Three-dimensional angle interlocking structure composite material and forming process

Abstract

The application belongs to the field of high-efficiency preparation and processing of composite materials, and particularly relates to a three-dimensional angle interlocking structure composite material and a forming process. The composite material comprises a reinforcing phase and a matrix phase, and the reinforcing phase is a carbon fiber three-dimensional angle interlocking structure fabric. 5%-40% of wave-transparent fibers are mixed into the carbon fiber three-dimensional angle interlocking structure fabric, and the wave-transparent fiber material is one or more of glass fiber, polyamide fiber and polyester fiber. In the condition of not increasing the thickness of the fiber reinforcing phase or adding microwave-sensitive materials in the resin matrix, the microwave penetration ability in the thickness direction of the composite material is improved by adjusting the structure of the preform, and the practical application of the high-efficiency microwave curing technology of the composite material is realized.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of efficient preparation and processing of composite materials, in particular, a three-dimensional angle interlocking structure composite material and a forming process. BACKGROUND

[0002] Fiber reinforced resin matrix composite materials are widely used in the fields of aviation, aerospace, automobile, shipbuilding, etc. due to their characteristics of light weight, high strength, strong chemical stability, heat resistance, fatigue resistance, creep resistance, and noise reduction. The structure of the composite material is composed of one or more fiber materials as the reinforcing phase and the resin as the matrix phase. The reinforcing phase plays a role in bearing load and improving the performance of the composite material. The matrix phase plays a role in bonding and fixing the reinforcing phase, transferring stress between the reinforcing phase, and protecting the reinforcing phase from environmental factors.

[0003] Three-dimensional angle interlocking composite material is a kind of fiber reinforced composite material with three-dimensional angle interlocking fabric as the reinforcing phase and wave-transparent resin material as the matrix phase. Unlike laminated plates or two-dimensional laminated structure composite materials, the bent warp yarns in the reinforcing phase of the three-dimensional angle interlocking composite material bundle several layers of weft yarns together. The Z-direction component formed by the bent warp yarns in the thickness direction of the composite material enhances the mechanical properties of the composite material in the thickness direction, specifically in the form of improved interlaminar shear strength and improved interlaminar bonding.

[0004] Currently, the main curing forming process used in the preparation of composite materials is the traditional hot pressing process. RTM, autoclave, VARTM, etc. are all hot pressing forming processes. Hot pressing process has the advantages of high maturity, low equipment cost, simple process, etc. However, it also has many problems such as low heat conduction efficiency, high energy consumption, large temperature gradient, long forming cycle, low efficiency, etc. Compared with the traditional hot pressing process, the microwave curing process has the advantages of high efficiency, low energy consumption, and high uniformity of heating. The principle of microwave curing process is that the polar molecules in the matrix phase of the composite material rotate, oscillate, and collide under the action of alternating electromagnetic field. The internal energy is diffused into the material in the form of heat, which converts microwave energy into internal energy, and then initiates the crosslinking curing reaction in the matrix phase.

[0005] Although the microwave curing process has the above-mentioned numerous advantages, since the carbon fiber has the electric conductivity close to that of metal, electromagnetic shielding effect is generated under the action of electromagnetic field. Therefore, the microwave is strongly reflected on the surface of the carbon fiber composite material, and the interior located at a certain distance from the surface of the composite material cannot be heated or the heating efficiency is greatly reduced due to the electromagnetic shielding effect of the surface. In addition, when the carbon fiber shields the electromagnetic field generated by the microwave oven, the electric charge is redistributed on the surface of the conductor, thereby generating a potential difference. If the potential difference is large enough, an electric arc can be generated, thereby damaging the inner wall of the microwave oven or damaging other electronic components such as the magnetron in the microwave oven. SUMMARY

[0006] The present application aims to solve the problem that the microwave cannot smoothly penetrate the electromagnetic shielding effect of the surface layer carbon fiber fabric formed by the carbon fiber three-dimensional angle interlocking fabric reinforced resin matrix composite material in the microwave curing process, thereby cannot reach the interior of the composite material and effectively heat the carbon fiber and the resin matrix in the interior of the composite material. The present application provides a three-dimensional angle interlocking structure composite material and a forming process. By mixing the wave-transparent fiber material into the carbon fiber three-dimensional angle interlocking structure fabric, the wave-transparent property of the mixed fiber is utilized to reduce the electromagnetic shielding effect of the carbon fiber on the microwave, enhance the penetration of the microwave on the surface of the carbon fiber, and improve the curing efficiency of the carbon fiber reinforced resin matrix composite material in the microwave curing process.

[0007] The present application aims to solve the problem that the microwave cannot smoothly penetrate the electromagnetic shielding effect of the surface layer carbon fiber fabric formed by the carbon fiber three-dimensional angle interlocking fabric reinforced resin matrix composite material in the microwave curing process, thereby cannot reach the interior of the composite material and effectively heat the carbon fiber and the resin matrix in the interior of the composite material. The present application provides a three-dimensional angle interlocking structure composite material and a forming process. By mixing the wave-transparent fiber material into the carbon fiber three-dimensional angle interlocking structure fabric, the wave-transparent property of the mixed fiber is utilized to reduce the electromagnetic shielding effect of the carbon fiber on the microwave, enhance the penetration of the microwave on the surface of the carbon fiber, and improve the curing efficiency of the carbon fiber reinforced resin matrix composite material in the microwave curing process.

[0008] The technical solution of the present application is as follows:

[0009] A three-dimensional angle interlocking structure composite material, comprising a reinforcing phase and a matrix phase, the reinforcing phase is a carbon fiber three-dimensional angle interlocking structure fabric, and 5%-40% wave-transparent fiber (5%-40% wave-transparent fiber mixed into the volume of the carbon fiber three-dimensional angle interlocking structure fabric) is uniformly mixed into the carbon fiber three-dimensional angle interlocking structure fabric, the wave-transparent fiber is one or more of glass fiber, polyamide fiber and polyester fiber.

[0010] Preferably, the matrix phase is a wave-transparent resin, and further preferably, the wave-transparent resin material is one of epoxy resin, vinyl resin and phenolic resin.

[0011] Preferably, the three-dimensional interlocking structure used in the reinforcing phase is one of shallow interlocking structure and deep angle interlocking structure.

[0012] A forming process of a three-dimensional angle interlocking structure composite material, which composites the reinforcing phase and the matrix phase through a vacuum assisted forming process and is cured and formed in a microwave environment.

[0013] Preferably, the microwave environment is 2.45 GHz, 0.1 kW-6 kW power.

[0014] The present application makes the wave-transparent fiber material evenly distributed on the surface and inside of the three-dimensional angle interlocking structure fabric through the buckled through warp yarns and the straight weft yarns in the carbon fiber three-dimensional angle interlocking structure fabric. The fabric pattern is drawn according to the fabric structure design drawing, and the hybrid fiber three-dimensional angle interlocking fabric is woven according to the process of warping, harnessing and weaving. The "8" shaped warping method is adopted in the warping process, the warp beam is sent, and the counterweight hook is used to ensure that the warp tension is uniform and stable. The harnessing is carried out by using the forward harnessing method, one harness per reed, and the reed steel reed is passed through. According to the warp density, 15#-60# steel reed is selected to reduce the fluff phenomenon generated in the manufacturing process. One weft per beat is used in weaving. The hybrid fiber three-dimensional angle interlocking fabric is used as the reinforcing phase, and the wave-transparent resin is used as the matrix phase. The two are compounded through a vacuum assisted forming process. The composite material after compounding is moved into a microwave curing equipment. In the microwave environment of 2.45 GHz, 0.1 kW-6 kW power is used for heating and curing according to the thickness of the three-dimensional angle interlocking structure fabric.

[0015] Preferably, the forward harnessing method refers to sequentially passing each warp yarn in one fabric organization cycle through each page of the harness, that is, the required harness page number is equal to the number of warp yarns in the fabric organization cycle.

[0016] Preferably, the vacuum assisted forming process is to construct a vacuum environment by using a vacuum bag and other auxiliary materials, place the reinforcing phase in the vacuum environment, and inject the matrix phase into the reinforcing phase by relying on atmospheric pressure. Then, the resin cross-linking and curing are carried out by microwave heating to realize the forming of the composite material.

[0017] The present application improves the penetration ability of microwaves in the thickness direction to the surface of carbon fibers, enhances the heating effect of microwaves to the inside of the carbon fiber reinforced resin matrix composite material, and improves the process applicability of the carbon fiber reinforced composite material in the microwave curing process by designing the structure of the microwave fiber mixed in the carbon fiber three-dimensional angle interlocking fabric without increasing the thickness of the composite material and without using powder microwave sensitive material to fill between each layer of the reinforcing phase of the composite material. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 It is a three-dimensional deep angle interlocking diagram, in which the circle represents the straight weft yarn, and the curved line represents the buckled warp yarn.

[0019] Figure 2 is a three-dimensional shallow interlaced bending schematic diagram, wherein the circle represents the straightened weft yarn, and the curved line represents the bent warp yarn;

[0020] Figure 3 is a fabric pattern diagram drawn according to the three-dimensional angle interlocking fabric structure schematic diagram in Figure 1 ;

[0021] Figure 4 is a fabric pattern diagram drawn according to the three-dimensional angle interlocking fabric structure schematic diagram in Figure 2 ;

[0022] wherein the horizontal lattice represents different warp yarn states in one fabric structure cycle, the vertical direction from bottom to top represents the beating-up times of the weft yarn in one fabric structure cycle, the black lattice represents the warp lifting state, and the white lattice represents the non-warp lifting, and the warp yarn is located at the heald position. DETAILED DESCRIPTION

[0023] The scheme proposed by the present application is further described below in combination with examples, but is not used as a limitation on the technical scheme. Any technical method that can realize the present application constitutes a part of the technical scheme designed by the present application.

[0024] The fiber volume content of the composite material in the following examples and comparative examples is 55%.

[0025] Example 1

[0026] A three-dimensional angle interlocking structure composite material:

[0027] A deep angle interlocking structure three-dimensional fabric reinforcing phase including 20 layers of weft yarns + 40 warp yarns in one weaving cycle, 15% glass fibers are mixed into the warp yarns, 5% aromatic polyamide fibers are mixed into the weft yarns as wave-transparent fibers, in order to ensure the uniformity of the distribution of the wave-transparent fibers in the three-dimensional fabric reinforcing phase, the 4th, 11th, 17th, 24th, 31st and 37th warp yarns in the 40 warp yarn fiber cycle are replaced by glass fiber mixing, and the 10th layer of weft yarns in the 20 layers of weft yarns is replaced by aromatic polyamide fiber mixing;

[0028] According to the designed deep angle interlocking structure three-dimensional fabric, a weaving pattern plate is drawn and written into the weaving program of an automatic loom. In one weaving cycle, 34 carbon fiber and 6 glass fiber warp yarn barrels are prepared. In the preparation of the warp yarn barrel, an "8" shaped warping method is used. The warp yarn barrel is placed on the barrel stand, and the counterweight hook is used to control the uniformity and constancy of the warp yarn tension. The warp yarn on the warp yarn barrel is sequentially threaded through the warp stop piece, the heald eye and the reed according to the established order. Only one warp yarn is threaded through each heald eye. The warp yarn is threaded through the 30# reed in a one-reed-one-thread manner. The deep angle interlocking structure three-dimensional fabric is woven as a reinforcing phase of a composite material in a one-weft-one-beat manner. When the weft yarn is beaten to the 10th layer, aromatic polyamide fiber is used to replace carbon fiber.

[0029] A polyester film is laid on a movable glass table as a bottom layer. The carbon fiber three-dimensional angle interlocking structure fabric is placed on the polyester film, and a release cloth and a flow guide net are sequentially placed. An injection device and a vacuum device are set. A sealing strip and a vacuum bag are used to complete the construction of the vacuum system. Epoxy resin is used as the matrix phase of the composite material. The epoxy resin is injected into the vacuum system under atmospheric pressure, and the process of impregnation and compounding is completed. Subsequently, the injection device and the vacuum device in the vacuum system are removed. The vacuum degree of the vacuum system is kept stable during this process. The vacuum system and the composite material therein are moved into a microwave curing device. A 2.45GHz microwave with a power of 2kW is used to heat the composite material system. The microwave curing process of the composite material is completed after 20 minutes. After cooling in the natural environment, the vacuum system is removed, and the composite material is obtained.

[0030] Example 2

[0031] A three-dimensional angle interlocking structure composite material:

[0032] A deep angle interlocking structure three-dimensional fabric reinforcing phase including 30 layers of weft yarn + 60 warp yarns in one weaving cycle. 20% of aromatic polyamide fiber is mixed into the warp yarns, and 10% of polyester fiber is mixed into the weft yarns as a wave-transparent fiber. In order to ensure the uniformity of the distribution of the wave-transparent fiber in the three-dimensional fabric reinforcing phase, the 3rd, 8th, 13th, 18th, 23rd, 28th, 33rd, 38th, 43rd, 48th, 53rd and 58th warp yarns in the 60 warp yarn fiber cycle are replaced by aromatic polyamide fiber. In the 30-layer weft yarn cycle, the 5th, 15th and 25th layers of weft yarns are replaced by polyester fiber.

[0033] According to the designed deep angle interlocking structure three-dimensional fabric, a weaving pattern plate is drawn and written into the weaving program of an automatic loom; in one weaving cycle, 48 carbon fibers and 12 aramid fiber warp yarn barrels are prepared, an "8" shaped warping method is used in the preparation of the warp yarn barrel, the warp yarn barrel is placed on the barrel stand, and a counterweight hook is used to control the uniformity and constancy of the warp yarn tension, the warp yarn on the warp yarn barrel is sequentially threaded through the warp stop piece, the heald eye and the reed according to the established order by using the forward threading method, only one warp yarn is threaded through each heald eye, the warp yarn is threaded through the 20# reed in the manner of one reed one thread, the deep angle interlocking structure three-dimensional fabric is woven as a reinforcing phase of a composite material in the manner of one weft one beat, and polyester fiber is used to replace carbon fiber when beating the weft to the 5th, 15th and 25th layers of weft yarns;

[0034] The polyester film is laid on the movable glass table as the bottom layer, the carbon fiber three-dimensional angle interlocking structure fabric is placed on the polyester film, and the release cloth and the flow guide net are sequentially placed, the glue injection device and the air extraction device are set, the sealant strip and the vacuum bag are used to complete the construction of the vacuum system; the epoxy resin is used as the matrix phase of the composite material, the epoxy resin is injected into the vacuum system by using atmospheric pressure, and the glue dipping and compounding process is completed; then, the glue injection device and the air extraction device in the vacuum system are removed, the vacuum degree of the vacuum system is kept stable in this process, the vacuum system and the composite material therein are integrally moved into the microwave curing equipment, the composite material system is heated by using a 3.5kW power 2.45GHz microwave, and the microwave curing process of the composite material is completed after 20 minutes; after cooling in the natural environment, the vacuum system is removed, and the composite material is obtained.

[0035] Example 3

[0036] A three-dimensional angle interlocking structure composite material:

[0037] A shallow intersection bending interlocking structure three-dimensional fabric reinforcing phase including 6 layers of weft yarns + 10 warp yarns in one weaving cycle; 10% glass fiber is mixed into the warp yarns and the weft yarns as a wave-transparent fiber; in order to ensure the uniformity of the distribution of the wave-transparent fiber in the three-dimensional fabric reinforcing phase, the 5th warp yarn in the 10 warp yarn fiber cycle is replaced by glass fiber mixed with the 5th warp yarn, and the 4th warp yarn in the 2nd column, the 1st warp yarn in the 4th column, the 5th warp yarn in the 6th column and the 3rd warp yarn in the 8th column in one weaving cycle are replaced by glass fiber mixed with the 4th warp yarn in the 2nd column.

[0038] According to the designed shallow intersection bend interlocking structure three-dimensional fabric, a weaving pattern plate is drawn and written into the weaving program of an automatic loom; in one weaving cycle, nine carbon fiber and one glass fiber warp beam are prepared, an "8" shaped warping method is used in the preparation of the warp beam, the warp beam is placed on the beam stand, and the counterweight hook is used to control the uniformity and constancy of the warp tension, the warp on the warp beam is sequentially threaded through the warp stop sheet, the heald eye and the reed according to the predetermined order by using the forward threading method, only one warp is threaded through each heald eye, and the warp is threaded through the 45# reed in a one reed one thread manner; the deep angle interlocking structure three-dimensional fabric is woven as the reinforcing phase of the composite material in a one weft one beat manner, and the glass fiber is used to replace the carbon fiber when beating the weft to the 2nd column 4th, 4th column 1st, 6th column 5th and 8th column 3rd weft.

[0039] The polyester film is laid on the movable glass table as the bottom layer, the carbon fiber three-dimensional angle interlocking structure fabric is placed on the polyester film, and the release cloth and the flow guide net are sequentially placed, the glue injection device and the air extraction device are set, the sealant and the vacuum bag are used to complete the construction of the vacuum system; the epoxy resin is used as the composite material matrix, the epoxy resin is injected into the vacuum system by using atmospheric pressure, and the glue dipping and compounding process is completed; then, the glue injection device and the air extraction device in the vacuum system are removed, the vacuum degree of the vacuum system is kept stable in this process, the vacuum system and the composite material in the vacuum system are integrally moved into the microwave curing equipment, and the composite material system is heated by using 0.5 kW power 2.45 GHz microwave. The microwave curing process of the composite material is completed after 10 minutes, the vacuum system is removed after cooling in the natural environment, and the composite material is obtained.

[0040] Example 4

[0041] A three-dimensional angle interlocking structure composite material:

[0042] The three-dimensional fabric reinforcing phase of the shallow intersection bend interlocking structure in one weaving cycle includes 25 layers of weft yarns + 48 warp yarns, 20% of the aromatic polyamide fibers are mixed into the warp yarns as the wave-transparent fibers, and 20% of the polyester fibers are mixed into the weft yarns as the wave-transparent fibers; in order to ensure the uniformity of the distribution of the wave-transparent fibers in the three-dimensional fabric reinforcing phase, the 3rd, 8th, 13th, 18th, 23rd, 28th, 33rd, 38th, 43rd and 46th warp yarns in the 48 warp yarn cycles are selected to be mixed and replaced by aromatic polyamide fibers, and the 3rd, 8th, 13th, 18th and 23rd layers of weft yarns in one weaving cycle are mixed and replaced by polyester fibers.

[0043] According to the designed shallow intersection bend interlocking structure three-dimensional fabric, a weaving pattern plate is drawn and written into the weaving program of an automatic loom. In one weaving cycle, 38 carbon fiber and 10 aramid fiber warp yarn barrels are prepared. In the preparation of the warp yarn barrel, an "8" shaped warping method is used. The warp yarn barrel is placed on the barrel stand, and the counterweight hook is used to control the uniformity and constancy of the warp yarn tension. The warp yarn on the warp yarn barrel is sequentially threaded through the warp stop plate, the heald eye and the reed according to the established order. Only one warp yarn is threaded through each heald eye. The warp yarn is threaded through the 30# reed in a one-reed-one-thread manner. The deep angle interlocking structure three-dimensional fabric is woven in a one-weft-one-beat manner as the reinforcing phase of the composite material. Polyester fiber is used to replace carbon fiber when beating the weft to the 3rd, 8th, 13th, 18th and 23rd layers of weft yarns.

[0044] A polyester film is laid on a movable glass table as a bottom layer. The carbon fiber three-dimensional angle interlocking structure fabric is placed on the polyester film, and a release cloth and a flow guide net are sequentially placed. The glue injection device and the air extraction device are set. The vacuum system is completed by using sealing tape and vacuum bag. Epoxy resin is used as the matrix phase of the composite material. The epoxy resin is injected into the vacuum system by using atmospheric pressure, and the glue dipping and compounding process is completed. Then, the glue injection device and the air extraction device in the vacuum system are removed. In this process, the vacuum degree of the vacuum system is kept stable. The vacuum system and the composite material in it are moved into the microwave curing equipment. The composite material system is heated by using a 3.5kW power 2.45GHz microwave. The microwave curing process of the composite material is completed after 30 minutes. After cooling in the natural environment, the vacuum system is removed, and the composite material is obtained.

[0045] Example 5

[0046] A three-dimensional angle interlocking structure composite material:

[0047] A three-dimensional fabric reinforcing phase with a shallow intersection bend interlocking structure including 10 layers of weft yarns + 18 warp yarns in one weaving cycle. 22% of aramid fiber is mixed into the warp yarns as a wave-transparent fiber. 30% of polyester fiber is mixed into the weft yarns as a wave-transparent fiber. In order to ensure the uniformity of the distribution of the wave-transparent fiber in the three-dimensional fabric reinforcing phase, the 3rd, 8th, 13th and 17th warp yarns in the 18 warp yarn fiber cycle are replaced by aramid fiber mixed with them. In the 10-layer weft yarn cycle, the 2nd, 5th and 8th layers of weft yarns in one weaving cycle are replaced by polyester fiber mixed with them.

[0048] According to the designed shallow intersection bending joint structure three-dimensional fabric, a weaving pattern plate is drawn, and the weaving program of the automatic loom is written. In one weaving cycle, 9 carbon fiber and 1 aramid fiber warp yarn barrels are prepared. When preparing the warp yarn barrel, the “8” type warping method is adopted. The warp yarn barrel is placed on the bobbin creel, and the counterweight hook is used to control the uniformity and constancy of the warp yarn tension. The warp yarn on the warp yarn barrel is sequentially threaded through the warp stop piece, the heald and the reed in a predetermined order by using the forward threading method. Only one warp yarn is threaded through each heald. The warp yarn is threaded through the 30# reed in a one-reed-one-thread manner. The deep angle joint structure three-dimensional fabric is woven as the reinforcing phase of the composite material in a one-weft-one-beat manner. Polyester fiber is used to replace carbon fiber when beating the weft to the 2nd, 5th and 8th layers of weft yarns.

[0049] A polyester film is laid on a movable glass table as a bottom layer. The carbon fiber three-dimensional angle interlocking structure fabric is placed on the polyester film, and a release cloth and a flow guide net are sequentially placed. The glue injection device and the air extraction device are set. The vacuum system is completed by using sealing tape and a vacuum bag. Epoxy resin is used as the matrix phase of the composite material. The epoxy resin is injected into the vacuum system by using atmospheric pressure, and the glue dipping and compounding process is completed. Then, the glue injection device and the air extraction device in the vacuum system are removed. The vacuum degree of the vacuum system is kept stable during the process. The vacuum system and the composite material in it are moved into the microwave curing equipment as a whole. The composite material system is heated by using a 2.45GHz microwave with a power of 1.5kW. The microwave curing process of the composite material is completed after 10 minutes. After cooling in the natural environment, the vacuum system is removed, and the composite material is obtained.

[0050] Comparative Example 1

[0051] A three-dimensional angle interlocking structure composite material:

[0052] A deep angle joint structure three-dimensional fabric reinforcing phase including 20 layers of weft yarns + 40 warp yarns in one weaving cycle does not use wave-transparent fiber to replace carbon fiber.

[0053] According to the designed deep angle joint structure three-dimensional fabric, a weaving pattern plate is drawn, and the weaving program of the automatic loom is written. In one weaving cycle, 40 carbon fibers are prepared. When preparing the warp yarn barrel, the “8” type warping method is adopted. The warp yarn barrel is placed on the bobbin creel, and the counterweight hook is used to control the uniformity and constancy of the warp yarn tension. The warp yarn on the warp yarn barrel is sequentially threaded through the warp stop piece, the heald and the reed in a predetermined order by using the forward threading method. Only one warp yarn is threaded through each heald. The warp yarn is threaded through the 30# reed in a one-reed-one-thread manner. The deep angle joint structure three-dimensional fabric is woven as the reinforcing phase of the composite material in a one-weft-one-beat manner.

[0054] The polyester film is laid on the movable glass table as a bottom layer, the carbon fiber three-dimensional angle interlocking structure fabric is placed on the polyester film, release cloth and flow guide net are sequentially placed, glue injection device and air extraction device are arranged, sealant and vacuum bag are used to complete the construction of the vacuum system, epoxy resin is used as the composite matrix phase, atmospheric pressure is used to inject the epoxy resin into the vacuum system, and the process of impregnation and compounding is completed; then, the glue injection device and the air extraction device in the vacuum system are removed, the vacuum degree of the vacuum system is kept stable during the process, the vacuum system and the composite material therein are integrally moved into the microwave curing equipment, 2kW power 2.45GHz microwave is used to heat the composite material system, and the microwave curing process of the composite material is completed after 20 minutes; after cooling in the natural environment, the vacuum system is removed, and the composite material is obtained.

[0055] Through observation, the upper surface of the composite material prepared by the method has high curing degree, but there is almost no curing trace in the internal part about 2mm away from the upper surface and the bottom surface, which is due to the electromagnetic shielding effect of the microwave which cannot penetrate the carbon fiber preform. Compared with Example 1, under the same time and energy consumption conditions, the three-dimensional angle interlocking carbon fiber reinforced composite material prepared by using the microwave curing process cannot achieve the same performance as the three-dimensional angle interlocking carbon fiber reinforced composite material prepared by using the fiber hybrid method.

[0056] Comparative Example 2

[0057] A three-dimensional angle interlocking structure composite material:

[0058] The deep angle interlocking structure three-dimensional fabric reinforced phase in one weaving cycle includes 20 layers of weft yarns + 40 warp yarns, 15% glass fibers are mixed in the warp yarns, and 5% aromatic polyamide fibers are mixed in the weft yarns as wave-penetrating fibers. In order to ensure the uniformity of the wave-penetrating fibers in the three-dimensional fabric reinforced phase, the 4th, 11th, 17th, 24th, 31st and 37th warp yarns in the 40 warp yarn fiber cycle are replaced by glass fiber hybrid, and the 10th layer of weft yarn in the 20 layers of weft yarn cycle is replaced by aromatic polyamide fiber hybrid;

[0059] According to the designed deep angle interlocking structure three-dimensional fabric, a weaving pattern plate is drawn and written into the weaving program of an automatic loom. In one weaving cycle, 34 carbon fiber and 6 glass fiber warp yarn barrels are prepared. In the preparation of the warp yarn barrel, an "8" shaped warping method is used. The warp yarn barrel is placed on the barrel stand, and the counterweight hook is used to control the uniformity and constancy of the warp yarn tension. The warp yarn on the warp yarn barrel is sequentially threaded through the warp stop piece, the heald eye and the reed according to the established order. Only one warp yarn is threaded through each heald eye. The warp yarn is threaded through the 30# reed in a one-reed-one-thread manner. The deep angle interlocking structure three-dimensional fabric is woven as a reinforcing phase of the composite material in a one-weft-one-beat manner. When beating the weft to the 10th layer of weft yarn, aromatic polyamide fiber is used to replace carbon fiber.

[0060] A polyester film is laid on a movable glass table as a bottom layer. The three-dimensional angle interlocking structure fabric is placed on the polyester film, and a release cloth and a flow guide net are placed in turn. The glue injection device and the air extraction device are set. The vacuum system is completed by using sealing tape and vacuum bag. Epoxy resin is used as the matrix phase of the composite material. The epoxy resin is injected into the vacuum system at atmospheric pressure, and the glue dipping and compounding process is completed. Subsequently, the glue injection device and the air extraction device in the vacuum system are removed. In this process, the vacuum degree of the vacuum system is kept stable. The vacuum system and the composite material therein are moved into an electric heating curing equipment with a power of 3kW for heating and curing at 100℃. The curing state of the composite material is observed and recorded in 20 minutes. After testing, the composite material prepared by using the heating and curing process needs 100 minutes to reach the same state as the composite material of Example 1. The energy consumption of the heating and curing process of Comparative Example 2 is 2.5 times that of the microwave curing process, and the time is 5 times.

[0061] By comparing Comparative Example 2 with Example 1, it can be found that the ordinary heating and curing process has many problems such as low heat conduction efficiency, high energy consumption, large temperature gradient, long forming cycle and low efficiency. Example 1 has obvious advantages of energy saving and short cycle time compared with Comparative Example 2. By comparing Comparative Example 1 with Example 1, under the condition of not adding wave-transparent fiber, the microwave cannot penetrate the electromagnetic shielding effect formed by the carbon fiber preform. Under the same time and energy consumption conditions, the three-dimensional angle interlocking carbon fiber reinforced composite material prepared by using the microwave curing process in Comparative Example 1 cannot achieve the same performance as the three-dimensional angle interlocking carbon fiber reinforced composite material prepared by using the fiber hybrid method in Example 1.

[0062] The application improves the penetration ability of microwaves to the surface electromagnetic shielding effect of carbon fibers in the thickness direction, enhances the heating effect of microwaves to the inside of the carbon fiber reinforced resin matrix composite, and improves the process applicability of the carbon fiber reinforced composite in the microwave curing process by the structural design of mixing microwave fibers into the three-dimensional angle interlocking fabric of carbon fibers.

Claims

1. A three-dimensional angular interlocking structure composite material comprising a reinforcing phase and a matrix phase, characterized in that: The reinforcing phase is a carbon fiber three-dimensional angle interlocking structure fabric, and 5-40% wave-transparent fibers are uniformly mixed in the carbon fiber three-dimensional angle interlocking structure fabric, wherein the wave-transparent fibers are one or more of glass fibers, polyamide fibers and polyester fibers; The base phase is a wave-transparent resin; The three-dimensional interlocking structure used in the reinforcing phase is one of a shallow interlocking structure and a deep angle interlocking structure; The bent-through warp yarns and the straight weft yarns in the carbon fiber three-dimensional angle interlocking structure fabric make the wave-transparent fibers uniformly distributed on the surface and inside of the three-dimensional angle interlocking structure fabric; The hybrid fiber three-dimensional angle interlocking fabric is woven according to the process of warping, drawing-in and weaving, the "8" type warping method is used in the warping process, the warp is sent by the bobbin rack, and the counterweight hook is used to ensure that the warp tension is uniform and stable; the weft yarns are drawn in by using the direct drawing-in method, one weft yarn is drawn in for one reed, and the weft yarn is drawn through the reed steel reed; 15#-60# steel reeds are selected according to the warp yarn density, and one weft one beat beating method is used during weaving; the woven hybrid fiber three-dimensional angle interlocking fabric is used as the reinforcing phase, and the wave-transparent resin is used as the base phase to composite the two by the vacuum assisted forming process.

2. A three-dimensional angular interlocking structure composite material according to claim 1, characterized in that: The wave-transparent resin is one of an epoxy resin, a vinyl resin and a phenolic resin.

3. A process for forming a three-dimensional gusseted composite material according to claim 1 or 2, wherein: The reinforcing phase and the base phase are composited by the vacuum assisted forming process, and are cured and formed in a microwave environment.

4. A process for forming a three-dimensional angle interlocking structure composite material according to claim 3, characterized in that: The microwave environment is 2.45 GHz and 0.1 kW-6 kW power.

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