Manufacturing processes for composite materials to enhance their impact and wear resistance

Abstract

This invention provides a manufacturing process for composite materials that enhances their impact and wear resistance, relating to the field of composite material technology. The process includes the following steps: Step 1: Selecting a modified epoxy resin system with low, medium, and high temperature curing adhesives; Step 2: Dissolving the solid adhesive using acetone or ethyl acetate, and then applying the dissolved adhesive to the surface of composite material sheets such as metal or carbon fiber plates; Step 3: Selecting a high-hardness material and forming it into spheres as a coating strength reinforcement, laying the reinforcement on a high-density fiberboard, initially heating the coated sheet, and then covering the adhesive-coated surface of the sheet with the reinforcement; Step 4: Applying adhesive to the reinforcement surface of the sheet, then placing the material in a high-temperature oven, attaching release paper, increasing the oven temperature for curing, and finally cooling to complete the process. This method results in low material usage, light weight, and a significant increase in strength, thanks to improvements in both the adhesive and the reinforcement.

Description

Technical Field

[0001] This invention relates to the field of composite material technology, specifically to a composite material manufacturing process for increasing the impact and wear resistance of materials. Background Technology

[0002] Composite materials are new materials created by combining different material components using advanced material preparation technologies. The matrix materials of composite materials are divided into two main categories: metals and non-metals. Commonly used metal matrices include aluminum, magnesium, copper, titanium and their alloys. Non-metal matrices mainly include synthetic resins, rubber, ceramics, graphite, carbon, etc. Reinforcing materials mainly include glass fiber, carbon fiber, boron fiber, aramid fiber, silicon carbide fiber, asbestos fiber, whiskers and metals.

[0003] Composite materials have the following disadvantages in use and production: 1. Existing similar products require a large amount of material, resulting in excessive weight gain and excessive energy consumption; 2. They have poor strength and can only prevent damage from soft and weak materials such as resins, offering no protection against scratches from metals or stones; 3. They have a short actual lifespan, wear out quickly, and require frequent repairs. Furthermore, current technologies mainly use polyurethane as a coating material. Polyurethane itself is a foamed elastic material, which is relatively soft and therefore has low strength, leading to the aforementioned defects; 4. Due to the low density of this type of material, a large amount is required to achieve the desired effect, resulting in high usage costs.

[0004] To this end, we have developed a new manufacturing process for composite materials that enhances their impact and wear resistance. Summary of the Invention

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this invention provides a composite material manufacturing process that enhances the impact and wear resistance of materials, solving the problems of large usage, poor strength, short lifespan, and low density in existing similar products, thereby increasing usage costs.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the present invention provides a manufacturing process for composite materials that increases their impact and wear resistance, comprising the following steps:

[0009] Step 1: Select a low-, medium-, and high-temperature curing adhesive based on a modified epoxy resin system with special strength.

[0010] Step 2: Dissolve the solid adhesive with acetone or ethyl acetate, and apply the dissolved adhesive evenly to the surface of the carbon fiber board or metal sheet;

[0011] Step 3: Select a high-hardness material and make it into spheres as a coating strength reinforcement. Spread the reinforcement evenly on a horizontal high-density board for further processing. Heat the board after applying the adhesive in an oven or a flat press to melt the adhesive on the board surface. Place the self-adhesive board with the adhesive side facing down, parallel and without additional pressure, onto the board surface where the reinforcement has been laid.

[0012] Step 4: Place the pre-bonded reinforcement plate horizontally with the reinforcement side facing up, apply adhesive to its surface again, place the pre-treated reinforcement plate horizontally in a high-temperature oven or high-temperature press, attach release paper for epoxy resin to the surface, increase the temperature of the oven or plate press and maintain it for a certain time to cure, and after natural cooling, the plate and coating are completed.

[0013] Preferably, the mechanical properties of the adhesive in step one are a shear strength of 30 MPa or higher and a peel strength of 4 kN / m or higher.

[0014] The above technical solution achieves good overall fluidity, with a viscosity not exceeding 100,000 centipoise at 40°C.

[0015] Preferably, in step two, the ratio of acetone or ethyl acetate to adhesive is 4:1.

[0016] The above technical solution enables a room temperature viscosity of 10,000 centipoise.

[0017] Preferably, in step two, the areal density of the adhesive is 75 g / m², and the thickness of the adhesive layer is 0.1-0.15 mm.

[0018] Preferably, the diameter of the spherical reinforcement in step three is in the range of 0.3-0.8 mm.

[0019] Preferably, in step three, the sheet material is initially heated to 60°C using an oven or a flatbed press.

[0020] The above technical solution enables the adhesive on the surface of the board to be thermally melted, thereby giving it a certain degree of self-adhesion. The standard for adhesion and viscosity is that when the board is placed vertically on a horizontal plane, the reinforcement can be naturally fixed on the surface without flowing downwards.

[0021] Preferably, in step three, the surface density of the adhesive used to coat the surface of the reinforcing plate is 75 g / m².

[0022] The above technical solutions enhance the robustness of the reinforced structure.

[0023] Preferably, the thickness of the release paper in step four is 0.5 mm or more.

[0024] The above technical solutions prevent the colloid from overflowing.

[0025] Preferably, in step four, the temperature of the oven or plate press is increased to 120 degrees and maintained for 120 minutes.

[0026] Using the above technical solution, the board and coating are completed after natural cooling.

[0027] (III) Beneficial Effects

[0028] This invention provides a manufacturing process for composite materials that increases their impact and wear resistance.

[0029] It has the following beneficial effects:

[0030] 1. It requires less dosage and is lightweight, with approximately 0.35 kg used per square meter of surface, while traditional products require nearly 1.5 kg per square meter of surface.

[0031] 2. The strength is greatly improved, and it can easily protect against scratches and damage from sharp metal objects such as knives and keys. No visible marks will be left on the surface after being damaged.

[0032] 3. Thanks to the improved strength of both the adhesive and the reinforcement, the coating's service life is significantly longer than that of similar products;

[0033] 4. Due to the special optical properties of the reinforcing material, the reinforced sheet exhibits a crystal-like sparkle effect similar to crushed diamonds, giving it a significant aesthetic advantage compared to existing similar products; Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the process flow of the present invention. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] like Figure 1 This invention provides a manufacturing process for composite materials that increases their impact and wear resistance, comprising the following steps:

[0037] Step 1: Select a low-, medium-, and high-temperature curing adhesive with a modified epoxy resin system of special strength. The mechanical properties of the adhesive are a shear strength of 30 MPa or higher and a peel strength of 4 kN / m or higher, so that the overall fluidity is good and the viscosity at 40°C is not higher than 100,000 centipoise.

[0038] Step 2: Dissolve the solid adhesive using acetone or ethyl acetate in a 4:1 ratio to achieve a room temperature viscosity of 10,000 centipoise. Apply the dissolved adhesive evenly to the surface of the carbon fiber board or metal sheet. The adhesive surface density is 75 g / m², and the adhesive layer thickness is 0.1-0.15 mm.

[0039] Step 3: Select a high-hardness material and form it into spheres as a coating strength reinforcement. The high-hardness material is a mixture of sodium silicate, calcium silicate, and silicon dioxide, and the diameter of the sphere reinforcement ranges from 0.3 to 0.8 mm. Spread the reinforcement evenly on a horizontal high-density board for further processing. Pre-heat the board after applying the adhesive by using an oven or flatbed press to melt the adhesive on the board surface. The board is pre-heated to 60°C by using an oven or flatbed press to melt the adhesive on the board surface, thus giving it a certain degree of self-adhesion. The standard for adhesion and viscosity is that when the board is placed vertically on a horizontal plane, the reinforcement can be naturally fixed on the surface without flowing downwards. Place the self-adhesive board with the adhesive side facing down, parallel and without additional pressure, onto the board surface where the reinforcement has been laid, thereby achieving the purpose of evenly bonding the reinforcement to the board surface.

[0040] Step 4: Place the pre-bonded reinforcement plate horizontally with the reinforcement side facing up, and apply adhesive again to its surface. The surface density of the adhesive applied to the surface of the pre-bonded reinforcement plate should be 75g / ㎡ to enhance the reinforcement's firmness. Place the pre-treated reinforcement plate horizontally in a high-temperature oven or high-temperature press, and attach release paper for epoxy resin to the surface. The release paper should be at least 0.5mm thick to prevent adhesive overflow. Increase the temperature of the oven or plate press and maintain it for a certain time to cure. Increase the temperature of the oven or plate press to 120 degrees Celsius and maintain it for 120 minutes. After natural cooling, the plate and coating are complete.

[0041] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A composite manufacturing process for increasing the impact and wear resistance of materials, comprising the following steps: Step one: select the low, medium and high temperature curing adhesive of modified epoxy resin system with special strength; the mechanical property index of the adhesive is shear strength of 30 MPa or more, peeling strength of 4 kN / m or more, 40 ° The viscosity under C temperature state is not higher than 100,000 centipoise; Step two: Dissolve the solid adhesive using acetone or ethyl acetate so that the room temperature viscosity reaches 10,000 centipoise, and evenly coat the dissolved adhesive on the surface of the carbon fiber composite plate or metal plate material; Step three: Select high-hardness material and make it into a sphere as a coating strength enhancer, evenly lay the enhancer on the horizontal high-density plate for further processing, and pass the coated plate through the oven or flat press for preliminary heating to make the plate surface glue hot, and the self-adhesive plate is placed horizontally downward, parallel and without additional pressure, covering the plate surface with the enhancer; Step four: Place the plate with the preliminary bonding enhancer with the enhancer face horizontally upwards, coat the surface again, and place the pre-processed enhanced plate horizontally in the high-temperature oven or high-temperature press, and paste the release paper used for epoxy resin on the surface, adjust the temperature of the oven or flat press and maintain for a certain time, then solidify, and the plate and coating are completed after natural cooling.

2. The process of claim 1, wherein: The ratio of acetone or ethyl acetate to adhesive in step two is 4:

1.

3. The process of claim 1, wherein: The surface density of the adhesive in step two is 75g / m2, and the adhesive layer thickness is 0.1-0.15mm.

4. The process of claim 1, wherein: The diameter of the spherical enhancer in step three is 0.3-0.8mm.

5. The process of claim 1, wherein: The plate material in step three is initially heated to 60 ° C.

6. The process of manufacturing a composite material for increasing impact and wear resistance properties of a material according to claim 1, characterized in that: The surface density of the adhesive for coating the surface of the plate with the preliminary bonding enhancer in step three is 75g / m2.

7. The process of manufacturing a composite material for increasing impact and wear resistance properties of a material according to claim 1, characterized in that: The thickness of the release paper is more than 0.5mm.

8. The process of manufacturing a composite material for increasing impact and wear resistance properties of a material according to claim 1, characterized in that: The temperature of the oven or flat press in step four is adjusted to 120 degrees and maintained for 120 minutes.

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