Carbon fiber-based composite part and preparation method thereof, frame and glasses

Abstract

The present invention discloses a carbon fiber-based composite component, a method for manufacturing the component, a frame, and glasses. The component comprises a main body and a connecting portion. The main body comprises a carbon fiber composite layer. The connecting portion is disposed on the side of the carbon fiber composite layer and is made of resin. The connecting portion and the carbon fiber composite layer are integrally formed by hot pressing. The carbon fiber-based composite component of the present invention can meet various performance requirements and has excellent connection stability.

Description

Technical Field

[0001] The present invention relates to the technical field of composite material preparation, and in particular to a carbon fiber-based composite part and a preparation method thereof, a spectacle frame and glasses. Background Art

[0002] With the increasing prevalence of electronic products, the number of people suffering from myopia in my country has increased significantly. However, current myopia surgery still has certain drawbacks, and most people still choose to wear glasses. Due to the long-term nature of glasses, the performance requirements for frames are becoming increasingly demanding. Currently, frames are primarily made of metal, sheet metal, ordinary plastic, composite materials, wood, TR90, and carbon fiber. Each of these materials has its own advantages and disadvantages.

[0003] Among them, frames made of carbon fiber have advantages over frames made of other materials due to their light weight, corrosion resistance, and resistance to deformation. They combine the two major characteristics of carbon fiber: strong tensile strength and softness and processability, making them strong, durable, and with a strong color. However, one disadvantage of carbon fiber parts is that they are relatively brittle. They will break after bending to a certain degree, and once damaged, they are difficult to repair. Carbon fiber parts also need to be connected to other structures during use. Therefore, if the connection is also made of carbon fiber, the corresponding bending performance cannot be achieved. If the connection is achieved by bonding, the connection structure is not stable and is prone to cracking. Summary of the Invention

[0004] The main purpose of the present invention is to provide a carbon fiber-based composite part, aiming to obtain a carbon fiber-based composite part that can achieve different performance requirements and has good connection stability.

[0005] To achieve the above-mentioned purpose, the carbon fiber-based composite component proposed by the present invention comprises:

[0006] a main body portion, the main body portion comprising a carbon fiber composite layer; and

[0007] A connecting portion is provided on a side surface of the carbon fiber composite layer, the connecting portion is made of resin, and the connecting portion and the carbon fiber composite layer are a hot-pressed integrally formed structure.

[0008] In an optional embodiment, the carbon fiber composite layer includes a plain carbon fiber layer and a thermoplastic film layer stacked on top of each other, and the plain carbon fiber layer and the thermoplastic film layer are connected by hot pressing.

[0009] In an optional embodiment, the raw yarn of the plain carbon fiber layer is one of 3K, 6K, 12K, 24K, and 36K;

[0010] And / or, the material of the thermoplastic film layer is one of polyetherimide (PEI), polyetherketone (PEK), polysulfone (PSF) and polyethersulfone (PES);

[0011] And / or, the resin is one of polyvinyl acetate, polyvinyl acetal, perchlorethylene resin, polyacrylate, polyamide and polysulfone.

[0012] In an optional embodiment, the main body includes a plurality of carbon fiber composite layers stacked and press-formed, and thermoplastic bonding powder is sandwiched between two adjacent carbon fiber composite layers.

[0013] In an optional embodiment, the number of layers of the carbon fiber composite layer is 3-5;

[0014] And / or, the thickness of the main body is in the range of 0.5 mm to 1.5 mm.

[0015] In an optional embodiment, the thermoplastic bonding powder is one of polyamide powder, polyethylene powder and polyurethane powder;

[0016] And / or, the particle size of the thermoplastic bonding powder is between 200 and 2000 meshes.

[0017] The present invention also provides a method for preparing a carbon fiber-based composite part, wherein the carbon fiber-based composite part includes a main body and a connecting part provided on a side of the main body. The preparation method includes:

[0018] Providing a mold, wherein the mold is formed with a main cavity for accommodating the main body and a hollow cavity forming the connecting portion, wherein the hollow cavity is connected to the main cavity;

[0019] Making carbon fiber prepregs;

[0020] Laying the carbon fiber prepreg in the main cavity, and heating and pressurizing the mold;

[0021] After curing, the carbon fiber-based composite part is demoulded.

[0022] In an optional embodiment, the mold includes a main mold, a core mold and an additional mold, the main mold forms an installation cavity, the core mold is placed in the installation cavity, and is enclosed with the cavity wall of the installation cavity to form a U-shaped main cavity, the additional film forms a hollow cavity, and is installed on the outer peripheral side of the main mold, and the cavity wall of the installation cavity is provided with an opening connecting to the hollow cavity.

[0023] In an optional embodiment, the steps of making a carbon fiber prepreg specifically include:

[0024] Cutting the plain carbon fiber cloth and the thermoplastic film to form a plain carbon fiber layer and a thermoplastic film layer;

[0025] The plain carbon fiber layer and the thermoplastic film layer are stacked and hot-pressed to form a carbon fiber composite layer;

[0026] Multiple carbon fiber composite layers are stacked and laid, and thermoplastic bonding powder is sprayed between two adjacent carbon fiber composite layers to form a carbon fiber prepreg.

[0027] In an optional embodiment, the raw yarn of the plain carbon fiber layer is one of 3K, 6K, 12K, 24K, and 36K;

[0028] And / or, the material of the thermoplastic film layer is one of polyetherimide, polyetherketone, polysulfone and polyethersulfone;

[0029] And / or, the thermoplastic bonding powder is one of polyamide powder, polyethylene powder and polyurethane powder;

[0030] And / or, the particle size of the thermoplastic bonding powder is between 200 and 2000 meshes.

[0031] In an optional embodiment, the resin content of the carbon fiber prepreg ranges from 55% to 65%;

[0032] And / or, the number of layers of the carbon fiber composite layer is 3 to 5.

[0033] In an optional embodiment, during the step of heating and pressurizing the mold, 5% to 15% of the resin in the carbon fiber prepreg flows into the hollow cavity to form the connecting portion.

[0034] In an optional embodiment, the step of heating and pressurizing the mold is specifically as follows:

[0035] The mold is placed in a preheated hot press, and the heating temperature range is set to 130° C.-180° C., the applied pressure is set to 0.5-2 MPa, and the pressing time is 20-60 min.

[0036] In an optional embodiment, before the step of laying the carbon fiber prepreg in the main cavity, the method further includes the following steps:

[0037] The main cavity of the mold is cleaned and a release agent is applied.

[0038] The present invention also proposes a frame, which is a carbon fiber-based composite part as described above, or is made by the preparation method of a carbon fiber-based composite part as described above. The cross-section of the main body is U-shaped, and there are two connecting parts, which are respectively arranged on two outer side surfaces of the main body that are opposite to each other.

[0039] The present invention further provides a pair of glasses, comprising a frame and lenses mounted on the frame, wherein the frame is the frame described above.

[0040] In the technical solution of the present invention, the carbon fiber-based composite part comprises a main body and a connecting part. The main body is made of a carbon fiber composite layer, which takes advantage of the carbon fiber composite's light weight, corrosion resistance, and deformation resistance, making the part lightweight and stable. The connecting part is made of resin, which meets the required toughness and is easy to bend. The two are integrally formed by hot pressing, forming an integrated composite part with a relatively stable connection structure. This eliminates the need for separate reinforcement and assembly later, reduces assembly difficulty, and improves production efficiency. It also improves product dimensional accuracy and enhances product dimensional stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. 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 the structures shown in these drawings without paying any creative work.

[0042] Figure 1 This is a schematic structural diagram of an embodiment of a carbon fiber-based composite component of the present invention;

[0043] Figure 2 for Figure 1 A left side view of the carbon fiber-based composite part shown;

[0044] Figure 3 for Figure 1 Schematic diagram of the microstructure of the carbon fiber composite layer in the carbon fiber-based composite part shown;

[0045] Figure 4 A flowchart of the steps of an embodiment of a method for preparing a carbon fiber-based composite part according to the present invention;

[0046] Figure 5 A flowchart of another embodiment of a method for preparing a carbon fiber-based composite part according to the present invention;

[0047] Figure 6 for Figure 4 An exploded view of a mold in the method for preparing a carbon fiber-based composite part;

[0048] Figure 7 for Figure 6 Schematic diagram of the structure of the auxiliary mold in the mold shown.

[0049] Description of Figure Numbers:

[0050] Label name Label name 1 Carbon fiber-based composite parts 212 lower die 11 Main body 213 Left Model 111 Plain carbon fiber layer 214 Right Model 113 Thermoplastic film layer 215 Front Model 115 Thermoplastic bonding powder 216 Back mold 13 Connection 22 core mold 2 mold 24 Additional film 21 Master Model 241 Hollow cavity 211 Upper mold

[0051] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0052] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0053] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0054] In addition, the terms "first," "second," and so on, used in this disclosure are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referenced. Thus, a feature specified as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of this disclosure, "plurality" means at least two, such as two or three, unless otherwise specifically defined.

[0055] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in this field can implement it. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0056] Based on the fact that the parts made of carbon fiber materials in the prior art are brittle and cannot be bent at will, they cannot meet the requirements of structures that need to be connected or bent at the connection position. Therefore, the present invention proposes a carbon fiber-based composite part. This structure combines the lightweight and stability advantages of the carbon fiber composite layer with the high toughness advantage of the resin part, and through the integrated molding of the two, a light-weight and stable part can be obtained, which meets the requirements for different performance at different positions of the part.

[0057] Please refer to Figures 1 to 3In an optional embodiment of the present invention, the carbon fiber-based composite part 1 includes a main body 11 and a connecting part 13, the main body 11 includes a carbon fiber composite layer; the connecting part 13 is arranged on the side of the carbon fiber composite layer, the connecting part 13 is made of resin, and the connecting part 13 and the carbon fiber composite layer are a hot-pressed integrated molding structure.

[0058] It can be understood that the carbon fiber-based composite component 1 can be applied to the appearance structural parts of various head-mounted devices, so as to achieve the effect of light weight and stable structure, such as AR head-mounted devices, VR head-mounted devices or AR glasses, myopia glasses, etc.

[0059] In this embodiment, the carbon fiber-based composite component 1 refers to a structural component mainly made of a carbon fiber material combined with a resin material. The main body 11 is the main structure of the carbon fiber-based composite component 1. For example, when the component is a spectacle frame, it can be a temple or a frame, so the main body 11 has a certain structural shape and extension direction. The shape of its cross section is not limited here. For example, its cross-sectional shape can be a solid square, a circular ring or a U-shape. The main body 11 includes a carbon fiber composite layer, which is a composite layer structure including a carbon fiber layer. Optionally, in other embodiments, other material layers can be provided for composite molding, or the number of carbon fiber composite layers can be increased as needed. The connecting portion 13 is provided on the outer side of the main body 11 and mainly serves a connecting function. For example, when the main body 11 is a temple, the connecting portion 13 is an axial structure provided at its end, so that it can be rotatably connected to the frame.

[0060] In the technical solution of the present invention, a carbon fiber-based composite part 1 comprises a main body 11 and a connecting part 13. Main body 11 is made of a carbon fiber composite layer, which takes advantage of its light weight, corrosion resistance, and deformation resistance, making the part lightweight and stable. Connecting part 13 is made of resin, which meets the required toughness and is easy to bend. The two are integrally formed by hot pressing, forming an integrated composite part with a relatively stable connection structure. This eliminates the need for separate reinforcement and assembly later, reduces assembly difficulty, and improves production efficiency. It also improves product dimensional accuracy and enhances product dimensional stability.

[0061] In an optional embodiment, the carbon fiber composite layer includes a plain carbon fiber layer 111 and a thermoplastic film layer 113 stacked on top of each other, and the plain carbon fiber layer 111 and the thermoplastic film layer 113 are connected by hot pressing.

[0062] In this embodiment, the carbon fiber composite layer includes a plain carbon fiber layer 111 and a thermoplastic film layer 113. Plain carbon fiber layer 111 is a structural layer made of plain carbon fiber fabric. Its characteristic is that the warp and weft yarns are interwoven in an up-and-down pattern, meaning every other warp and weft yarn interlaces once. This results in numerous interlacing points, making the fabric strong, wear-resistant, stiff, and smooth. This type of carbon fiber fabric also has numerous fiber bundle bending points, resulting in high elongation and tensile strength during stretching, making it easier to handle given its simple structure. Furthermore, the thermoplastic film layer 113 is stacked with the plain carbon fiber layer 111 to form a physically mixed prepreg fabric. This is then subjected to a heat pressing process. Due to the resin material properties of the thermoplastic film layer 113, the structural stability and corrosion resistance of the carbon fiber composite layer are further improved. Furthermore, the connection portion 13 between the carbon fiber composite layer and the resin material is more easily integrated into a single structure, improving the connection stability.

[0063] In an optional embodiment, the raw yarn type of the plain carbon fiber layer 111 is one of 3K, 6K, 12K, 24K, and 36K;

[0064] And / or, the material of the thermoplastic film layer 113 is one of polyetherimide, polyetherketone, polysulfone and polyethersulfone;

[0065] And / or, the resin is one of polyvinyl acetate, polyvinyl acetal, perchlorethylene resin, polyacrylate, polyamide and polysulfone.

[0066] In this embodiment, the raw yarn type of the plain carbon fiber layer 111 can be one of 3K, 6K, 12K, 24K, and 36K. Using any of the above plain carbon fiber layers 111 can ensure its structural strength while reducing material costs. Of course, the raw yarn types of the plain carbon fiber layer 111 are not limited to the above types.

[0067] With or without the aforementioned material limitations, the thermoplastic film layer 113 is selected from one of polyetherimide (PEI), polyetherketone (PEK), polysulfone (PSF), and polyethersulfone resin (PES) to provide a better wetting effect on the carbon fiber layer, thereby improving the heat resistance, corrosion resistance, and structural stability of the carbon fiber composite layer. Of course, the thermoplastic film layer 113 is not limited to the aforementioned materials and may also be a thermoplastic polyurethane elastomer (TPU).

[0068] With or without limiting the above materials, the resin is one of polyvinyl acetate (PVAc), polyvinyl acetal (Poly (vinyl formal)), chlorinated PVC resin (chlorinated PVC resin), polyacrylate (polyacrylate), polyamide (Nylon) and polysulfone (Polysalfone, PSF), so as to have good wear resistance and corrosion resistance.

[0069] Please refer to Figure 4 In an optional embodiment, the main body 11 includes multiple carbon fiber composite layers that are stacked and press-formed, and thermoplastic bonding powder 115 is sandwiched between two adjacent carbon fiber composite layers.

[0070] In this embodiment, in order to further improve the structural strength of the main body 11, the main body 11 is configured to include multiple carbon fiber composite layers. At the same time, a thermoplastic bonding powder 115 is provided between two adjacent carbon fiber composite layers. This is also a physically mixed prepreg, thereby increasing the resin content of the main body 11 to ensure an integrated molding effect with the connecting portion 13 and improve product yield. Optionally, the thermoplastic bonding powder 115 can be selected from one of polyamide powder, polyethylene powder, and polyurethane powder, thereby having better adhesion and heat resistance, and good impregnation and connection effects. The thermoplastic film layer 113 and the thermoplastic bonding powder 115 are matched to effectively strengthen the interface bonding between adjacent carbon fiber composite layers, making the product performance better and the service life longer.

[0071] It can be understood that the particle size of the thermoplastic bonding powder 115 should not be too large, otherwise it will affect the density and thermoplastic effect of the main body 11. Of course, the particle size of the thermoplastic bonding powder 115 will not be too small, otherwise it will increase the processing cost. The particle size of the thermoplastic bonding powder 115 is set at 200-2000 mesh, for example, 300 mesh, 500 mesh, 700 mesh, 900 mesh, 1100 mesh, 1300 mesh, 1600 mesh, 1800 mesh, etc., so as to have a better thermoplastic connection effect and save costs.

[0072] In an optional embodiment, the number of carbon fiber composite layers is 3-5 layers, for example, 3 layers, 4 layers or 5 layers, so as to have a better reinforcement effect without increasing the cost too much.

[0073] Based on whether or not the number of carbon fiber composite layers is set, the thickness of the main body 11 is set to a range of 0.5 mm to 1.5 mm. It is understandable that in the scenario where the carbon fiber-based composite component 1 is used, the structural weight requirement is low and the strength requirement is high. Therefore, in this embodiment, the thickness of the main body 11 is set to a range of 0.5 mm to 1.5 mm, for example, 0.5 mm, 0.7 mm, 1 mm, or 1.2 mm, etc., so as to make the component lighter and improve wearing comfort while ensuring structural strength.

[0074] Please refer to Figure 1 and Figure 4 The present invention also proposes a method for preparing a carbon fiber-based composite part. The carbon fiber-based composite part 1 includes a main body 11 and a connecting portion 13 provided on a side of the main body 11. The preparation method includes:

[0075] Step S1: providing a mold 2, wherein the mold 2 is formed with a main cavity for accommodating the main body 11 and a hollow cavity 241 forming the connecting portion 13, wherein the hollow cavity 241 is connected to the main cavity;

[0076] Step S2: making carbon fiber prepregs;

[0077] Step S3: laying the carbon fiber prepreg in the main cavity and performing heating and pressurizing treatment on the mold 2;

[0078] Step S4: demoulding the carbon fiber-based composite part 1 after curing.

[0079] In this embodiment, in step S1, a mold 2 of a specific structure is provided. Due to the particularity of the structure of the carbon fiber-based composite part 1 of this application, a mold 2 of a corresponding structure needs to be designed before processing and preparation can be carried out. Since the carbon fiber-based composite part 1 includes a main body 11 and a connecting part 13, the mold 2 is formed with a main cavity for accommodating the main body 11 and a hollow cavity 241 for accommodating the connecting part 13. The hollow cavity 241 is connected to the main cavity, so that it can be connected into an integrated structure during the subsequent hot pressing process. In step S2, a carbon fiber prepreg needs to be made. The carbon fiber prepreg is the main material for forming the main body 11. It is an intermediate material in which the carbon fiber material can play a role by compounding the resin on the carbon fiber through high pressure and high temperature technology. After the carbon fiber prepreg is made, step S3 is entered to lay the carbon fiber prepreg into the main cavity, thereby forming a main body 11 of the same shape as the main cavity of the mold 2. At the same time, the mold 2 is heated and pressurized, that is, hot-pressed, so that the resin material in the carbon fiber prepreg enters the hollow cavity 241 and forms the connecting portion 13 after curing. Finally, in step S4, the mold 2 is cooled and then demolded to obtain a carbon fiber-based composite part 1 with the main body 11 and the connecting portion 13 as an integrated structure.

[0080] Please refer to Figure 6 and Figure 7 In an optional embodiment, the mold 2 includes a main mold 21, a core mold 22 and an additional mold. The main mold 21 forms an installation cavity. The core mold 22 is placed in the installation cavity and is enclosed with the cavity wall of the installation cavity to form a U-shaped main cavity. The additional film 24 forms a hollow cavity 241 and is installed on the outer peripheral side of the main mold 21. The cavity wall of the installation cavity is provided with an opening connected to the hollow cavity 241.

[0081] In this embodiment, the mold 2 is an assembled structure comprising a main mold 21, a core mold 22, and an additional mold. The main mold 21 comprises an upper mold 211, a lower mold 212, a front mold 215, a rear mold 216, a left mold 213, and a right mold 214, which are interconnected to form a rectangular parallelepiped structure with an internal mounting cavity. The core mold 22 is disposed within the mounting cavity and is connected to the inner surface of the upper mold 211, thereby forming a U-shaped main cavity. When the carbon fiber prepreg is laid in the main cavity, the carbon fiber main cavity is also bent into a U-shape. The additional mold is mounted on the front mold 215 and / or the rear mold 216 and has a hollow cavity 241. It is connected to the main cavity through an opening formed in the cavity wall of the mounting cavity. This opening serves as a channel for resin inflow, so the size of the opening can be set to be the same as the opening size of the hollow cavity 241 to ensure glue flow efficiency. The U-shaped main body 11 can make the final product lighter and have higher structural strength.

[0082] Optionally, the upper mold 211, the lower mold 212, the front mold 215, the back mold 216, the left mold 213 and the right mold 214 are all connected by threads, so as to facilitate demoulding and subsequent maintenance and replacement. Specifically, positioning pins and positioning holes can be provided to achieve preliminary positioning. The upper mold 211 is now threadedly connected to the core mold 22, and then the front mold 215 and the lower mold 212 are threadedly connected, and the back mold 216 and the lower mold 212 are threadedly connected. Then, the left mold 213 and the front mold 215 are connected, the right mold 214 and the front mold 215 are connected, the left mold 213 and the back mold 216 are connected, and the right mold 214 and the back mold 216 are connected. Finally, the additional mold is connected to the front mold 215 and the back mold 216 to achieve mold 2 locking. After the carbon fiber prepreg is laid, the core mold 22 is placed in the installation cavity and locked, and the assembly of the mold 2 and the carbon fiber prepreg is completed.

[0083] In one embodiment, the dimensions of the additional mold are designed based on the dimensions of the main mold 21. For example, if the length of the main mold 21 ranges from 85 mm to 105 mm, the width ranges from 5 mm to 15 mm, and the height ranges from 4 mm to 6 mm, the length of the hollow cavity 241 can be set to range from 15 mm to 25 mm, the width ranges from 1 mm to 3 mm, and the height ranges from 1 mm to 3 mm. Of course, in other embodiments, the desired dimensions can also be set as needed.

[0084] Please refer to Figure 5 In an optional embodiment, step S2 of making a carbon fiber prepreg specifically includes:

[0085] Step S21: cutting the plain carbon fiber cloth and the thermoplastic film to form a plain carbon fiber layer 111 and a thermoplastic film layer 113;

[0086] Step S22: stacking the plain carbon fiber layer 111 and the thermoplastic film layer 113 and performing hot pressing to form a carbon fiber composite layer;

[0087] Step S23: stacking and laying multiple carbon fiber composite layers, and spraying thermoplastic bonding powder 115 between two adjacent carbon fiber composite layers to form a carbon fiber prepreg.

[0088] In this embodiment, the carbon fiber prepreg comprises a multi-layer carbon fiber composite layer, which is formed by hot pressing a plain carbon fiber layer 111 and a thermoplastic film layer 113. First, the plain carbon fiber fabric is cut to a suitable size and shape, for example, into a 25 cm long by 25 cm wide square structure. It is then flame-oxidized using a spray gun to transform it into a heat-resistant structure and increase its density, forming the plain carbon fiber layer 111. The thermoplastic film is then cut, for example, into a 25 cm long by 25 cm wide square structure. The two are then stacked and hot-pressed to form the carbon fiber composite layer. During this process, the resin in the thermoplastic film layer 113 flows and infiltrates into the plain carbon fiber layer 111, forming a single-piece impregnation material. The use of thermoplastic film and ultrafine thermoplastic adhesive powder 115, which are matched, effectively strengthens the interface bonding between adjacent layers, resulting in superior product performance and a longer service life.

[0089] In step 23, multiple carbon fiber composite layers are stacked, and thermoplastic bonding powder 115 is sprayed between two adjacent carbon fiber composite layers. This structure is physically mixed and impregnated, thereby forming a carbon fiber prepreg.

[0090] It is then laid into the mold 2. During the hot pressing process, the thermoplastic adhesive powder 115 will form an infiltrated form and partially flow into the hollow cavity 241 together with part of the resin in the thermoplastic film layer 113. After solidification, a connecting portion 13 is formed. The remaining resin forms a stable connection structure after solidification, thereby ensuring the integrated structure of the carbon fiber-based composite component 1.

[0091] In an optional embodiment, the raw yarn type of the plain carbon fiber layer 111 is one of 3K, 6K, 12K, 24K, and 36K;

[0092] And / or, the material of the thermoplastic film layer 113 is one of polyetherimide, polyetherketone, polysulfone and polyethersulfone;

[0093] And / or, the thermoplastic bonding powder 115 is one of polyamide powder, polyethylene powder and polyurethane powder;

[0094] And / or, the particle size of the thermoplastic bonding powder 115 is between 200 and 2000 meshes.

[0095] In this embodiment, the raw yarn type of the plain carbon fiber layer 111 can be one of 3K, 6K, 12K, 24K, and 36K. Using any of the above plain carbon fiber layers 111 can ensure its structural strength while reducing material costs. Of course, the raw yarn types of the plain carbon fiber layer 111 are not limited to the above types.

[0096] With or without the aforementioned material limitations, the thermoplastic film layer 113 is selected from one of polyetherimide (PEI), polyetherketone (PEK), polysulfone (PSF), and polyethersulfone resin (PES) to provide a better wetting effect on the carbon fiber layer, thereby improving the heat resistance, corrosion resistance, and structural stability of the carbon fiber composite layer. Of course, the thermoplastic film layer 113 is not limited to the aforementioned materials and may also be a thermoplastic polyurethane elastomer (TPU).

[0097] The thermoplastic bonding powder 115 can be selected from polyamide powder, polyethylene powder, and polyurethane powder, thereby having good adhesion and heat resistance, and good infiltration and connection effects. Of course, the thermoplastic bonding powder 115 can be selected to be the same or similar resin type as the thermoplastic film layer 113, so that during the hot pressing process, the bonding between the carbon fiber-based composite can be improved, and the structural strength of the one-piece molding can be increased.

[0098] It can be understood that the particle size of the thermoplastic bonding powder 115 should not be too large, otherwise it will affect the density and thermoplastic effect of the main body 11. Of course, the particle size of the thermoplastic bonding powder 115 will not be too small, otherwise it will increase the processing cost. The particle size of the thermoplastic bonding powder 115 is set at 200-2000 mesh, for example, 300 mesh, 500 mesh, 700 mesh, 900 mesh, 1100 mesh, 1300 mesh, 1600 mesh, 1800 mesh, etc., so as to have a better thermoplastic connection effect and save costs.

[0099] In an optional embodiment, the resin content of the carbon fiber prepreg ranges from 55% to 65%;

[0100] And / or, the number of layers of the carbon fiber composite layer is 3 to 5.

[0101] In this embodiment, in order to ensure the formation of the connecting portion 13, the resin content in the carbon fiber prepreg should not be too low. Of course, the resin content in the carbon fiber prepreg should not be too high, otherwise the reinforcement effect will be poor. Therefore, the resin content in the carbon fiber prepreg is selected to be in the range of 55% to 65%, for example, 55%, 57%, 59%, 60%, 62%, 63%, etc., so as to ensure the amount of glue entering the hollow cavity 241, while also ensuring the structural strength of the main body 11.

[0102] With or without limiting the resin content, the number of carbon fiber composite layers is set to 3 to 5 layers, for example, 3 layers, 4 layers or 5 layers, so as to have a better reinforcement effect without increasing the cost too much.

[0103] In an optional embodiment, during the step of heating and pressurizing the mold 2 , 5% to 15% of the resin in the carbon fiber prepreg flows into the hollow cavity 241 to form the connecting portion 13 .

[0104] In this embodiment, the carbon fiber prepreg contains 55% to 65% resin to ensure the amount of resin injected. During the hot pressing process, 5% to 15% of the resin in the carbon fiber prepreg is set to flow into the hollow cavity 241, for example, 6%, 8%, 10% or 13%, so as to ensure the yield of the connection portion 13. Optionally, the additional mold is set at a position where the front mold 215 and the rear mold 216 are close to the lower mold 212, so that the position of the hollow cavity 241 is relatively low, which facilitates the flow of the colloid.

[0105] In an optional embodiment, the step of heating and pressurizing the mold 2 is specifically as follows:

[0106] The mold 2 is placed in a preheated hot press, and the heating temperature range is set to 130° C.-180° C., the applied pressure is set to 0.5-2 MPa, and the pressing time is set to 20-60 min.

[0107] In this embodiment, in order to obtain a better one-piece molding structure, the temperature, pressure and time during the hot pressing process need to be set within an appropriate range. Here, the heating temperature range is set to 130°C-180°C, for example, 140°C, 150°C, 160°C, 170°C, the pressure is set to 0.5-2MPa, for example, 0.8MPa, 1MPa or 1.5MPa, etc., and the pressing time is 20-60min, for example, 30min, 40min, 50min, etc., so as to ensure the flow type without excessive molten liquid and improve the hot pressing molding effect. Here, the hot press is preheated in advance to improve processing efficiency.

[0108] During the hot pressing process, the pressure is first released 3-4 times, with an interval of 10s-20s between each time, and then the pressure is applied to ensure the pressure effect. When the heating and pressing time is completed, the heating is stopped and maintained for 40-60 minutes. The mold 2 is then demolded after it cools down.

[0109] In an optional embodiment, before the step of laying the carbon fiber prepreg in the main cavity, the method further includes step S31:

[0110] The main cavity of the mold 2 is cleaned and a release agent is applied.

[0111] It is understandable that after the mold 2 is assembled, some oil stains or greasy dirt will usually remain in its internal space. Therefore, in this embodiment, before laying the carbon fiber prepreg, it needs to be cleaned, for example, using clean water or alkaline substances to clean it to remove surface oil stains and impurities. At the same time, in order to facilitate subsequent demolding, a release agent is applied to the inner wall surface of the main cavity, thereby improving the demolding efficiency of the carbon fiber-based composite part 1 and reducing processing time. Of course, during the mold closing process, lubricating oil can also be applied to the bolts or screws to further improve the efficiency of demolding and ensure smooth mold opening.

[0112] The above preparation method can be specifically described through the following four examples.

[0113] Example 1

[0114] A thermoplastic film made of thermoplastic polyurethane (TPU) and 3K plain-weave carbon fiber fabric were cut into a 25cm x 25cm square structure and hot-pressed to produce a carbon fiber composite layer, namely a single-layer prepreg. Three layers of prepreg were laminated and pressed. During the hot-pressing process, polyamide thermoplastic bonding powder with a particle size of 500 mesh was sprayed between adjacent single-layer prepregs. The resin content of the carbon fiber prepreg was 55%. The integrally formed carbon fiber-based composite part was 85mm long, 5mm wide, 4mm high, and 0.5mm thick. 7% of the resin flowed into the glue injection area of ​​the hollow cavity. The glue injection area of ​​the hollow cavity was 15mm long, 1mm wide, and 1mm high.

[0115] During the hot pressing process, the heating temperature of the hot press was set to 150°C, the pressure was set to 1 MPa, and the pressure was released three times before pressing, with an interval of 20 seconds. The pressing time was 40 minutes, and the heating time was 60 minutes.

[0116] Example 2

[0117] A thermoplastic film made of PEI and a 3K plain carbon fiber fabric were cut into a 25cm×25cm square structure and hot-pressed to prepare a carbon fiber composite layer, i.e., a single-layer prepreg. Four layers of prepreg were laminated and pressed. During the hot-pressing treatment, ultra-fine thermoplastic bonding powder made of polyurethane was sprayed between adjacent single-layer prepregs. The powder particle size was 700 mesh, and the resin content of the carbon fiber prepreg was 58%.

[0118] The one-piece carbon fiber-based composite part is 90 mm long, 7 mm wide, 4 mm high and 0.7 mm thick. 9% of the resin flows into the glue injection area of ​​the hollow cavity. The glue injection area of ​​the hollow cavity is 17 mm long, 1.5 mm wide and 1.5 mm high.

[0119] During the hot pressing process, the heating temperature of the hot press was set to 140°C, the pressure was set to 1.5 MPa, and the pressure was released three times before pressing, with an interval of 10 seconds. The pressing time was 45 minutes, and the heating time was 50 minutes.

[0120] Example 3

[0121] A thermoplastic film made of PES material and a 3K plain carbon fiber fabric were cut into 25cm×25cm squares and hot-pressed to prepare a carbon fiber composite layer, i.e., a single-layer prepreg. Five layers of prepreg were laminated and pressed. During the hot-pressing treatment, ultra-fine thermoplastic bonding powder of polyamide was sprayed between adjacent single-layer prepregs. The powder particle size was 800 mesh, and the resin content of the carbon fiber prepreg was 62%.

[0122] The one-piece carbon fiber-based composite part is 95 mm long, 10 mm wide, 5 mm high and 1 mm thick. 12% of the resin flows into the glue injection area of ​​the hollow cavity. The glue injection area of ​​the hollow cavity is 20 mm long, 2 mm wide and 2 mm high.

[0123] During the hot pressing treatment, the heating temperature of the hot press was set to 150°C, the pressure was set to 1 MPa, and the pressure was released three times before pressing, with an interval of 15 seconds. The pressing time was 50 minutes, and the heating time was 40 minutes.

[0124] Example 4

[0125] A thermoplastic film made of PEI and a 6K plain carbon fiber fabric were cut into 25cm×25cm squares and hot-pressed to prepare a carbon fiber composite layer, i.e., a single-layer prepreg. Four layers of prepreg were laminated and pressed. During the hot-pressing treatment, ultra-fine thermoplastic bonding powder made of polyurethane was sprayed between adjacent single-layer prepregs. The powder particle size was 700 mesh, and the resin content of the carbon fiber prepreg was 65%.

[0126] The integrally molded carbon fiber-based composite part measures 100 mm in length, 12 mm in width, 6 mm in height, and 1.2 mm in thickness. 15% of the resin flows into the injection area, which measures 23 mm in length, 3 mm in width, and 3 mm in height. During hot pressing, the press was set to a heating temperature of 150°C and a pressure of 1.5 MPa. The press was depressurized three times before pressing, with intervals of 10 seconds between each press. The press lasted 60 minutes, with a 60-minute heating interval.

[0127] The present invention further provides a frame (not shown), comprising a carbon fiber-based composite member as described above, or manufactured using the method for manufacturing a carbon fiber-based composite member as described above, wherein the main body has a U-shaped cross-section, and two connecting portions are provided, one on each of the opposing outer sides of the main body. Because the frame utilizes all of the technical solutions of all of the aforementioned embodiments, it possesses at least the beneficial effects of the technical solutions of the aforementioned embodiments, and thus will not be further elaborated upon herein.

[0128] It should be noted that after demoulding, the frame needs to undergo a series of post-processing to obtain the shape required by the user and then pass the inspection.

[0129] The present invention further provides a pair of glasses comprising a frame and lenses mounted on the frame, wherein the frame is the frame described above. Since the frame employs all of the technical solutions of all of the aforementioned embodiments, it at least exhibits the beneficial effects of the technical solutions of the aforementioned embodiments, and therefore will not be further elaborated upon here.

[0130] The glasses here can be myopia glasses, AR glasses, VR glasses, etc., and are not limited here.

[0131] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made by using the contents of the present invention description and drawings under the inventive concept of the present invention, or direct / indirect application in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A carbon fiber-based composite part, characterized in that: The carbon fiber-based composite part comprises: a main body portion, the main body portion comprising a carbon fiber composite layer; and A connecting portion, the connecting portion being provided on a side of the carbon fiber composite layer, the connecting portion being made of resin, and the connecting portion and the carbon fiber composite layer being a hot-pressed integrally formed structure; The carbon fiber composite layer comprises a stacked plain carbon fiber layer and a thermoplastic film layer, wherein the plain carbon fiber layer and the thermoplastic film layer are stacked and hot-pressed to form the carbon fiber composite layer; The main body comprises a plurality of carbon fiber composite layers stacked and press-formed, with thermoplastic bonding powder sandwiched between two adjacent carbon fiber composite layers to form a carbon fiber prepreg; The carbon fiber prepreg is hot-pressed, and the resin material in the carbon fiber prepreg overflows and solidifies to form the connecting portion.

2. The carbon fiber-based composite part according to claim 1, wherein: The carbon fiber composite layer comprises a plain carbon fiber layer and a thermoplastic film layer stacked on each other, and the plain carbon fiber layer and the thermoplastic film layer are connected by hot pressing.

3. The carbon fiber-based composite part according to claim 2, wherein: The raw yarn type of the plain carbon fiber layer is one of 3K, 6K, 12K, 24K, and 36K; And / or, the material of the thermoplastic film layer is one of polyetherimide, polyetherketone, polysulfone and polyethersulfone; And / or, the resin is one of polyvinyl acetate, polyvinyl acetal, perchlorethylene resin, polyacrylate, polyamide and polysulfone.

4. The carbon fiber-based composite part according to claim 1, wherein: The number of carbon fiber composite layers is 3-5; And / or, the thickness of the main body is in the range of 0.5 mm to 1.5 mm.

5. The carbon fiber-based composite part according to claim 1, wherein: The thermoplastic bonding powder is one of polyamide powder, polyethylene powder and polyurethane powder; And / or, the particle size of the thermoplastic bonding powder is between 200 and 2000 meshes.

6. A method for preparing a carbon fiber-based composite part, characterized in that: The carbon fiber-based composite part includes a main body and a connecting part provided on a side of the main body, and the preparation method includes: Providing a mold, wherein the mold is formed with a main cavity for accommodating the main body and a hollow cavity forming the connecting portion, wherein the hollow cavity is connected to the main cavity; Cutting the plain carbon fiber cloth and the thermoplastic film to form a plain carbon fiber layer and a thermoplastic film layer; The plain carbon fiber layer and the thermoplastic film layer are stacked and hot-pressed to form a carbon fiber composite layer; Multiple carbon fiber composite layers are stacked and laid, and thermoplastic bonding powder is sprayed between two adjacent carbon fiber composite layers to form a carbon fiber prepreg; Laying the carbon fiber prepreg in the main cavity, and heating and pressurizing the mold; After curing, the carbon fiber-based composite part is demoulded.

7. The method for preparing a carbon fiber-based composite part according to claim 6, wherein: The mold includes a main mold, a core mold and an additional mold. The main mold forms an installation cavity. The core mold is placed in the installation cavity and is enclosed with the cavity wall of the installation cavity to form a U-shaped main cavity. The additional mold forms a hollow cavity and is installed on the outer side of the main mold. The cavity wall of the installation cavity is provided with an opening connecting to the hollow cavity.

8. The method for preparing a carbon fiber-based composite part according to claim 7, wherein: The raw yarn type of the plain carbon fiber layer is one of 3K, 6K, 12K, 24K, and 36K; And / or, the material of the thermoplastic film layer is one of polyetherimide, polyetherketone, polysulfone and polyethersulfone; And / or, the thermoplastic bonding powder is one of polyamide powder, polyethylene powder and polyurethane powder; And / or, the particle size of the thermoplastic bonding powder is between 200 and 2000 meshes.

9. The method for preparing a carbon fiber-based composite part according to claim 7, wherein: The resin content of the carbon fiber prepreg is in the range of 55% to 65%; And / or, the number of layers of the carbon fiber composite layer is 3 to 5.

10. The method for preparing a carbon fiber-based composite part according to claim 9, wherein: During the step of heating and pressurizing the mold, 5% to 15% of the resin in the carbon fiber prepreg flows into the hollow cavity to form the connecting portion.

11. The method for preparing a carbon fiber-based composite part according to any one of claims 6 to 10, characterized in that: The steps of heating and pressurizing the mold are specifically as follows: The mold is placed in a preheated hot press, and the heating temperature range is set to 130° C.-180° C., the applied pressure is set to 0.5-2 MPa, and the pressing time is 20-60 min.

12. The method for preparing a carbon fiber-based composite part according to any one of claims 6 to 10, characterized in that: Before the step of laying the carbon fiber prepreg in the main cavity, the method further includes the following steps: The main cavity of the mold is cleaned and a release agent is applied.

13. A glasses frame, characterized in that: The frame is a carbon fiber-based composite part as described in any one of claims 1 to 5, or is made by the preparation method of a carbon fiber-based composite part as described in any one of claims 6 to 12, the cross-section of the main body is U-shaped, and there are two connecting parts, which are respectively arranged on two outer side surfaces of the main body that are opposite to each other.

14. A pair of glasses, characterized in that: The glasses include a frame and lenses mounted on the frame, and the frame is the frame according to claim 13.

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