Manufacturing method of carbon fiber composite material with three-dimensional textures

Abstract

The invention discloses a manufacturing method of a carbon fiber composite material with three-dimensional textures, which comprises the following steps: providing a carbon fiber fabric, and coating at least one side of the carbon fiber fabric with an adhesive dispersion liquid; putting the carbon fiber fabric treated by the adhesive dispersion liquid into a drying oven at 35-45 DEG C, and heating for 5-50 minutes; putting the heated carbon fiber fabric into a curing oven at the temperature of 85-95 DEG C, and heating and curing for 25-35 minutes; paving a film on at least one side of the cured carbon fiber fabric, putting the cured carbon fiber fabric into a vacuum adsorption table, closing the mold, and then starting a vacuum pump to vacuumize the interior of a mold cavity; the press machine provided with the silicone rubber plate is heated to 130 DEG C to 150 DEG C; and putting the vacuumized carbon fiber fabric into a press machine, and pressing for 7-15 minutes by applying a pressure of 48-172 kPa, so as to prepare the carbon fiber composite material with textures.

Description

Technical Field

[0001] The invention relates to the field of manufacturing carbon fiber composite materials, and in particular to a method for manufacturing a carbon fiber composite material with three-dimensional texture. Background Art

[0002] Generally, high-end shoe uppers, handbags, suitcases, etc. use carbon fiber composite materials with textured surfaces. While retaining the original texture of carbon fiber, carbon fiber composite materials with textured surfaces have the advantages of being lightweight, tensile-resistant, and wear-resistant. Using thermoplastic film to heat-press carbon fiber usually requires heating and pressurizing with a thermoplastic film with a high melt index to penetrate the fiber bundle and fabric layer. This processing method results in poor bonding between the film and the carbon fiber, and it is easy to fall off after long-term use. Summary of the invention

[0003] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides a method for manufacturing a carbon fiber composite material with a three-dimensional texture, wherein an adhesive dispersion is coated on the surface of a carbon fiber fabric, and a film is pressed on the surface of the carbon fiber, so that the bonding strength between the carbon fiber fabric and the film is greatly increased.

[0004] The technical solution adopted by the present invention to solve its technical problem is: A method for manufacturing a carbon fiber composite material with a three-dimensional texture comprises the following steps: Step 1: providing a carbon fiber fabric, and applying an adhesive dispersion on at least one side of the carbon fiber fabric; Step 2: Place the carbon fiber fabric treated with the adhesive dispersion in an oven at 35°C to 45°C and heat for 45 to 55 minutes; Step 3: Place the heat-treated carbon fiber fabric in a curing oven at 85°C to 95°C for 25 to 35 minutes; Step 4: Cover at least one side of the cured carbon fiber fabric with a film, place it on a vacuum adsorption table and heat it with a baking lamp, and then start a vacuum pump to evacuate the carbon fiber fabric; Step 5: coating the outer surface of the carbon fiber fabric covered with the film and vacuum-adsorbed with water-based polyurethane, blowing it dry after coating, and drying it in an oven at 85° C. to 95° C. for 5 to 50 minutes; Step 6: Heat the press equipped with the silicone rubber sheet to 130°C to 150°C; Step 7: Place the dried carbon fiber fabric into a press and apply a pressure of 48 kPa to 172 kPa for 7 to 15 minutes to produce a carbon fiber composite material with a three-dimensional texture.

[0005] According to an embodiment of the present invention, a method for manufacturing a carbon fiber composite material with a three-dimensional texture has at least the following beneficial effects: the adhesive dispersion is applied to at least one side of the carbon fiber fabric by spraying or rod coating, wherein the adhesive dispersion applied during the spraying process is controlled by the spraying speed, pressure and nozzle size. In addition, a large amount of adhesive dispersion can be applied to the fabric surface by a rod coating method, and the adhesive dispersion is evenly applied to the carbon fiber fabric using a steel rod, and the excess adhesive dispersion is removed. The carbon fiber fabric treated with the adhesive dispersion is heated in an oven at 35°C to 45°C for 45 to 55 minutes, the oven is configured to accommodate multiple sheets at a time, and the carbon fiber fabric treated with the adhesive dispersion is heated until all moisture is substantially removed, and the carbon fiber fabric treated with the dried adhesive dispersion is heated in a curing oven at 85°C to 95°C for 25 to 35 minutes, so that the adhesive dispersion can be cured on the carbon fiber fabric, and the carbon fiber fabric treated with the adhesive dispersion is placed in a vacuum adsorption table, a film is laid on it and vacuumed, so that the film can be initially bonded to the surface of the carbon fiber fabric treated with the adhesive dispersion, and the air between the carbon fiber fabric and the film is extracted, so that the film is more closely attached to the surface of the carbon fiber fabric. The water-based polyurethane with matte and soft properties is evenly coated on the side of the carbon fiber fabric covered with the film by rolling to provide a softer luster and a softer skin-friendly feel. The carbon fiber fabric covered with the film is laminated by using a heated silicone rubber sheet press. Since the silicone rubber sheet has a certain degree of softness, preferably, a silicone rubber sheet with a Shore hardness of 00 type 20 to 50 degrees is used for lamination, so that the silicone rubber sheet can fully fit the texture of the carbon fiber fabric during the lamination process, and then the film can evenly cover each texture of the carbon fiber fabric, thereby making a textured carbon fiber composite material.

[0006] According to some embodiments of the present invention, the carbon fiber fabric is 3K carbon fiber cloth, and a single fiber bundle of the 3K carbon fiber cloth is woven into a 2×2 twill fabric style by 3000 carbon fibers.

[0007] The advantage is that carbon fiber cloth has the characteristics of low density, thin thickness, light weight, waterproof, wear-resistant, high temperature resistant and corrosion-resistant.

[0008] According to some embodiments of the present invention, the adhesive dispersion is prepared by mixing a dispersion solvent and an adhesive. The dispersion solvent is water, and the adhesive is one or more of waterborne polyurethane, acrylic polymer, polyethylene, polypropylene, polyamide, thermoplastic or thermosetting elastomer materials. The adhesive concentration is 0.5% to 10%.

[0009] Advantageously, the adhesive is prepared by mixing a dispersing solvent and an adhesive so that the adhesive has better adhesion and fluidity, so that the adhesive can be fully sprayed or rod-coated onto the carbon fiber fabric, and the adhesion between the film and the carbon fiber fabric is also better.

[0010] According to some embodiments of the present invention, the film includes one or more of thermoplastic polyurethane, ethylene-vinyl acetate copolymer, polyolefin, polypropylene, and carboxylated acrylonitrile-butadiene copolymer, and the thickness of the film is 0.01 mm to 0.6 mm.

[0011] Advantageously, by arranging a film to be pasted on the carbon fiber fabric, the film covers the carbon fiber fabric to protect the fabric and at the same time can enhance the waterproofness of the carbon fiber composite material.

[0012] According to some embodiments of the present invention, a plurality of vacuum adsorption holes are arranged on the table top of the vacuum adsorption table, and the vacuum adsorption holes are used to adsorb the film. A baking lamp is arranged above the vacuum adsorption table, and the baking lamp is used to heat the film.

[0013] The benefit is that: by setting a number of vacuum adsorption holes on the vacuum adsorption table, the various parts of the carbon fiber fabric can be evenly vacuumed, so that the film can be evenly adsorbed on the texture of the carbon fiber fabric. By setting a baking lamp, the film is heated to soften it, which further increases the fit of the film.

[0014] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0016] Figure 1 is a flowchart of steps of an embodiment of the present invention; Figure 2 is a schematic diagram of a cross-sectional structure of an embodiment of the present invention; Figure 3 A schematic diagram of a vacuum adsorption table of a manufacturing device of the present invention; Figure 4 Schematic diagram of a press machine for manufacturing the device of the present invention.

[0017] Reference numerals: carbon fiber fabric 100 , adhesive dispersion 110 , film 120 , vacuum adsorption table 130 , vacuum pump 140 , silicone rubber sheet 150 , press machine 160 , vacuum adsorption hole 170 , baking lamp 180 . DETAILED DESCRIPTION

[0018] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0019] In the description of the present invention, it is necessary to understand that descriptions involving orientation, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0020] In the description of the present invention, "several" means one or more, "more" means more than two, "greater than", "less than", "exceed", etc. are understood to exclude the number itself, and "above", "below", "within", etc. are understood to include the number itself. If there is a description of first and second, this is only for the purpose of distinguishing the technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0021] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installation, connection and connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0022] Reference below Figure 1-Figure 4 A method for manufacturing a carbon fiber composite material with a three-dimensional texture is described in detail with a specific embodiment. It is worth noting that the following description is only an exemplary description and is not a specific limitation of the invention.

[0023] like Figure 1 , Figure 2 , Figure 3 , Figure 4 As shown, a method for manufacturing a carbon fiber composite material with a three-dimensional texture comprises the following steps: Step 1: providing a carbon fiber fabric 100, and applying an adhesive dispersion 110 on at least one side of the carbon fiber fabric 100; Step 2: placing the carbon fiber fabric 100 treated with the adhesive dispersion 110 in an oven at 35° C. to 45° C. and heating for 45 to 50 minutes; Step 3: placing the heat-treated carbon fiber fabric 100 in a curing furnace at 85° C. to 95° C. for heating and curing for 25 to 35 minutes; Step 4: Cover at least one side of the cured carbon fiber fabric 100 with a film 120, place it in a vacuum adsorption table 130, heat the baking lamp 180, and then start the vacuum pump 140 to evacuate the carbon fiber fabric 100; Step 5: coating the outer surface of the carbon fiber fabric 100 covered with the film 120 and vacuum-adsorbed with water-based polyurethane, blowing it dry after coating, and drying it in an oven at 85° C. to 95° C. for 35 to 45 minutes; Step 6: heating the press 160 provided with the silicone rubber sheet 150 to 130° C. to 150° C.; Step 7: Place the dried carbon fiber fabric 100 into a press 160 and apply a pressure of 48 kPa to 172 kPa for 7 to 15 minutes to produce a carbon fiber composite material with a three-dimensional texture.

[0024] The adhesive dispersion 110 is applied to at least one side of the carbon fiber fabric 100 by spraying or rod coating, wherein the adhesive dispersion 110 applied during the spraying process is controlled by the spraying speed, pressure and nozzle size. In addition, a large amount of adhesive dispersion 110 can be applied to the fabric surface using a rod coating method, and the adhesive dispersion 110 can be evenly applied to the carbon fiber fabric 100 using a steel rod, and excess adhesive dispersion 110 can be removed. The carbon fiber fabric 100 treated with the adhesive dispersion 110 is heated in an oven at 35°C to 45°C for 45 to 55 minutes, the oven is configured to accommodate multiple plates at a time, and the carbon fiber fabric 100 treated with the adhesive dispersion is heated until all moisture is substantially removed, the carbon fiber fabric 100 treated with the dried adhesive dispersion 110 is heated in a curing oven at 85°C to 95°C for 25 to 35 minutes, so that the adhesive dispersion 110 can be cured on the carbon fiber fabric 100, the carbon fiber fabric 100 treated with the adhesive dispersion 110 is placed on a vacuum adsorption table 130, a film 120 is laid on it and vacuumed, so that the film 120 can be preliminarily bonded to the surface of the carbon fiber fabric 100 treated with the adhesive dispersion 110, and the air between the carbon fiber fabric 100 and the film 120 is extracted, so that the film 120 is more closely attached to the surface of the carbon fiber fabric 100. The water-based polyurethane with matte and soft properties is evenly coated on the side of the carbon fiber fabric 100 covered with the film 120 by rolling, so as to provide a softer luster and a softer skin-friendly feel. The carbon fiber fabric 100 covered with the film 120 is laminated by using a heated silicone rubber sheet 150 press 160. Since the silicone rubber sheet 150 has a certain degree of softness, preferably, a silicone rubber sheet 150 with a Shore hardness of 20 to 50 is used for lamination, so that the silicone rubber sheet can fully fit the texture of the carbon fiber fabric 100 during the lamination process, and then the film 120 can evenly cover each texture of the carbon fiber fabric 100, thereby making a textured carbon fiber composite material.

[0025] Preferably, the carbon fiber fabric 100 is a 3K carbon fiber cloth, and a single fiber bundle of the 3K carbon fiber cloth is woven into a 2×2 twill fabric style by 3000 carbon fibers.

[0026] In some preferred embodiments of the present invention, the carbon fiber cloth has the characteristics of low density, thin thickness, light weight, waterproofness, wear resistance, high temperature resistance and corrosion resistance.

[0027] Specifically, the adhesive dispersion 110 is made by mixing a dispersion solvent and an adhesive. The dispersion solvent is water. The adhesive is one or more of polyurethane, acrylic polymer, polyethylene, polypropylene, polyamide, thermoplastic or thermosetting series of elastomeric materials. The adhesive concentration is 0.5% to 10%. The film 120 includes one or more of thermoplastic polyurethane, ethylene-vinyl acetate copolymer, polyolefin, polypropylene, carboxylated acrylonitrile-butadiene copolymer, and the thickness of the film 120 is 0.01 mm to 0.6 mm.

[0028] In some specific embodiments of the present invention, the adhesive is prepared by mixing a dispersed solvent and an adhesive, so that the adhesive has better adhesion and fluidity, so that the adhesive can be fully sprayed or rod-coated on the carbon fiber fabric 100, and the adhesion between the film 120 and the carbon fiber fabric 100 is also better. By setting the film 120 to be attached to the carbon fiber fabric 100, the film 120 covers the carbon fiber fabric 100 to protect the fabric, and at the same time can enhance the waterproofness of the carbon fiber composite material.

[0029] Specifically, a plurality of vacuum adsorption holes 170 are provided on the table surface of the vacuum adsorption table 130 , and the vacuum adsorption holes 170 are used to adsorb the film 120 . A heating lamp 180 is provided on the vacuum adsorption table 130 , and the heating lamp 180 is used to heat the film 120 .

[0030] In some specific embodiments of the present invention, by setting a plurality of vacuum adsorption holes 170 on the vacuum adsorption table 130, various parts of the carbon fiber fabric 100 can be evenly vacuumed, so that the film 120 can be evenly adsorbed on the texture of the carbon fiber fabric 100. By setting a baking lamp 180, the film 120 is heated to soften it, thereby further increasing the fit of the film 120.

[0031] In the description of this specification, the description with reference to the terms "one embodiment, some embodiments, illustrative embodiments, examples, specific examples or some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0032] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of ordinary technicians in the relevant technical field without departing from the purpose of the present invention.

Claims

1. A method for manufacturing a carbon fiber composite material with a three-dimensional texture, characterized in that: The following steps are involved: Step 1: providing a carbon fiber fabric (100), and applying an adhesive dispersion (110) on at least one side of the carbon fiber fabric (100); Step 2: placing the carbon fiber fabric (100) treated with the adhesive dispersion (110) in an oven at 35°C to 45°C and heating for 45 to 55 minutes; Step 3: placing the heat-treated carbon fiber fabric (100) in a curing furnace at 85° C. to 95° C. for curing for 25 to 35 minutes; Step 4: laying a film (120) on at least one side of the carbon fiber fabric (100) after the curing treatment, placing the fabric on a vacuum adsorption table (130), starting a vacuum pump (140) to evacuate the carbon fiber fabric (100), and heating the fabric using a heating lamp (180); Step 5: coating the outer surface of the carbon fiber fabric (100) covered with the film (120) and vacuum-adsorbed with water-based polyurethane, blowing it dry after coating, and placing it in an oven at 85°C to 95°C for drying for 5 to 50 minutes; Step 6: heating the press (160) provided with the silicone rubber sheet (150) to 130°C to 150°C; Step 7: placing the carbon fiber fabric (100) after the drying process into the press (160), and applying a pressure of 48 kPa to 172 kPa for 7 to 15 minutes to produce a carbon fiber composite material with a three-dimensional texture.

2. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The carbon fiber fabric (100) is a 3K carbon fiber cloth, wherein a single fiber bundle of the 3K carbon fiber cloth is woven into a 2×2 twill fabric style by 3000 carbon fibers.

3. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The adhesive dispersion (110) is prepared by mixing a dispersion solvent and an adhesive.

4. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The dispersing solvent is water.

5. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The adhesive is one or more of polyurethane, acrylic polymer, polyethylene, polypropylene, polyamide, thermoplastic or thermosetting elastomeric materials.

6. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The binder concentration of the binder dispersion (110) is 0.5% to 10%.

7. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The film (120) includes one or more of thermoplastic polyurethane, ethylene-vinyl acetate copolymer, polyolefin, polypropylene, and carboxylated acrylonitrile-butadiene copolymer.

8. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: The film (120) has a thickness of 0.01 mm to 0.6 mm.

9. The method for manufacturing a carbon fiber composite material with a three-dimensional texture according to claim 1, characterized in that: A plurality of vacuum adsorption holes (170) are arranged on the table surface of the vacuum adsorption table (130), and the vacuum adsorption holes (170) are used to adsorb the film (120). The heating lamp (180) is arranged above the vacuum adsorption table (130), and the heating lamp (180) is used to heat the film (120).

Images