprise at least one of polymer fibers, kevlar fibers, carbon fibers, glass fibers, basalt fibers, quartz fibers, and natural fibers.

7. The method of claim 1, wherein the at least one layer is a plurality of layers, and the fiber alignment direction of each layer is different from the fiber alignment direction of at least one of the plurality of layers.

8. The method according to claim 1, wherein the at least one layer is a plurality of layers, the plurality of layers includes a surface layer and at least one unidirectional fiber layer, the at least one unidirectional fiber layer has a fiber arrangement direction including at least one of 0 °, ± 15 °, ± 17 °, ± 22 °, ± 30 °, ± 45 °, ± 60 °, ± 75 °, and 90 ° with respect to a reference line of the thermosetting prepreg.

9. The method of claim 1, wherein at least one of the layers is formed by weaving a plurality of unidirectional fiber tapes, and the fiber arrangement directions of adjacent unidirectional fiber tapes are perpendicular to each other.

10. The method according to claim 1, wherein in the step (1), the layers are respectively pre-impregnated with the thermoplastic resin to a porosity of not more than 1%.