High heat-resistant high-modulus carbon fiber plate and manufacturing method thereof

Abstract

The application provides a high-heat-resistance high-modulus carbon fiber plate and a manufacturing method thereof, and relates to the technical field of carbon fibers.The high-heat-resistance high-modulus carbon fiber plate comprises a carbon fiber base plate, a wear-resistant layer and a heat-resistant layer, the wear-resistant layer is arranged on the outer surface of the carbon fiber base plate, the heat-resistant layer is arranged on the outer surface of the wear-resistant layer, the carbon fiber base plate is composed of at least five layers of carbon fiber yarns impregnated with matrix resin and then heat-pressed and solidified, and the matrix resin comprises 10-20 parts of ceramic fibers and 2-6 parts of a mixed curing agent of E-300 and DDM.The application uses a special matrix resin for impregnation of carbon fiber yarns, ceramic fibers and magnesium hydroxide particles are added to the resin, the heat resistance of the resin is improved, the ceramic fibers and magnesium hydroxide particles are pressed into the multiple layers of the carbon fiber base plate along with the resin, the overall heat resistance is improved, the surface-coated heat-resistant layer is matched, the temperature resistance effect is provided when the plate body is externally coated, and compared with common carbon fiber plates, the plate body prepared by the application has better heat resistance.

Description

Technical Field

[0001] This invention relates to the field of carbon fiber technology, and in particular to a high heat-resistant, high-modulus carbon fiber sheet and its manufacturing method. Background Technology

[0002] Carbon fiber sheets are formed by impregnating and hardening carbon fibers arranged in the same direction with resin. They can effectively solve the problems of difficult construction and large amount of work in multi-layer carbon fiber cloth. They have good reinforcement effect, are easy to construct, and use high-quality carbon fiber raw materials and good base resin. Carbon fiber sheets have good properties such as high tensile strength, corrosion resistance, seismic resistance and impact resistance.

[0003] Currently, most commonly used carbon fiber sheets are resin-based carbon fiber composite sheets. The high-temperature resistance of the resin matrix is ​​not outstanding, and can even be described as very weak. For example, epoxy resin melts at 140°C, so it cannot withstand high temperatures when placed on a carbon fiber sheet. Even thermoplastic carbon fiber sheets, which are highly anticipated in the materials industry, do not have strong high-temperature resistance. For example, the high-temperature resistance of polyetheretherketone resin-based carbon fiber sheets can only reach about 250°C. How to improve the heat resistance of ordinary carbon fiber sheets is a problem that needs to be solved. Therefore, this invention proposes a high-heat-resistant, high-modulus carbon fiber sheet and its manufacturing method to solve the problems existing in the prior art. Summary of the Invention

[0004] To address the aforementioned problems, this invention proposes a high heat-resistant, high-modulus carbon fiber plate and its manufacturing method, which produces a plate with better heat resistance.

[0005] To achieve the objectives of this invention, the following technical solution is provided: a high heat-resistant, high-modulus carbon fiber plate, comprising a carbon fiber substrate, a wear-resistant layer, and a heat-resistant layer. The wear-resistant layer is disposed on the outer surface of the carbon fiber substrate, and the heat-resistant layer is disposed on the outer surface of the wear-resistant layer. The carbon fiber substrate is composed of at least five layers of carbon fiber yarn impregnated with a matrix resin and then hot-pressed and cured. The matrix resin comprises: 10-20 parts of ceramic fiber, 2-6 parts of a mixed curing agent of E-300 and DDM, and 50-80 parts of epoxy resin. The wear-resistant layer comprises 3-9 parts magnesium hydroxide granules and 2-5 parts reactive diluent; the wear-resistant layer comprises 20-30 parts epoxy modified polyurethane resin, 2-9 parts phenolic antioxidant, 1-3 parts silica and 1-3 parts ultraviolet absorber; the heat-resistant layer comprises 10-20 parts dihydroxy polysiloxane, 15-30 parts polyethylene wax, 20-30 parts polyethylene oxide, 8-15 parts porous quartz powder, 2-10 parts polyacrylic acid, 1-3 parts coupling agent, 10-18 parts flame retardant and 5-8 parts film-forming agent.

[0006] Further improvements are made in that: the matrix resin comprises: 15 parts ceramic fiber, 4 parts E-300 and DDM mixed curing agent, 60 parts epoxy resin, 6 parts magnesium hydroxide particles, and 3 parts reactive diluent; the wear-resistant layer comprises: 25 parts epoxy modified polyurethane resin, 5 parts phenolic antioxidant, 2 parts silica, and 2 parts ultraviolet absorber; the heat-resistant layer comprises: 15 parts dihydroxy polysiloxane, 20 parts polyethylene wax, 25 parts polyethylene oxide, 10 parts porous quartz powder, 5 parts polyacrylic acid, 2 parts coupling agent, 15 parts flame retardant, and 7 parts film-forming agent.

[0007] A further improvement is that the E-300 and DDM mixed curing agent is specifically a mixed curing agent of E-300 and DDM in a mass ratio of 1:1.

[0008] A further improvement is that the epoxy resin is a mixture of TDE-85 and AFG-90, and the reactive diluent is a mixture of the product obtained by polycondensation of trimethylolpropane and epichlorohydrin in an alkaline medium and propylene oxide butyl ether.

[0009] A further improvement is that the coupling agent is a metal composite coupling agent, the flame retardant is a mixture of aluminum hydroxide and magnesium hydroxide, and the film-forming agent is a mixture of two or more of butadiene resin film-forming agents, polyurethane film-forming agents, and nitrocellulose film-forming agents.

[0010] Further improvements are made in that: the carbon fiber raw yarn is selected from 2k-4k raw materials according to its bundle size; the thickness of the carbon fiber substrate is controlled to be 1-3mm; the thickness of the wear-resistant layer is controlled to be 0.5-0.8mm; and the thickness of the heat-resistant layer is controlled to be 0.4-0.6mm.

[0011] A method for manufacturing a high heat-resistant, high-modulus carbon fiber sheet includes the following steps:

[0012] Step 1: Prepare at least five layers of carbon fiber raw yarn as the substrate for the carbon fiber substrate;

[0013] Step 2: Prepare the matrix resin by mixing ceramic fibers, E-300 and DDM curing agent, epoxy resin, magnesium hydroxide particles and reactive diluent;

[0014] Step 3: Impregnate the carbon fiber raw yarn in the matrix resin to obtain carbon fiber prepreg;

[0015] Step 4: Lay out and stack the multi-layer carbon fiber prepreg according to the main direction of the load;

[0016] Step 5: Place the laminated prepreg in a mold with a set temperature, heat and pressurize it, then close the mold and cure it under hot pressing to obtain a carbon fiber substrate;

[0017] Step 6: Dissolve and mix the epoxy-modified polyurethane resin with toluene, add phenolic antioxidants, silica and ultraviolet absorbers, disperse and grind, then coat the ground material onto the carbon fiber substrate and dry to form a wear-resistant layer;

[0018] Step 7: Prepare a coating by mixing dihydroxy polysiloxane, polyethylene wax, polyethylene oxide, porous quartz powder, polyacrylic acid, coupling agent, flame retardant and film-forming agent, apply it to the outside of the wear-resistant layer and dry it to form a heat-resistant layer.

[0019] A further improvement is made in step two, where ultrasonic homogenization is performed for 20-30 minutes during the mixing process, and the ultrasonic pressure is controlled to be 1.16-1.2 MPa.

[0020] Further improvements are made in the following steps: In step four, when the load on the carbon fiber prepreg is mainly tensile and compressive, the layup direction is selected according to the direction of tensile and compressive loads; when the load on the carbon fiber prepreg is mainly shear loads, the layup is laid in pairs at ±45°; when the load on the carbon fiber prepreg includes multiple loads, the layup design uses a mixed layup of 0°, ±45°, and 90° directions.

[0021] A further improvement is made in step six, during the dispersion and grinding process, until the particle size of the ground material is controlled to be 0.8-1.2 μm.

[0022] The beneficial effects of this invention are as follows:

[0023] 1. This invention uses a specially formulated matrix resin as the impregnation agent for carbon fiber yarn. Ceramic fibers and magnesium hydroxide particles are added to the resin to increase its heat resistance. During preparation, the ceramic fibers and magnesium hydroxide particles are pressed into the multiple layers of the carbon fiber substrate along with the resin to increase the overall heat resistance. Combined with the heat-resistant layer coated on the surface, it provides a temperature-blocking effect when externally coated. It has been verified that the board prepared by this invention has better heat resistance than ordinary carbon fiber boards.

[0024] 2. The resin formulation of this invention uses E-300 and DDM 1:1 as curing agents, TDE-85 and AFG-90 epoxy as the main resin, and combines it with trimethylolpropane and epichlorohydrin condensation polymer in alkaline medium and epoxy butyl ether as reactive diluents. The resin matrix properties are improved by using DDM modification and toughening modification by using reactive diluents, which can better wet the fibers. Combined with the properties of ceramic fibers, the board not only has good toughness, but also outstanding tensile and bending properties and high modulus.

[0025] 3. The present invention provides a wear-resistant layer, which is made of epoxy-modified polyurethane resin in combination with phenolic antioxidants to provide wear resistance and oxidation resistance. It also uses silica and ultraviolet absorbers to absorb ultraviolet rays, which helps to provide antioxidant performance while blocking the external ultraviolet rays from corroding the matrix resin on the carbon fiber substrate 1, thereby improving durability and ensuring the stability of the board. Attached Figure Description

[0026] Figure 1 This is the front view of the present invention;

[0027] Figure 2 This is a schematic diagram of the process of the present invention.

[0028] The components are: 1. Carbon fiber substrate; 2. Wear-resistant layer; 3. Heat-resistant layer. Detailed Implementation

[0029] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0030] Example 1

[0031] according to Figure 1 As shown, this embodiment proposes a high heat-resistant and high-modulus carbon fiber plate, including a carbon fiber substrate 1, a wear-resistant layer 2, and a heat-resistant layer 3. The wear-resistant layer 2 is disposed on the outer surface of the carbon fiber substrate 1, and the heat-resistant layer 3 is disposed on the outer surface of the wear-resistant layer 2. The carbon fiber substrate 1 is composed of at least five layers of carbon fiber raw yarn impregnated with matrix resin and hot-pressed and cured. The matrix resin includes: 10 parts of ceramic fiber, 2 parts of E-300 and DDM mixed curing agent, 50 parts of epoxy resin, 3 parts of magnesium hydroxide particles, and 2 parts of reactive diluent. The wear-resistant layer 2 includes 20 parts of epoxy-modified polyurethane resin, 2 parts of phenolic antioxidant, 1 part of silica, and 1 part of ultraviolet absorber. The heat-resistant layer 3 includes 10 parts of dihydroxy polysiloxane, 15 parts of polyethylene wax, 20 parts of polyethylene oxide, 8 parts of porous quartz powder, 2 parts of polyacrylic acid, 1 part of coupling agent, 10 parts of flame retardant, and 5 parts of film-forming agent.

[0032] Adding ceramic fibers and magnesium hydroxide particles to the resin increases its heat resistance. During preparation, the ceramic fibers and magnesium hydroxide particles are pressed into the multilayer of the carbon fiber substrate along with the resin, increasing the overall heat resistance. Combined with the heat-resistant layer coated on the surface, it provides a temperature-insulating effect when externally coated.

[0033] The E-300 and DDM mixed curing agent is specifically a mixture of E-300 and DDM in a 1:1 mass ratio. The epoxy resin is a mixture of TDE-85 and AFG-90. The reactive diluent is a mixture of the product obtained by polycondensation of trimethylolpropane and epichlorohydrin in an alkaline medium and propylene oxide butyl ether. The coupling agent is a metal composite coupling agent. The flame retardant is a mixture of aluminum hydroxide and magnesium hydroxide. The film-forming agent is a mixture of two or more of butadiene resin film-forming agents, polyurethane film-forming agents, and nitrocellulose film-forming agents. Because the curing temperature is too high when using E-300 as a curing agent alone, a certain amount of DDM is added for modification. This resin formulation uses E-300 and DDM in a 1:1 ratio as curing agents, and TDE-85 and AFG-90 epoxy resins as the main resins, combined with a condensation polymer of trimethylolpropane and epichlorohydrin in an alkaline medium and epoxy butyl ether as reactive diluents to form the resin matrix. The addition of DDM further improves the properties of the resin matrix. Both TDE-85 and AFG-90 epoxy resins have high epoxy values, resulting in a brittle matrix after curing. Therefore, an appropriate amount of toughening agent must be added for modification. To better wet the fibers, a reactive diluent is used for toughening and dilution. Combined with the properties of ceramic fibers, this results in not only good toughness but also outstanding tensile and flexural properties.

[0034] The carbon fiber raw yarn is selected from 3k raw materials according to its bundle size, the thickness of the carbon fiber substrate 1 is controlled to be 1mm, the thickness of the wear-resistant layer is controlled to be 0.5mm, and the thickness of the heat-resistant layer 3 is controlled to be 0.4mm.

[0035] Example 2

[0036] according to Figure 1 As shown, this embodiment proposes a high heat-resistant and high-modulus carbon fiber plate, including a carbon fiber substrate 1, a wear-resistant layer 2, and a heat-resistant layer 3. The wear-resistant layer 2 is disposed on the outer surface of the carbon fiber substrate 1, and the heat-resistant layer 3 is disposed on the outer surface of the wear-resistant layer 2. The carbon fiber substrate 1 is composed of at least five layers of carbon fiber raw yarn impregnated with matrix resin and hot-pressed and cured. The matrix resin includes: 15 parts of ceramic fiber, 4 parts of E-300 and DDM mixed curing agent, 60 parts of epoxy resin, 6 parts of magnesium hydroxide particles, and 3 parts of reactive diluent. The wear-resistant layer includes 25 parts of epoxy-modified polyurethane resin, 5 parts of phenolic antioxidant, 2 parts of silica, and 2 parts of ultraviolet absorber. The heat-resistant layer includes 15 parts of dihydroxy polysiloxane, 20 parts of polyethylene wax, 25 parts of polyethylene oxide, 10 parts of porous quartz powder, 5 parts of polyacrylic acid, 2 parts of coupling agent, 15 parts of flame retardant, and 7 parts of film-forming agent.

[0037] Adding ceramic fibers and magnesium hydroxide particles to the resin increases its heat resistance. During preparation, the ceramic fibers and magnesium hydroxide particles are pressed into the multilayer of the carbon fiber substrate along with the resin, increasing the overall heat resistance. Combined with the heat-resistant layer coated on the surface, it provides a temperature-insulating effect when externally coated.

[0038] The E-300 and DDM mixed curing agent is specifically a mixture of E-300 and DDM in a 1:1 mass ratio. The epoxy resin is a mixture of TDE-85 and AFG-90. The reactive diluent is a mixture of the product obtained by polycondensation of trimethylolpropane and epichlorohydrin in an alkaline medium and propylene oxide butyl ether. The coupling agent is a metal composite coupling agent. The flame retardant is a mixture of aluminum hydroxide and magnesium hydroxide. The film-forming agent is a mixture of two or more of butadiene resin film-forming agents, polyurethane film-forming agents, and nitrocellulose film-forming agents. Because the curing temperature is too high when using E-300 as a curing agent alone, a certain amount of DDM is added for modification. This resin formulation uses E-300 and DDM in a 1:1 ratio as curing agents, and TDE-85 and AFG-90 epoxy resins as the main resins, combined with a condensation polymer of trimethylolpropane and epichlorohydrin in an alkaline medium and epoxy butyl ether as reactive diluents to form the resin matrix. The addition of DDM further improves the properties of the resin matrix. Both TDE-85 and AFG-90 epoxy resins have high epoxy values, resulting in a brittle matrix after curing. Therefore, an appropriate amount of toughening agent must be added for modification. To better wet the fibers, a reactive diluent is used for toughening and dilution. Combined with the properties of ceramic fibers, this results in not only good toughness but also outstanding tensile and flexural properties.

[0039] The carbon fiber raw yarn is selected from 3k raw materials according to its bundle size, the thickness of the carbon fiber substrate 1 is controlled to be 1mm, the thickness of the wear-resistant layer is controlled to be 0.5mm, and the thickness of the heat-resistant layer 3 is controlled to be 0.4mm.

[0040] Example 3

[0041] according to Figure 1As shown, this embodiment proposes a high heat-resistant and high-modulus carbon fiber plate, including a carbon fiber substrate 1, a wear-resistant layer 2, and a heat-resistant layer 3. The wear-resistant layer 2 is disposed on the outer surface of the carbon fiber substrate 1, and the heat-resistant layer 3 is disposed on the outer surface of the wear-resistant layer 2. The carbon fiber substrate 1 is composed of at least five layers of carbon fiber yarn impregnated with matrix resin and hot-pressed and cured. The matrix resin includes: 20 parts of ceramic fiber, 6 parts of E-300 and DDM mixed curing agent, 80 parts of epoxy resin, 9 parts of magnesium hydroxide particles, and 5 parts of reactive diluent. The wear-resistant layer 2 includes 30 parts of epoxy-modified polyurethane resin, 9 parts of phenolic antioxidant, 3 parts of silica, and 3 parts of ultraviolet absorber. The heat-resistant layer 3 includes 20 parts of dihydroxy polysiloxane, 30 parts of polyethylene wax, 30 parts of polyethylene oxide, 15 parts of porous quartz powder, 10 parts of polyacrylic acid, 3 parts of coupling agent, 18 parts of flame retardant, and 8 parts of film-forming agent.

[0042] Adding ceramic fibers and magnesium hydroxide particles to the resin increases its heat resistance. During preparation, the ceramic fibers and magnesium hydroxide particles are pressed into the multilayer of the carbon fiber substrate along with the resin, increasing the overall heat resistance. Combined with the heat-resistant layer coated on the surface, it provides a temperature-insulating effect when externally coated.

[0043] The E-300 and DDM mixed curing agent is specifically a mixture of E-300 and DDM in a 1:1 mass ratio. The epoxy resin is a mixture of TDE-85 and AFG-90. The reactive diluent is a mixture of the product obtained by polycondensation of trimethylolpropane and epichlorohydrin in an alkaline medium and propylene oxide butyl ether. The coupling agent is a metal composite coupling agent. The flame retardant is a mixture of aluminum hydroxide and magnesium hydroxide. The film-forming agent is a mixture of two or more of butadiene resin film-forming agents, polyurethane film-forming agents, and nitrocellulose film-forming agents. Because the curing temperature is too high when using E-300 as a curing agent alone, a certain amount of DDM is added for modification. This resin formulation uses E-300 and DDM in a 1:1 ratio as curing agents, and TDE-85 and AFG-90 epoxy resins as the main resins, combined with a condensation polymer of trimethylolpropane and epichlorohydrin in an alkaline medium and epoxy butyl ether as reactive diluents to form the resin matrix. The addition of DDM further improves the properties of the resin matrix. Both TDE-85 and AFG-90 epoxy resins have high epoxy values, resulting in a brittle matrix after curing. Therefore, an appropriate amount of toughening agent must be added for modification. To better wet the fibers, a reactive diluent is used for toughening and dilution. Combined with the properties of ceramic fibers, this results in not only good toughness but also outstanding tensile and flexural properties.

[0044] The carbon fiber raw yarn is selected from 3k raw materials according to its bundle size, the thickness of the carbon fiber substrate 1 is controlled to be 1mm, the thickness of the wear-resistant layer is controlled to be 0.5mm, and the thickness of the heat-resistant layer 3 is controlled to be 0.4mm.

[0045] Based on Examples 1, 2, and 3, it can be concluded that the carbon fiber plate prepared by the present invention with the following mass ratio components: the matrix resin includes 10-20 parts of ceramic fiber, 2-6 parts of E-300 and DDM mixed curing agent, 50-80 parts of epoxy resin, 3-9 parts of magnesium hydroxide particles, and 2-5 parts of reactive diluent; the wear-resistant layer 2 includes 20-30 parts of epoxy modified polyurethane resin, 2-9 parts of phenolic antioxidant, 1-3 parts of silica, and 1-3 parts of ultraviolet absorber; the heat-resistant layer 3 includes 10-20 parts of dihydroxy polysiloxane, 15-30 parts of polyethylene wax, 20-30 parts of polyethylene oxide, 8-15 parts of porous quartz powder, 2-10 parts of polyacrylic acid, 1-3 parts of coupling agent, 10-18 parts of flame retardant, and 5-8 parts of film-forming agent, has better heat resistance and higher modulus.

[0046] Verification example:

[0047] ordinary carbon fiber sheet 140-200 240 Example 1 350-400 350 Example 2 350-400 370 Example 3 350-400 365

[0048] Example 4

[0049] according to Figure 1 , 2 As shown in the figure, this embodiment proposes a method for manufacturing a high heat-resistant, high-modulus carbon fiber plate, including the following steps:

[0050] Step 1: Prepare five layers of carbon fiber raw yarn as the substrate of carbon fiber substrate 1; generally, a 1mm carbon fiber board requires about 5 layers of prepreg.

[0051] Step 2: Prepare the matrix resin by mixing ceramic fibers, E-300 and DDM mixed curing agent, epoxy resin, magnesium hydroxide particles and reactive diluent; during the mixing process, use ultrasonic homogenization for 20-30 minutes, and control the ultrasonic pressure to 1.16-1.2 MPa.

[0052] Step 3: Impregnate the carbon fiber raw yarn in the matrix resin to obtain carbon fiber prepreg;

[0053] Step 4: Lay out and stack the multi-layer carbon fiber prepreg according to the main direction of the load; when the load on the carbon fiber prepreg is mainly tensile and compressive, the lay-up direction is selected according to the direction of tensile and compressive load; when the load on the carbon fiber prepreg is mainly shear load, the lay-up is laid in pairs at ±45°; when the load on the carbon fiber prepreg includes multiple loads, the lay-up design uses a mixed lay-up of 0°, ±45°, and 90°.

[0054] Step 5: Place the laminated prepreg in a mold with a set temperature, heat and pressurize it, then close the mold and cure it under hot pressing to obtain carbon fiber substrate 1. During the entire curing process, the heating and pressurization time needs to be adjusted according to the different usage requirements of the carbon fiber board. Different temperatures and heating times will affect the material properties of the carbon fiber board. In actual production, the hot pressing time should be shortened as much as possible while ensuring dimensional stability during the curing stage of the part.

[0055] Step 6: Dissolve and mix the epoxy-modified polyurethane resin with toluene, add phenolic antioxidant, silica and ultraviolet absorber, disperse and grind until the particle size of the ground material is controlled to 0.8-1.2μm. Then coat the ground material onto the carbon fiber substrate 1 and dry it to form the wear-resistant layer 2.

[0056] Step 7: Prepare a coating by mixing dihydroxy polysiloxane, polyethylene wax, polyethylene oxide, porous quartz powder, polyacrylic acid, coupling agent, flame retardant, and film-forming agent. Apply the coating to the outside of the wear-resistant layer 2 and dry it to form the heat-resistant layer 3. Subsequently, for precision requirements or assembly needs, post-processing such as cutting and drilling will be performed. Select sharp tools with diamond coating and solid carbide drill bits. High wear-resistant tools reduce damage to the plate.

[0057] This invention uses a specially formulated matrix resin as the impregnation agent for carbon fiber yarn. Ceramic fibers and magnesium hydroxide particles are added to the resin to increase its heat resistance. During preparation, the ceramic fibers and magnesium hydroxide particles are pressed into multiple layers of the carbon fiber substrate along with the resin, further enhancing the overall heat resistance. Combined with a heat-resistant coating on the surface, this provides a thermal insulation effect during external coating. Verification has shown that the heat resistance of the board prepared by this invention is 100-150℃ higher than that of ordinary carbon fiber boards. Furthermore, the resin formulation of this invention uses E-300 and DDM 1:1 as curing agents, TDE-85 and AFG-90 epoxy as the main resin, and incorporates a condensation polymer of trimethylolpropane and epichlorohydrin in an alkaline medium and propylene oxide butyl ether as reactive diluents. DDM modification improves the resin matrix properties, and the reactive diluents provide toughening modification, resulting in better fiber wetting. Combined with the properties of ceramic fibers, the board not only has good toughness but also outstanding tensile and flexural properties, exhibiting high modulus. Meanwhile, the present invention provides a wear-resistant layer, which, through the action of epoxy-modified polyurethane resin and phenolic antioxidants, provides wear resistance and oxidation resistance. It also utilizes the action of silica and ultraviolet absorbers to absorb ultraviolet rays, which helps to provide antioxidant performance while blocking external ultraviolet rays from corroding the matrix resin on the carbon fiber substrate 1, thereby improving durability and ensuring the stability of the board.

[0058] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high heat-resistant, high-modulus carbon fiber plate, comprising a carbon fiber substrate (1), a wear-resistant layer (2), and a heat-resistant layer (3), characterized in that: The wear-resistant layer (2) is disposed on the outer surface of the carbon fiber substrate (1), and the heat-resistant layer (3) is disposed on the outer surface of the wear-resistant layer (2). The carbon fiber substrate (1) is composed of at least five layers of carbon fiber yarn impregnated with matrix resin and hot-pressed and cured. The matrix resin includes: 10-20 parts of ceramic fiber, 2-6 parts of E-300 and DDM mixed curing agent, 50-80 parts of epoxy resin, 3-9 parts of magnesium hydroxide particles and 2-5 parts of reactive diluent. The wear-resistant layer (2) comprises 20-30 parts of epoxy-modified polyurethane resin, 2-9 parts of phenolic antioxidant, 1-3 parts of silica and 1-3 parts of ultraviolet absorber; the heat-resistant layer (3) comprises 10-20 parts of dihydroxy polysiloxane, 15-30 parts of polyethylene wax, 20-30 parts of polyethylene oxide, 8-15 parts of porous quartz powder, 2-10 parts of polyacrylic acid, 1-3 parts of coupling agent, 10-18 parts of flame retardant and 5-8 parts of film-forming agent.

2. The high heat-resistant, high-modulus carbon fiber plate according to claim 1, characterized in that: The matrix resin comprises: 15 parts ceramic fiber, 4 parts E-300 and DDM mixed curing agent, 60 parts epoxy resin, 6 parts magnesium hydroxide particles, and 3 parts reactive diluent; the wear-resistant layer comprises: 25 parts epoxy modified polyurethane resin, 5 parts phenolic antioxidant, 2 parts silica, and 2 parts ultraviolet absorber; the heat-resistant layer comprises: 15 parts dihydroxy polysiloxane, 20 parts polyethylene wax, 25 parts polyethylene oxide, 10 parts porous quartz powder, 5 parts polyacrylic acid, 2 coupling agent, 15 parts flame retardant, and 7 parts film-forming agent.

3. The high heat-resistant, high-modulus carbon fiber plate according to claim 1, characterized in that: The E-300 and DDM mixed curing agent is specifically a mixed curing agent of E-300 and DDM in a mass ratio of 1:

1.

4. The high heat-resistant, high-modulus carbon fiber plate according to claim 1, characterized in that: The epoxy resin is a mixture of TDE-85 and AFG-90, and the reactive diluent is a mixture of the product obtained by polycondensation of trimethylolpropane and epichlorohydrin in an alkaline medium and propylene oxide butyl ether.

5. The high heat-resistant, high-modulus carbon fiber plate according to claim 1, characterized in that: The coupling agent is a metal composite coupling agent, the flame retardant is a mixture of aluminum hydroxide and magnesium hydroxide, and the film-forming agent is a mixture of two or more of butadiene resin film-forming agents, polyurethane film-forming agents, and nitrocellulose film-forming agents.

6. The high heat-resistant, high-modulus carbon fiber plate according to claim 1, characterized in that: The carbon fiber raw yarn is selected from 2k-4k raw materials according to its bundle size. The thickness of the carbon fiber substrate (1) is controlled to be 1-3mm. The thickness of the wear-resistant layer is controlled to be 0.5-0.8mm. The thickness of the heat-resistant layer (3) is controlled to be 0.4-0.6mm.

7. A method for manufacturing a high heat-resistant, high-modulus carbon fiber plate as described in any one of claims 1-6, characterized in that, Includes the following steps: Step 1: Prepare at least five layers of carbon fiber raw yarn as the substrate of carbon fiber substrate (1); Step 2: Prepare the matrix resin by mixing ceramic fibers, E-300 and DDM curing agent, epoxy resin, magnesium hydroxide particles and reactive diluent; Step 3: Impregnate the carbon fiber raw yarn in the matrix resin to obtain carbon fiber prepreg; Step 4: Lay out and stack the multi-layer carbon fiber prepreg according to the main direction of the load; Step 5: Place the laminated prepreg in a mold with the set temperature, heat and pressurize it, close the mold, and cure it under hot pressing to obtain a carbon fiber substrate (1). Step 6: Dissolve and mix the epoxy-modified polyurethane resin with toluene, add phenolic antioxidant, silica and ultraviolet absorber, disperse and grind, then coat the ground material onto the carbon fiber substrate (1) and dry it to form a wear-resistant layer (2). Step 7: Prepare a coating by mixing dihydroxy polysiloxane, polyethylene wax, polyethylene oxide, porous quartz powder, polyacrylic acid, coupling agent, flame retardant and film-forming agent, apply it to the outside of the wear-resistant layer (2) and dry it to form a heat-resistant layer (3).

8. The method for manufacturing a high heat-resistant, high-modulus carbon fiber plate according to claim 7, characterized in that: In step two, during the mixing process, ultrasonic homogenization is performed for 20-30 minutes, during which the ultrasonic pressure is controlled to be 1.16-1.2 MPa.

9. The method for manufacturing a high heat-resistant, high-modulus carbon fiber plate according to claim 7, characterized in that: In step four, when the load on the carbon fiber prepreg is mainly tensile and compressive, the layup direction is selected according to the direction of tensile and compressive load. When the load on the carbon fiber prepreg is mainly shear load, the layup is laid in pairs at ±45°. When the load on the carbon fiber prepreg includes multiple loads, the layup design uses a mixed layup of 0°, ±45°, and 90° directions.

10. The method for manufacturing a high heat-resistant, high-modulus carbon fiber plate according to claim 7, characterized in that: In step six, the dispersion and grinding process continues until the particle size of the ground material is controlled to be 0.8-1.2 μm.

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