A glass fiber reinforced composite material and a method for producing the same

Abstract

This invention relates to a glass fiber reinforced composite material and its preparation method. The glass fiber reinforced composite material comprises at least three stacked glass fiber layers and a resin layer between every two adjacent glass fiber layers, with the glass fiber orientations between at least two glass fiber layers forming a 90° angle. The finished product of the glass fiber reinforced composite material meets the requirements for energy-saving building doors, windows, and curtain walls in terms of structural integrity, thermal insulation, and thickness accuracy.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, and in particular to a glass fiber reinforced composite material and its preparation method. Background Technology

[0002] With the rapid development of my country's economy, energy consumption has also risen rapidly, with building energy consumption accounting for more than 40%. Given the increasingly severe energy situation, the requirements for building energy conservation are becoming increasingly stringent, leading to increased glass thickness in energy-efficient curtain walls and higher demands on the thermal conductivity of thermally broken glass.

[0003] Commonly used structural materials for glass curtain walls include metals such as steel, iron, and aluminum alloys, but these materials have high thermal conductivity. Functional materials used for thermal insulation include wood, plastics, and nylon, but these materials have poor structural strength. Furthermore, existing fiberglass-reinforced composite materials typically have high longitudinal mechanical strength, often exceeding 1000 MPa, but poor transverse mechanical strength, usually less than 1 / 10 of their longitudinal strength. Therefore, existing fiberglass composite materials, as building structural components, only possess the characteristic of strong uniaxial load-bearing capacity. Their poor transverse strength significantly limits the application areas and scope of fiberglass composite materials.

[0004] Therefore, existing fiberglass composite materials cannot meet market demands for energy-efficient building doors, windows, and curtain walls. Summary of the Invention

[0005] The technical problem to be solved by this invention is to improve the defect of poor isotropic stress performance of existing glass fiber resin composite materials and make them applicable to existing mature processing technology, thereby greatly expanding the application fields and scope of glass fiber composite materials, and enabling the finished glass fiber composite materials to meet the requirements of building energy-saving doors, windows and curtain walls in terms of structure, thermal insulation and thickness accuracy.

[0006] To achieve the above objectives, a first aspect of the present invention provides a glass fiber reinforced composite material comprising at least three stacked glass fiber layers and a resin layer between every two adjacent glass fiber layers, wherein the glass fiber directions between at least two glass fiber layers are at a 90° angle, and the glass fiber directions between the two outer glass fiber layers are parallel.

[0007] The fiberglass layer can typically be a fiberglass board, for example, made by pultrusion from glass fiber and a curing binder, exhibiting high mechanical and dielectric properties, good heat and moisture resistance, and good processability. The ratio of glass fiber to curing binder can be determined according to the process and specific requirements. A typical composition of fiberglass board includes 70-85% glass fiber and 15-30% resin. This is for illustrative purposes only, and the composition and ratio of the fiberglass board used in this invention are not limited thereto.

[0008] The main components of the glass fiber are silicon dioxide, aluminum oxide, calcium oxide, boron oxide, magnesium oxide, sodium oxide, etc. According to the amount of alkali in the glass, it can usually be divided into alkali-free glass fiber (0% to 2% sodium oxide, belonging to aluminoborosilicate glass), medium alkali glass fiber (8% to 12% sodium oxide, belonging to boron-containing or boron-free sodium-calcium silicate glass) and high alkali glass fiber (sodium oxide 13% or more, belonging to sodium-calcium silicate glass).

[0009] The glass fiber can be replaced with basalt fiber, ceramic fiber, carbon fiber, etc.

[0010] The curing and bonding material can be a resin (e.g., epoxy resin, polyurethane resin, phenolic resin, urea-formaldehyde resin, melamine copolymer resin, silicone resin, etc.), asphalt, atactic polypropylene, etc. Epoxy resin and polyurethane resin are preferred.

[0011] The thickness, width, and length of the fiberglass layer or fiberglass board can be determined based on the type of fiberglass used or specific requirements, and therefore there are no specific limitations. Typically, the forming speed of fiberglass boards can be 0.1-1.0 m / s, for example, 0.2-0.8 m / s, depending on the characteristics of the curing and bonding materials used.

[0012] For example, in one embodiment, the fiberglass layer can be prepared by the following process steps: one or more continuous fiberglass fibers are guided and pulled into a molding die with a certain cross-sectional shape through a positioning mechanism / guide roller and a traction mechanism; the fibers are cured or gelled within the mold cavity; extruded; heated and cured after demolding; and continuously drawn out as a profile product under the pulling force of the traction mechanism, followed by cutting to a fixed length as needed. During this process, the gap of the extrusion rollers can be adjusted to control the resin content; and the temperature, airflow, and speed of each zone of the oven can be adjusted to control the gelation time and volatile content.

[0013] The fiberglass boards prepared in this way typically have only one main fiber direction (e.g., longitudinal direction). Typically, the longitudinal strength (e.g., tensile or flexural strength) of the fiberglass board can reach 1440 MPa, while the transverse strength is only about 100 MPa.

[0014] The technical solution of this invention utilizes multilayer fiberglass boards with a specific number and arrangement, and through specific process steps, to achieve near-isotropic stress distribution in the prepared fiberglass reinforced composite material, for example, achieving a longitudinal and transverse stress strength of 1440 MPa. Specifically, this technical effect is achieved by setting at least three stacked fiberglass layers, with at least two of these layers having fiber directions at a 90° angle. Preferably, apart from the difference in fiber direction, each stacked fiberglass layer / fiberglass board is of the same type, including the same glass fiber, curing and bonding material, and molding process; the different fiberglass layers are formed only due to different fiber cutting directions / sizes after molding.

[0015] As a specific embodiment of the present invention, the glass fiber reinforced composite material preferably comprises four or six stacked glass fiber layers, as described in detail below.

[0016] In the first embodiment, the glass fiber reinforced composite material comprises four stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer. The glass fiber directions between the two inner glass fiber layers are parallel and the glass fibers are staggered in the stacking direction. Furthermore, the glass fiber directions of the two inner glass fiber layers form a 90° angle with the glass fiber directions of the two outer glass fiber layers.

[0017] In the second embodiment, the glass fiber reinforced composite material comprises four stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer. The glass fiber direction of the first inner glass fiber layer forms a 45° angle with the glass fiber directions of the two outer glass fiber layers, and the glass fiber direction of the second inner glass fiber layer forms a 90° angle with the glass fiber direction of the first inner glass fiber layer.

[0018] In the embodiments of the present invention, the first embodiment described above is preferred for glass fiber reinforced composite materials comprising four glass fiber layers, because this lamination method makes it easier to achieve isotropic stress in the glass fiber reinforced composite material.

[0019] In the third embodiment, the glass fiber reinforced composite material comprises six stacked glass fiber layers, arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer, wherein...

[0020] The fiber directions of the two inner fiberglass layers are parallel and staggered in the stacking direction, and the fiber directions of the two inner fiberglass layers form a 90° angle with the fiber directions of the two outer fiberglass layers; and

[0021] The fiber direction of the first intermediate fiberglass layer forms a 45° angle with the fiber direction of the two outer fiberglass layers, and the fiber direction of the second intermediate fiberglass layer forms a 90° angle with the fiber direction of the first intermediate fiberglass layer.

[0022] In the fourth embodiment, the glass fiber reinforced composite material comprises six stacked glass fiber layers, arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer.

[0023] The fiber direction of the first inner fiberglass layer forms a 45° angle with the fiber direction of the two outer fiberglass layers, and the fiber direction of the second inner fiberglass layer forms a 90° angle with the fiber direction of the first inner fiberglass layer; and

[0024] The fiber directions between the two intermediate fiberglass layers are parallel and form a 90° angle with the fiber directions of the two outer fiberglass layers.

[0025] In the fifth embodiment, the glass fiber reinforced composite material comprises six stacked glass fiber layers, arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer.

[0026] The fiber direction of the first intermediate fiberglass layer is parallel to the fiber direction of the second inner fiberglass layer, and forms a 45° angle with the fiber directions of the two outer fiberglass layers; and

[0027] The fiber directions of the first inner fiberglass layer and the second intermediate fiberglass layer are parallel, and they form a 90° angle with the fiber direction of the first intermediate fiberglass layer.

[0028] In the embodiments of the present invention, for glass fiber reinforced composite materials comprising six glass fiber layers, the third and fourth embodiments described above are preferred because these layering methods make it easier to achieve isotropic stress in the glass fiber reinforced composite material.

[0029] Besides the preferred configuration of four or six stacked glass fiber layers described above, the glass fiber reinforced composite material may also include configurations with an odd number of glass fiber layers, such as three, five, or seven. However, from the perspective of isotropic stress distribution, configurations with an odd number of glass fiber layers are not preferred over configurations with an even number of glass fiber layers.

[0030] In one embodiment, the glass fiber reinforced composite material comprises three stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, an inner glass fiber layer, and a second outer glass fiber layer, wherein the glass fiber direction of the inner glass fiber layer forms a 90° angle with the glass fiber direction of the two outer glass fiber layers.

[0031] In one embodiment, the glass fiber reinforced composite material comprises five stacked glass fiber layers, arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, an inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer, wherein the glass fiber direction of the inner glass fiber layer forms a 90° angle with the glass fiber directions of the two outer glass fiber layers; and

[0032] The fiber direction of the first intermediate fiberglass layer forms a 45° angle with the fiber direction of the two outer fiberglass layers, and the fiber direction of the second intermediate fiberglass layer forms a 90° angle with the fiber direction of the first intermediate fiberglass layer.

[0033] In one embodiment, the glass fiber reinforced composite material comprises seven stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a central glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer, wherein the glass fiber direction of the central glass fiber layer forms a 90° angle with the glass fiber directions of the two outer glass fiber layers.

[0034] The fiber direction of the first intermediate fiberglass layer is parallel to the fiber direction of the second inner fiberglass layer, and forms a 45° angle with the fiber directions of the two outer fiberglass layers; and

[0035] The fiber directions of the first inner fiberglass layer and the second intermediate fiberglass layer are parallel, and they form a 90° angle with the fiber direction of the first intermediate fiberglass layer.

[0036] The glass fiber reinforced composite material may also include a combination of six or more even-numbered glass fiber layers, such as eight or ten glass fiber layers. However, from the perspective of process complexity, resin layer bonding strength, and the specifications and acquisition methods of individual glass fiber layers, glass fiber reinforced composite materials including eight or more even-numbered glass fiber layers are not preferred.

[0037] In addition, for the resin layer between each two adjacent glass fiber layers, epoxy resin, polyurethane resin, phenolic resin, urea-formaldehyde resin, melamine copolymer resin or silicone resin can be selected, among which epoxy resin and polyurethane resin are preferred.

[0038] Furthermore, the resin layer contains a support member, and the height of the support member is the same as the thickness of the resin layer.

[0039] The purpose of placing the supports is to prevent the resin from flowing under pressure during the subsequent vacuum pre-compression thermosetting process, thereby ensuring the integrity and uniform thickness of the adhesive layer in the finished composite material. Multiple supports are typically provided and evenly distributed within each resin layer to provide good support.

[0040] To achieve the above objectives, typically at least some of the support members have a height equal to the thickness of the resin layer in the finished product, i.e., a predetermined resin layer thickness; preferably, the height of all support members is equal to the thickness of the resin layer in the finished product, for example, all support members are identical, and their heights are all equal to the thickness of the resin layer.

[0041] The support can be spherical, cylindrical, cubic, conical, frustum, or any other shape, as long as its height in one dimension meets the requirements for a support and it can be stably placed in the resin between two adjacent fiberglass layers in that dimension. Spherical supports are preferred because they have the smallest contact area with the fiberglass layers on both sides, thus minimizing the impact of the support on the composite material under stress.

[0042] In one embodiment, the support is a glass bead, and the diameter of the glass bead is equal to the thickness of the resin layer. There are no specific limitations on the composition of the glass bead; for example, quartz glass, silicate glass, soda-lime glass, or any other type of glass material can be used. Of course, the support can also be made of ceramic, resin, or other materials.

[0043] Furthermore, the thickness of each glass fiber layer in the glass fiber reinforced composite material is preferably 2-20 mm, and the thickness of the resin layer is preferably 0.5-1 mm.

[0044] There are no strict limitations on the thickness of the fiberglass layer; it can be determined based on the specifications of the fiberglass board used and the actual requirements. Factors affecting the thickness of the fiberglass board typically include the diameter and number of fiberglass layers used, as well as the corresponding manufacturing process. For example, the thickness of the fiberglass layer can be 1-50 mm, such as 2-20 mm, or 3-10 mm.

[0045] Furthermore, the width of the fiberglass layer can range from 10 to 1000 mm, for example, 20 to 500 mm, or 30 to 200 mm. Of course, it is not limited to these; this is just an example.

[0046] The thickness of the resin layer is typically determined based on the thickness of the glass fiber layers on both sides and the overall thickness of the composite material. For example, the thickness of the resin layer can be 0.3-3 mm, such as 0.4-2 mm, or 0.5-1 mm.

[0047] A second aspect of the present invention provides a method for preparing a glass fiber reinforced composite material, the method comprising the following steps:

[0048] (1) Coat the first fiberglass layer with a resin adhesive of a predetermined thickness and place the support evenly in the resin adhesive;

[0049] (2) Stack the remaining fiberglass layers in sequence. Except for the last fiberglass layer, after each fiberglass layer is stacked, apply a resin adhesive of a predetermined thickness on it and place the support evenly in the resin adhesive.

[0050] (3) Place the last glass fiber layer to form a glass fiber reinforced composite material preform;

[0051] (4) The formed glass fiber reinforced composite material preform is subjected to vacuum pre-compression thermo-curing to obtain the glass fiber reinforced composite material.

[0052] The fiberglass layer, resin adhesive, and support are as described above.

[0053] The vacuum pre-compression thermosetting process is generally carried out using vacuum pre-compression thermosetting equipment. The vacuum pre-compression method can be used to prepare high-performance composite materials and mainly includes steps such as material preparation, vacuum pre-compression, thermosetting, and subsequent processing.

[0054] Among them, steps (1) to (3) above can be regarded as material preparation steps.

[0055] For vacuum preloading, the glass fiber reinforced composite preform is placed in an optional mold and then inside a vacuum bag. The vacuum bag is sealed, and the air inside is extracted using a vacuum pump to ensure thorough bonding of the composite layers and eliminate air bubbles. During vacuum preloading, the appropriate preloading time and pressure need to be determined based on the material properties to ensure good molding results.

[0056] In the technical solution of this invention, the pressure of vacuum pre-compression is controlled at 10-30 kPa, for example 15-20 kPa, depending on the thickness and number of resin layers.

[0057] For thermosetting, the pre-compressed material is placed in a hot press and subjected to a certain temperature and pressure, so that the resin liquid can flow and cure fully during the thermosetting process, thereby forming a strong composite material.

[0058] In the technical solution of this invention, the temperature is controlled at 135℃-145℃, the curing time is 30-40 minutes, and the pressure is 10-30 kPa. In a preferred embodiment, the heat curing temperature is controlled at 145℃, the curing time is 35 minutes, and the pressure is 20 kPa.

[0059] After the composite material is thermocured, optional follow-up processing steps can be performed, such as trimming edges and corners, surface treatment, etc.

[0060] Furthermore, the preparation method further includes:

[0061] Before step (1), high-temperature tape is placed around the bottom surface of the first glass fiber layer. The width of the high-temperature tape is more than 20 mm greater than the thickness of the glass fiber reinforced composite preform.

[0062] Before step (4), the sides of the glass fiber reinforced composite preform are sealed with the high-temperature tape.

[0063] The high-temperature tape is a specialized adhesive tape designed for use in high-temperature operating environments, with a typical temperature resistance range of 120℃-260℃. High-temperature tapes include polyimide tape, Teflon tape, etc.

[0064] In this invention, high-temperature tape is used to seal the sides of the glass fiber reinforced composite preform to prevent resin from flowing out during vacuum pre-compression and heat curing. Preferably, the width of the high-temperature tape should be greater than the side thickness of the glass fiber reinforced composite preform, with a margin of at least 10 mm on both sides; more preferably, a margin of at least 15 mm on both sides.

[0065] The beneficial effects of this invention include:

[0066] 1. This invention solves the problem that existing glass fiber composite materials are strong in the longitudinal direction but weak in the transverse direction in terms of stress performance, making their transverse and longitudinal stress performance equally strong or nearly similar, achieving near-isotropic performance in all directions of stress, thereby greatly expanding the application fields and scope of glass fiber resin composite materials, such as being able to be applied to existing building energy-saving doors and windows and large glass curtain walls.

[0067] 2. The prepared glass fiber reinforced composite material has the characteristics of high strength, light weight, and good thermal insulation performance, which can meet the energy-saving requirements of current zero-energy or near-zero-energy passive energy-saving building curtain walls, such as the structural columns of various energy-saving curtain walls. In addition, it also has fire-resistant and flame-retardant properties, and high safety.

[0068] 3. The preparation process of the glass fiber reinforced composite material is in line with the performance level of existing equipment, has low equipment requirements, and is conducive to cost control and promotion. Attached Figure Description

[0069] Figure 1 The illustration shows a schematic fabrication process for a glass fiber layer (glass fiberboard) in one embodiment of the present invention.

[0070] Figure 2 The diagram shows an exploded view of the structure of the glass fiber reinforced composite material comprising four stacked glass fiber layers according to one embodiment of the present invention.

[0071] Figure 3 The diagram shows an exploded view of the structure of the glass fiber reinforced composite material comprising four stacked glass fiber layers, according to another embodiment of the present invention.

[0072] Figure 4 The diagram shows an exploded view of the structure of the glass fiber reinforced composite material comprising six stacked glass fiber layers according to one embodiment of the present invention.

[0073] Figure 5 The diagram shows an exploded view of the structure of the glass fiber reinforced composite material comprising six stacked glass fiber layers, according to another embodiment of the present invention.

[0074] Figure 6 The diagram shows an exploded view of the structure of the glass fiber reinforced composite material comprising six stacked glass fiber layers, according to another embodiment of the present invention.

[0075] Figure 7 The diagram shows a partial structural schematic of a glass fiber reinforced composite material preform comprising four stacked glass fiber layers, as described in one embodiment of the present invention.

[0076] Figure 8 The diagram shows a partial structural schematic of a glass fiber reinforced composite material preform comprising six stacked glass fiber layers, as described in one embodiment of the present invention.

[0077] Figure 9 The diagram shows a partial structural schematic of a glass fiber reinforced composite material preform comprising six stacked glass fiber layers, as described in another embodiment of the present invention. Detailed Implementation

[0078] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings.

[0079] While exemplary embodiments of the invention are shown in the accompanying drawings, it should be understood that the invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the invention can be understood more clearly and thoroughly, and that the scope of the invention can be fully conveyed to those skilled in the art.

[0080] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0081] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0082] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," or "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0083] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0084] Example 1

[0085] like Figure 1 The diagram shown illustrates a schematic flowchart of the preparation process of a glass fiber layer (glass fiber board) in one embodiment of the present invention.

[0086] One or more continuous glass fibers are guided and pulled by a positioning mechanism / guide roller and a traction mechanism into a forming mold with a certain cross-sectional shape. The forming mold includes a mixing tank at the front end and a pultrusion tank at the rear end. A glue injection port is located above the mixing tank. A curing adhesive material, such as resin, used in the production of the glass fiber board is injected into the mixing tank through the glue injection port and thoroughly impregnates and mixes with the glass fiber bundles passing through the mixing tank. Here, the components of the resin can be pre-mixed into a homogeneous colloid, or they can be mixed only when impregnating the glass fiber bundles in the mixing tank. In the latter case, the resin can include multiple components, such as component A and component B, which are injected into the glue injection port through different containers.

[0087] Subsequently, the glass fiber bundles, fully impregnated with resin, are cured and formed in the mold cavity of the pultrusion groove; or they are gelled and extruded in the mold cavity, then heated and cured after demolding, and continuously drawn out as profile products under the pulling force of the traction mechanism. Then, they are cut to a fixed length as needed to obtain the product.

[0088] Example 2

[0089] like Figure 2 As shown, in this embodiment, the glass fiber reinforced composite material includes four stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer. The glass fiber directions between the first inner glass fiber layer and the second inner glass fiber layer are parallel and the glass fibers are staggered in the stacking direction. Furthermore, the glass fiber directions of the two inner glass fiber layers form a 90° angle with the glass fiber directions of the two outer glass fiber layers.

[0090] The glass fibers between the first inner glass fiber layer and the second inner glass fiber layer are staggered in the stacking direction (i.e., in the thickness direction of the glass fiber reinforced composite material). This can increase the overall strength of two adjacent inner glass fiber layers with the same glass fiber direction and prevent the "seam" between the glass fibers in a glass fiber layer from continuing in different glass fiber layers in the thickness direction.

[0091] Example 3

[0092] like Figure 3 As shown, in this embodiment, the glass fiber reinforced composite material includes four stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer. The glass fiber direction of the first inner glass fiber layer forms a 45° angle with the glass fiber directions of the two outer glass fiber layers, and the glass fiber direction of the second inner glass fiber layer forms a 90° angle with the glass fiber direction of the first inner glass fiber layer.

[0093] Example 4

[0094] like Figure 4As shown, in this embodiment, the glass fiber reinforced composite material includes six stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer. The glass fiber directions of the first inner glass fiber layer and the second inner glass fiber layer are parallel and staggered in the stacking direction. The glass fiber directions of the two inner glass fiber layers form a 90° angle with the glass fiber directions of the two outer glass fiber layers. The glass fiber direction of the first middle glass fiber layer forms a 45° angle with the glass fiber directions of the two outer glass fiber layers, and the glass fiber direction of the second middle glass fiber layer forms a 90° angle with the glass fiber direction of the first middle glass fiber layer.

[0095] Example 5

[0096] like Figure 5 As shown, in this embodiment, the glass fiber reinforced composite material includes six stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer. The glass fiber direction of the first inner glass fiber layer forms a 45° angle with the glass fiber directions of the two outer glass fiber layers, and the glass fiber direction of the second inner glass fiber layer forms a 90° angle with the glass fiber direction of the first inner glass fiber layer. The glass fiber direction between the two middle glass fiber layers is parallel and forms a 90° angle with the glass fiber directions of the two outer glass fiber layers.

[0097] Example 6

[0098] like Figure 6 As shown, in this embodiment, the glass fiber reinforced composite material includes six stacked glass fiber layers, which are arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer. The glass fiber direction of the first middle glass fiber layer is parallel to the glass fiber direction of the second inner glass fiber layer and forms a 45° angle with the glass fiber directions of the two outer glass fiber layers. The glass fiber direction of the first inner glass fiber layer is parallel to the glass fiber direction of the second middle glass fiber layer and forms a 90° angle with the glass fiber direction of the first middle glass fiber layer.

[0099] Example 7

[0100] like Figure 7 As shown in Example 2, this embodiment provides a method for preparing a glass fiber reinforced composite material, which includes four stacked glass fiber layers, arranged from top to bottom as follows: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer. The glass fiber directions of the first and second inner glass fiber layers are parallel, and the glass fibers are staggered in the stacking direction. Furthermore, the glass fiber directions of the two inner glass fiber layers form a 90° angle with the glass fiber directions of the two outer glass fiber layers. The method includes the following steps:

[0101] (1) A resin adhesive of a predetermined thickness is coated on the second outer glass fiber layer, and glass beads are evenly placed in the resin adhesive;

[0102] (2) The second inner glass fiber layer, the first inner glass fiber layer, and the first outer glass fiber layer are stacked in sequence. Except for the first outer glass fiber layer, after each glass fiber layer is stacked, a resin adhesive of a predetermined thickness is coated on it, and multiple glass beads are evenly placed in the resin adhesive.

[0103] (3) Place the first outer glass fiber layer to form a glass fiber reinforced composite material preform;

[0104] (4) The formed glass fiber reinforced composite material preform is subjected to vacuum pre-compression thermo-curing to obtain the glass fiber reinforced composite material.

[0105] As a preferred option, further,

[0106] Before step (1), high-temperature tape is placed around the bottom surface of the first glass fiber layer. The width of the high-temperature tape is 20 mm greater than the thickness of the glass fiber reinforced composite preform (i.e., 10 mm width is left on each side of the glass fiber reinforced composite preform).

[0107] Before step (4), the sides of the glass fiber reinforced composite preform are sealed with the high-temperature tape.

[0108] Example 8

[0109] like Figure 8 As shown in Example 4, this embodiment provides a method for preparing a glass fiber reinforced composite material, which includes six stacked glass fiber layers, arranged from top to bottom as follows: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer. The glass fiber directions of the first and second inner glass fiber layers are parallel and staggered in the stacking direction. The glass fiber directions of the two inner glass fiber layers form a 90° angle with the glass fiber directions of the two outer glass fiber layers. The glass fiber direction of the first middle glass fiber layer forms a 45° angle with the glass fiber directions of the two outer glass fiber layers, and the glass fiber direction of the second middle glass fiber layer forms a 90° angle with the glass fiber direction of the first middle glass fiber layer. The method includes the following steps:

[0110] (1) A resin adhesive of a predetermined thickness is coated on the second outer glass fiber layer, and glass beads are evenly placed in the resin adhesive;

[0111] (2) The second intermediate glass fiber layer, the second inner glass fiber layer, the first inner glass fiber layer, the first intermediate glass fiber layer, and the first outer glass fiber layer are stacked in sequence. Except for the first outer glass fiber layer, after each glass fiber layer is stacked, a resin adhesive of a predetermined thickness is coated on it, and multiple glass beads are evenly placed in the resin adhesive.

[0112] (3) Place the first outer glass fiber layer to form a glass fiber reinforced composite material preform;

[0113] (4) The formed glass fiber reinforced composite material preform is subjected to vacuum pre-compression thermo-curing to obtain the glass fiber reinforced composite material.

[0114] As a preferred option, further,

[0115] Before step (1), high-temperature tape is placed around the bottom surface of the first glass fiber layer. The width of the high-temperature tape is 30 mm greater than the thickness of the glass fiber reinforced composite preform (i.e., 15 mm width is left on each side of the glass fiber reinforced composite preform).

[0116] Before step (4), the sides of the glass fiber reinforced composite preform are sealed with the high-temperature tape.

[0117] Example 9

[0118] In this embodiment, except that the arrangement of each fiberglass layer is the same as in Embodiment 5, such as Figure 9 As shown in Example 8, a method for preparing a glass fiber reinforced composite material is provided.

[0119] The following provides a specific preparation example.

[0120] Preparation Example 1

[0121] A fiberglass board was obtained following the steps described in Example 1. The fiberglass board was made of 80% glass fiber and 20% polyurethane resin. The composition and content of the glass fiber were as follows: 62% SiO2, 12% Al2O3, 8% CaO, 12% MgO, 2% ZrO2, and 4% B2O3. The polyurethane resin was prepared by reacting 75% isoflurane dicarboxylate, 20% polyether polyol, 3% sodium alkylbenzene sulfonate, and 2% N,N-dimethylcyclohexylamine.

[0122] Referring to Example 2, a first outer fiberglass layer, a first inner fiberglass layer, a second inner fiberglass layer, and a second outer fiberglass layer are obtained from the fiberglass board obtained above. Each fiberglass layer has uniform specifications: length 1000mm, width 600mm, and thickness 12mm. The fiber direction of the first outer fiberglass layer and the second outer fiberglass layer is along the length direction of the fiberglass board, and the fiber direction of the first inner fiberglass layer and the second inner fiberglass layer is along the width direction of the fiberglass board.

[0123] Referring to Example 7, a glass fiber reinforced composite material was prepared:

[0124] (1) Set polyimide high-temperature tape around the bottom surface of the second outer glass fiber layer (leaving a width of 10mm on each side of the glass fiber reinforced composite preform); then coat it with 1mm of polyurethane resin adhesive and place glass beads evenly in the resin adhesive.

[0125] (2) Stack the second inner glass fiber layer and the first inner glass fiber layer in sequence. After each glass fiber layer is stacked, apply 1 mm of polyurethane resin glue and place glass beads evenly in the resin glue.

[0126] (3) Place the first outer glass fiber layer, and seal the side of the glass fiber reinforced composite material preform with the high temperature tape to form a glass fiber reinforced composite material preform;

[0127] (4) The formed glass fiber reinforced composite material preform is subjected to vacuum pre-compression thermo-curing. The vacuum pre-compression pressure is 20 kPa, the thermo-curing temperature is 145℃, and the curing time is 35 minutes to obtain the glass fiber reinforced composite material (sample 1).

[0128] Preparation Example 2

[0129] As in Preparation Example 1, a fiberglass board was obtained.

[0130] Referring to Example 4, a first outer fiberglass layer, a first middle fiberglass layer, a first inner fiberglass layer, a second inner fiberglass layer, a second middle fiberglass layer, and a second outer fiberglass layer are obtained from the fiberglass board obtained above. Each fiberglass layer has uniform specifications: length 1000mm, width 600mm, and thickness 8mm. The fiber direction of the first outer fiberglass layer and the second outer fiberglass layer is along the length direction of the fiberglass board, the fiber direction of the first inner fiberglass layer and the second inner fiberglass layer is along the width direction of the fiberglass board, the fiber direction of the first middle fiberglass layer forms a 45-degree angle with the fiber direction of the outer fiberglass layer, and the fiber direction of the second middle fiberglass layer forms a 90-degree angle with the fiber direction of the first middle fiberglass layer.

[0131] Referring to Example 8, a glass fiber reinforced composite material was prepared:

[0132] (1) Set polyimide high-temperature tape around the bottom surface of the second outer glass fiber layer (leaving a width of 15mm on each side of the glass fiber reinforced composite preform); then coat it with 0.6mm of polyurethane resin adhesive and place glass beads evenly in the resin adhesive.

[0133] (2) Stack the second intermediate fiberglass layer, the second inner fiberglass layer, the first inner fiberglass layer and the first intermediate fiberglass layer in sequence. After each fiberglass layer is stacked, apply 0.6 mm of polyurethane resin adhesive and place glass beads evenly in the resin adhesive.

[0134] (3) Place the first outer glass fiber layer, and seal the side of the glass fiber reinforced composite material preform with the high temperature tape to form a glass fiber reinforced composite material preform;

[0135] (4) The formed glass fiber reinforced composite material preform was subjected to vacuum pre-compression thermo-curing. The vacuum pre-compression pressure was 20 kPa, the thermo-curing temperature was 145°C, and the curing time was 35 minutes to obtain the glass fiber reinforced composite material (sample 2).

[0136] Preparation Example 3

[0137] Except for the arrangement of each glass fiber layer as in Example 5, the glass fiber reinforced composite material (sample 3) was prepared in accordance with the steps of Preparation Example 2 and with reference to Example 9.

[0138] The performance test results of samples 1-3 obtained from preparation example 1-3 are shown in the table below.

[0139]

[0140] As can be seen from the table above, the glass fiber reinforced composite material prepared by this invention exhibits excellent performance, especially in terms of transverse tensile strength and transverse flexural strength, exceeding the required standards by more than 10 times, demonstrating good isotropic performance. Furthermore, the screw pull-out load capacity also reaches nearly 10 times the required standard, thus meeting the application requirements of glass fiber reinforced composite materials in energy-saving building doors, windows, and curtain walls. Moreover, the finished product also exhibits excellent performance in terms of overall structural integrity, thermal insulation, and thickness accuracy.

[0141] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for producing a glass fiber-reinforced composite material, characterized by, The glass fiber reinforced composite material comprises at least three stacked glass fiber layers and a resin layer between every two adjacent glass fiber layers, wherein, The fiber directions between at least two fiberglass layers are at a 90° angle, and the fiber directions between the two outer fiberglass layers are parallel. The fiberglass layer is a fiberglass board made of 70-85% glass fiber and 15-30% curing and bonding material; The resin layer contains a support member, and the height of the support member is the same as the thickness of the resin layer. The support member is used to prevent the resin adhesive from flowing under pressure during the subsequent vacuum pre-compression thermo-curing process, so that the adhesive layer in the finished glass fiber reinforced composite material is intact and has a uniform thickness. The preparation method of the glass fiber reinforced composite material includes the following steps: (1) Apply a resin adhesive of a predetermined thickness to the first fiberglass layer and place the support evenly in the resin adhesive; (2) Stack the remaining fiberglass layers in sequence. Except for the last fiberglass layer, after each fiberglass layer is stacked, apply a resin adhesive of a predetermined thickness on it and place the support evenly in the resin adhesive. (3) Place the last glass fiber layer to form a glass fiber reinforced composite preform; (4) The formed glass fiber reinforced composite material preform is subjected to vacuum pre-compression thermo-curing to obtain the glass fiber reinforced composite material.

2. The method of making a glass fiber reinforced composite material of claim 1, wherein, The glass fiber reinforced composite material comprises four stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer, wherein, The fiber directions of the two inner fiberglass layers are parallel and the fiberglasses are staggered in the stacking direction, and the fiber directions of the two inner fiberglass layers form a 90º angle with the fiber directions of the two outer fiberglass layers.

3. The method of making a glass fiber reinforced composite material of claim 1, wherein, The glass fiber reinforced composite material comprises four stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, and a second outer glass fiber layer, wherein, The fiber direction of the first inner fiberglass layer forms a 45° angle with the fiber direction of the two outer fiberglass layers, and the fiber direction of the second inner fiberglass layer forms a 90° angle with the fiber direction of the first inner fiberglass layer.

4. The method of making a glass fiber reinforced composite material of claim 1, wherein, The glass fiber reinforced composite material comprises six stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer, wherein... The fiber directions of the two inner fiberglass layers are parallel and staggered in the stacking direction, and the fiber directions of the two inner fiberglass layers form a 90° angle with the fiber directions of the two outer fiberglass layers; and The fiber direction of the first intermediate fiberglass layer forms a 45° angle with the fiber direction of the two outer fiberglass layers, and the fiber direction of the second intermediate fiberglass layer forms a 90° angle with the fiber direction of the first intermediate fiberglass layer.

5. The method of making a glass fiber reinforced composite material of claim 1, wherein, The glass fiber reinforced composite material comprises six stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer, wherein... The fiber direction of the first inner fiberglass layer forms a 45° angle with the fiber direction of the two outer fiberglass layers, and the fiber direction of the second inner fiberglass layer forms a 90° angle with the fiber direction of the first inner fiberglass layer; and The fiber directions between the two intermediate fiberglass layers are parallel and form a 90° angle with the fiber directions of the two outer fiberglass layers.

6. The method of making a glass fiber reinforced composite material of claim 1, wherein, The glass fiber reinforced composite material comprises six stacked glass fiber layers, from top to bottom: a first outer glass fiber layer, a first middle glass fiber layer, a first inner glass fiber layer, a second inner glass fiber layer, a second middle glass fiber layer, and a second outer glass fiber layer, wherein... The fiber direction of the first intermediate fiberglass layer is parallel to the fiber direction of the second inner fiberglass layer, and forms a 45° angle with the fiber directions of the two outer fiberglass layers; and The fiber direction of the first inner fiberglass layer is parallel to that of the second intermediate fiberglass layer, and forms a 90º angle with the fiber direction of the first intermediate fiberglass layer.

7. The method of making a glass fiber reinforced composite of any one of claims 1-6, wherein, The thickness of each glass fiber layer in the glass fiber reinforced composite material is 2-20 mm, and the thickness of the resin layer is 0.5-1 mm.

8. The method of making a glass fiber reinforced composite of claim 1, wherein, The preparation method further includes: Before step (1), high-temperature tape is placed around the bottom surface of the first glass fiber layer, and the width of the high-temperature tape is more than 20 mm greater than the thickness of the glass fiber reinforced composite preform. Before step (4), the sides of the glass fiber reinforced composite preform are sealed with the high-temperature tape.

Images