A carbon fiber thermoplastic prepreg fabric with a gradient structure

Abstract

The present invention discloses a carbon fiber thermoplastic prepreg fabric with a gradient structure, which is sequentially provided with a first thermoplastic high-temperature hot-melt matrix film layer, a first thermoplastic low-temperature hot-melt infiltration film layer, a first carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer, a unidirectionally arranged carbon fiber fabric layer, a second carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer, a second thermoplastic low-temperature hot-melt infiltration film layer, and a second thermoplastic high-temperature hot-melt matrix film layer from one side to the other side. Based on the fiber hybridization technology, a multi-layer gradient structure configuration is adopted, and hot-melt hybridization is used as the main production method, which can effectively ensure the overall stability and interfacial bonding force of the prepreg fabric.

Description

Technical Field

[0001] The present invention belongs to the technical field of carbon fiber thermoplastic prepreg fabrics, and particularly relates to a carbon fiber thermoplastic prepreg fabric with a gradient structure. Background Art

[0002] Disclosing the information of this background art section is only intended to enhance the understanding of the overall background of the present invention, and is not necessarily regarded as an admission or an implication in any form that this information constitutes the prior art already known to those of ordinary skill in the art.

[0003] Carbon fiber thermoplastic prepreg fabric is an intermediate product for producing thermoplastic carbon fiber composites. Using this product can better control the molding uniformity of thermoplastic composites. At the same time, the prepreg fabric impregnated with thermoplastic resin eliminates the impregnation and compounding processes of resin and fiber, improving the production efficiency of composites. Currently, the preparation of prepreg mainly adopts various composite methods such as emulsion impregnation method, hot melt impregnation method, fluidized bed impregnation method, etc. Different prepreg fabric preparation methods have their own advantages, but they also have their own problems. For example, the prepreg fabric prepared by injection hot melt process has complex equipment, high energy consumption, and low production efficiency. Among them, the penetration and interfacial bonding problems between the thermoplastic resin matrix and fiber tows of the prepreg fabric become the key to the effective play of the overall stability and mechanical properties of the subsequent composite material structure. Summary of the Invention

[0004] In order to solve the technical problems existing in the prior art, the purpose of the present invention is to provide a carbon fiber thermoplastic prepreg fabric with a gradient structure. Based on the fiber hybridization technology, adopting a multi-layer gradient structure configuration and using hot melt hybridization as the main production method can effectively ensure the overall stability and interfacial bonding force of the prepreg fabric.

[0005] To solve the above technical problems, the technical solution of the present disclosure is as follows:

[0006] On the one hand, the present invention provides a carbon fiber thermoplastic prepreg fabric with a gradient structure, which is sequentially provided with a first thermoplastic high-temperature hot melt matrix film layer, a first thermoplastic low-temperature hot melt penetration film layer, a first carbon fiber and thermoplastic hot melt fiber hybrid three-dimensional woven fabric layer, a carbon fiber fabric layer arranged unidirectionally, a second carbon fiber and thermoplastic hot melt fiber hybrid three-dimensional woven fabric layer, a second thermoplastic low-temperature hot melt penetration film layer, and a second thermoplastic high-temperature hot melt matrix film layer from one side to the other side.

[0007] Compared with the prior art, the beneficial effects of one or more of the above embodiments of the present invention are:

[0008] (1) The hybrid three-dimensional braided fabric layer is woven with a mixture of carbon fibers and thermoplastic hot-melt fibers. During hot pressing and forming, the thermoplastic hot-melt fibers melt, which can effectively improve the impregnation effect of the resin on the carbon fibers.

[0009] (2) The carbon fiber fabric layer arranged unidirectionally is located between two hybrid three-dimensional braided fabric layers, forming a sandwich hybrid structure, which can significantly improve the interlayer overall mechanical properties of the overall structure, making it not easy to delaminate. At the same time, the intermediate unidirectional fabric can improve the mechanical properties such as tensile and compressive properties within the layer; adopting a multi-dimensional carbon fiber fabric structure can flexibly adjust and design the overall mechanical strength and stiffness of the prepreg fabric.

[0010] (3) The low-temperature hot-melt resin film layer arranged on the outer side of the hybrid three-dimensional braided fabric layer melts during hot pressing and can penetrate into the interior of the internal multi-dimensional three-dimensional carbon fiber fabric, ensuring the infiltration and bonding effect of the internal interface of the fabric. A thermoplastic high-temperature hot-melt matrix film is arranged on the outermost layer and melts and penetrates during the process of hot pressing the final thermoplastic prepreg fabric to form a composite material, and is doped with the low-temperature permeable thermoplastic resin to form the overall matrix structure of the thermoplastic prepreg fabric;

[0011] The low-melting-point film improves the interlayer permeability, and the high-melting-point film improves the overall mechanical properties. The two cooperate with each other to comprehensively improve the melting permeability and the mechanical properties of the overall prepreg fabric. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The specification drawings forming a part of the present invention are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention.

[0013] Figure 1 It is a schematic structural diagram of a carbon fiber thermoplastic prepreg fabric with a gradient structure in an embodiment of the present invention.

[0014] Among them, 1. Carbon fiber fabric layer with unidirectional orthogonal arrangement, 2. Three-dimensional braided fabric layer, 3. Sandwich hybrid structure, 4. Thermoplastic low-temperature hot-melt permeation film layer, 5. Thermoplastic high-temperature hot-melt matrix film layer. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0015] It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs.

[0016] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular forms are also intended to include the plural forms. In addition, it should also be understood that when the terms "comprising" and / or "including" are used in this specification, they specify the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0017] A carbon fiber thermoplastic prepreg fabric with a gradient structure is successively provided with a first thermoplastic high-temperature hot-melt matrix film layer, a first thermoplastic low-temperature hot-melt permeation film layer, a first carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer, a unidirectionally arranged carbon fiber fabric layer, a second carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer, a second thermoplastic low-temperature hot-melt permeation film layer, and a second thermoplastic high-temperature hot-melt matrix film layer from one side to the other side.

[0018] The three layers of the first carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer, the unidirectionally arranged carbon fiber fabric layer, and the second carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer can be bonded by a film to prevent slippage between adjacent layers.

[0019] The unidirectionally arranged carbon fiber fabric layer can improve the mechanical properties of the overall in-plane of the prepreg fabric.

[0020] In some embodiments, the carbon fiber in the unidirectionally arranged carbon fiber fabric layer is selected from one or more of the following carbon fibers: T300, T700, T800, T1000, M40, M60, M40J, and M60J.

[0021] In some embodiments, the arrangement mode of the unidirectional fibers in the unidirectionally arranged carbon fiber fabric layer is orthogonal arrangement, skew arrangement, multi-axial arrangement, or quasi-isotropic arrangement.

[0022] Furthermore, the number of layers of the unidirectionally arranged fibers in the unidirectionally arranged carbon fiber fabric layer is 1-10 layers, such as 1 layer, 2 layers, 3 layers, 4 layers, 5 layers, 6 layers, 7 layers, 8 layers, 9 layers, or 10 layers.

[0023] In some embodiments, the three-dimensional weaving mode of the first carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer and the second carbon fiber and thermoplastic hot-melt fiber hybrid three-dimensional woven fabric layer is three-dimensional four-direction, three-dimensional five-direction, three-dimensional six-direction, or three-dimensional seven-direction.

[0024] Furthermore, the carbon fiber therein is selected from one or more of the following: T300, T700, T800, T1000, M40, M60, M40J, M60J.

[0025] Further, the hot-melt fiber is selected from polyamide, polyether ketone, polyether ether ketone, polyurethane, polyethylene or polyolefin resin.

[0026] Furthermore, the mass ratio of the hot-melt fiber to the carbon fiber is 0.2 - 0.7:1.

[0027] In some embodiments, the material of the thermoplastic low-temperature hot-melt permeable adhesive film layer is selected from polyethylene, polyolefin resin, polyurethane or EVA.

[0028] Further, the thickness of the thermoplastic low-temperature hot-melt permeable adhesive film layer is 0.1 - 0.9 mm.

[0029] In some embodiments, the material of the thermoplastic high-temperature hot-melt matrix adhesive film layer is selected from PPS, PET, PEEK, PA or PC.

[0030] Further, the thickness of the thermoplastic high-temperature hot-melt matrix adhesive film layer is 0.1 - 0.9 mm.

[0031] Flexibly adjusted according to the designed penetration requirements, the high-temperature hot-melt matrix adhesive film is applied to the outermost part of the low-temperature hot-melt permeable adhesive film layer, and undergoes melt penetration during the final hot pressing of the thermoplastic prepreg to form a composite material, and is intermingled with the low-temperature permeable thermoplastic resin to form the overall matrix structure of the thermoplastic prepreg.

[0032] Example 1

[0033] A gradient structure carbon fiber thermoplastic prepreg arrangement provided by the present invention can be specifically implemented with a three-layer structure, such as Figure 1 shown: The innermost part adopts a sandwich hybrid structure 3 of a three-dimensional woven fabric layer 2 and a unidirectional orthogonal arrangement of carbon fiber fabric layer 1. Among them, the innermost unidirectional orthogonal arrangement of carbon fiber fabric layer 1 is a four-layer structure arranged orthogonally with a hybrid ratio of 2:1 of T300 carbon fiber and M60J carbon fiber. On both sides of the unidirectional orthogonal arrangement of carbon fiber fabric, a hybrid of polyolefin filament fiber and T1000 carbon fiber with a hybrid ratio of 1:6 is used to form a three-dimensional fabric structure in a three-dimensional four-directional manner.

[0034] On both sides of the sandwich hybrid structure 3, a thermoplastic low-temperature hot-melt permeable adhesive film layer 4 with a thickness of 0.1 mm is prepared using polyethylene resin, and the final hot-melt temperature is controlled between 100 - 150 °C. On the outermost layer on both sides of the thermoplastic low-temperature hot-melt permeable adhesive film layer 4, a thermoplastic high-temperature hot-melt matrix adhesive film layer 5 of PPS system with a thickness of 0.1 mm is prepared, and the final hot-melt temperature is controlled between 180 - 220 °C. The thermoplastic high-temperature hot-melt matrix adhesive film is applied to the outermost part of the thermoplastic low-temperature hot-melt permeable adhesive film layer, and undergoes melt penetration during the final hot pressing of the thermoplastic prepreg to form a composite material, and is intermingled with the low-temperature permeable thermoplastic resin to form the overall matrix structure of the thermoplastic prepreg.

[0035] Example 2

[0036] A gradient structure carbon fiber thermoplastic prepreg fabric arrangement provided by the present invention can be specifically implemented by adopting a three-layer structure: the core part adopts a sandwich hybrid structure of a three-dimensional woven fabric layer and a carbon fiber fabric layer arranged unidirectionally and orthogonally. Among them, the very center is a four-layer structure in which T800 carbon fiber and M40 carbon fiber are arranged obliquely at 60° with a hybrid ratio of 1:2. On both sides of the carbon fiber fabric arranged unidirectionally and orthogonally, polyolefin filament fiber and T1000 carbon fiber are hybridized with a hybrid ratio of 1:8 to form a three-dimensional fabric structure in a three-dimensional seven-directional manner.

[0037] On both sides of the sandwich hybrid structure, a thermoplastic low-temperature hot-melt penetration adhesive film layer with a thickness of 0.5 mm is prepared by using EVA resin, and the final hot-melt temperature is controlled between 140 - 150 °C. On the outermost layers on both sides of the low-temperature hot-melt penetration adhesive film layer, a high-temperature hot-melt matrix adhesive film layer of PPS system with a thickness of 0.3 mm is prepared, and the final hot-melt temperature is controlled between 210 - 290 °C. The high-temperature hot-melt matrix adhesive film is applied to the outermost part of the low-temperature hot-melt penetration adhesive film layer, and during the process of hot-pressing the final thermoplastic prepreg to form a composite material, it undergoes melt penetration and is doped with the low-temperature permeable thermoplastic resin to form the overall matrix structure of the thermoplastic prepreg.

[0038] Example 3

[0039] A gradient structure carbon fiber thermoplastic prepreg fabric arrangement provided by the present invention can be specifically implemented by adopting a three-layer structure: the innermost part adopts a sandwich hybrid structure of a three-dimensional woven fabric layer and a carbon fiber fabric structure arranged unidirectionally and orthogonally. Among them, the very center is a six-layer structure in which M40J carbon fiber and T300 carbon fiber are arranged in a multi-axial manner with a hybrid ratio of 1:3. On both sides of the carbon fiber fabric arranged unidirectionally and orthogonally, polyurethane filament fiber and T1000 carbon fiber are hybridized with a hybrid ratio of 1:4 to form a three-dimensional fabric structure in a three-dimensional six-directional manner.

[0040] On both sides of the sandwich hybrid structure, a thermoplastic low-temperature hot-melt penetration adhesive film layer with a thickness of 0.25 mm is prepared by using polyethylene resin, and the final hot-melt temperature is controlled between 130 - 150 °C. On the outermost layers on both sides of the low-temperature hot-melt penetration adhesive film layer, a high-temperature hot-melt matrix adhesive film layer of PC system with a thickness of 0.2 mm is prepared, and the final hot-melt temperature is controlled between 220 - 240 °C. The high-temperature hot-melt matrix adhesive film is applied to the outermost part of the low-temperature hot-melt penetration adhesive film layer, and during the process of hot-pressing the final thermoplastic prepreg to form a composite material, it undergoes melt penetration and is doped with the low-temperature permeable thermoplastic resin to form the overall matrix structure of the thermoplastic prepreg.

[0041] Example 4

[0042] A gradient structure carbon fiber thermoplastic prepreg fabric arrangement provided by the present invention can be specifically implemented with a three-layer structure: the innermost part adopts a sandwich hybrid structure of a three-dimensional woven fabric layer and a carbon fiber fabric structure arranged unidirectionally and orthogonally. Among them, the center is a four-layer structure with T800 carbon fiber and M60J carbon fiber in a hybrid ratio of 3:1 and arranged in a 0 / 30 / 60 / 90 quasi-isotropic manner. On both sides of the unidirectionally and orthogonally arranged carbon fiber fabric, polyether ether ketone filament fibers and T700 carbon fiber are hybridized in a ratio of 1:5 to form a three-dimensional five-directional three-dimensional fabric structure.

[0043] On both sides of the sandwich hybrid structure, a thermoplastic low-temperature hot melt penetration adhesive film layer with a thickness of 0.1 mm is prepared using EVA resin, and the final hot melt temperature is controlled between 130 - 150 °C. On the outermost layers on both sides of the low-temperature hot melt penetration adhesive film layer, a high-temperature hot melt matrix adhesive film layer of the PA system with a thickness of 0.7 mm is prepared, and the final hot melt temperature is controlled between 230 - 250 °C. The high-temperature hot melt matrix adhesive film is applied to the outermost part of the low-temperature hot melt penetration adhesive film layer and undergoes melt penetration during the final hot pressing of the thermoplastic prepreg fabric to form a composite material, and is doped with the low-temperature permeable thermoplastic resin to form the overall matrix structure of the thermoplastic prepreg fabric.

[0044] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A carbon fiber thermoplastic prepreg fabric with a gradient structure, characterized in that: A first thermoplastic high-temperature hot-melt matrix film layer, a first thermoplastic low-temperature hot-melt penetration film layer, a first three-dimensional hybrid woven fabric layer of carbon fiber and thermoplastic hot-melt fiber, a unidirectionally arranged carbon fiber fabric layer, a second three-dimensional hybrid woven fabric layer of carbon fiber and thermoplastic hot-melt fiber, a second thermoplastic low-temperature hot-melt penetration film layer, and a second thermoplastic high-temperature hot-melt matrix film layer are sequentially arranged from one side to the other side; The three-dimensional weaving methods of the first three-dimensional hybrid woven fabric layer of carbon fiber and thermoplastic hot-melt fiber and the second three-dimensional hybrid woven fabric layer of carbon fiber and thermoplastic hot-melt fiber are three-dimensional four-direction, three-dimensional five-direction, three-dimensional six-direction or three-dimensional seven-direction; The carbon fiber is one or more selected from the following: T300, T700, T800, T1000, M40, M60, M40J, M60J; The thermoplastic hot-melt fiber is selected from polyamide, polyether ketone, polyether ether ketone, polyurethane, polyolefin resin; The mass ratio of the thermoplastic hot-melt fiber to the carbon fiber is 0.2-0.7:1; The material of the thermoplastic low-temperature hot-melt penetration film layer is selected from polyolefin resin, polyurethane or EVA; The thickness of the thermoplastic low-temperature hot-melt penetration film layer is 0.1-0.9 mm; The material of the thermoplastic high-temperature hot-melt matrix film layer is selected from PPS, PET, PEEK, PA or PC; The thickness of the thermoplastic high-temperature hot-melt matrix film layer is 0.1-0.9 mm.

2. The gradient-structured carbon fiber thermoplastic prepreg fabric according to claim 1, wherein: The arrangement mode of the unidirectional fibers in the unidirectionally arranged carbon fiber fabric layer is orthogonal arrangement, skew arrangement or multi-axial arrangement.

3. The gradient-structured carbon fiber thermoplastic prepreg fabric according to claim 2, wherein: The number of layers of the unidirectionally arranged fibers in the unidirectionally arranged carbon fiber fabric layer is 1-10 layers.

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