Thermosetting light carbon fiber composite board and manufacturing method thereof

Abstract

The invention relates to a thermosetting light carbon fiber composite board and a manufacturing method thereof, and the thermosetting light carbon fiber composite board comprises a surface layer which is a thermosetting resin impregnated carbon fiber layer; the middle layer is made of a continuous one-way or woven fibrilia material impregnated with thermosetting resin, and the required thickness can be formed according to the use requirement; the surface layer and the middle layer are laid according to design requirements of designed thickness, size, strength and the like and then are processed into the thermosetting light carbon fiber composite board through mixed hot pressing. The manufacturing method has the beneficial effects that the manufacturing method is simple in process and convenient to lay, the thickness of the composite board can be adjusted according to different requirements of products, meanwhile, the carbon fiber layer and the jute fiber layer which are impregnated with the thermosetting resin are used, so that the use amount of carbon fibers can be reduced, and the cost and the weight can be reduced by using the jute fibers; and meanwhile, low carbon and environmental protection are also realized, and the high strength and high modulus performance of the composite board are kept at the same time.

Description

[Technical field]

[0001] The invention relates to the technical field of thermosetting plates and hot pressing molding, in particular to a thermosetting lightweight carbon fiber composite plate and a manufacturing method thereof. [Background technology]

[0002] With the development of electronic devices and information equipment such as laptops, tablet notebooks, portable phones, portable information terminals or cameras, the market strongly demands the development of thin and lightweight products. Thin and lightweight products require the shell or internal components of the finished product to be thin-walled and lightweight, and also require high strength and high rigidity. Composite materials have the advantages of light weight, high strength and high modulus, chemical corrosion resistance, fatigue resistance, and easy overall molding. They are widely used in the production of military, aircraft, automobiles, wind power and other products. Due to the excellent mechanical properties of composite materials, they can also be used in the shells of electronic and electrical equipment and information equipment such as laptops, tablet notebooks, portable phones, portable information terminals or cameras, playing a role in making the shell thinner and reducing the weight of the equipment.

[0003] At present, more and more low-carbon environmentally friendly materials and degradable materials are used in electronic and electrical products, and hemp fiber is one of them. Hemp fiber is obtained from various hemp plants. Hemp fiber is a high-performance natural green plant fiber with excellent mechanical properties. It is often used to replace synthetic fibers and is widely used in green composite materials. The decomposition products of hemp fiber are organic matter, carbon dioxide and water. It is green and pollution-free, and can be completely degraded. Hemp fiber has a certain fineness and length and can be woven before use.

[0004] In view of this, it is necessary to develop a thermosetting lightweight carbon fiber composite plate and a manufacturing method thereof to solve the above problems. [Summary of the invention]

[0005] The technical problem to be solved by the present invention is that almost all carbon fiber products currently used in the market are composites of carbon fiber and polymer materials, and both the production and recycling of carbon fiber consume a lot of energy.

[0006] The solution of the present invention to solve the technical problem is:

[0007] A thermosetting lightweight carbon fiber composite plate, comprising:

[0008] A surface layer, wherein the surface layer is a carbon fiber layer impregnated with a thermosetting resin;

[0009] The middle layer is a continuous unidirectional or woven hemp fiber material impregnated with a thermosetting resin and can be formed into a desired thickness according to usage requirements;

[0010] The surface layer and the middle layer are stacked according to design requirements such as design thickness, size, strength, etc., and then processed by mixed hot pressing to form the thermosetting lightweight carbon fiber composite plate.

[0011] Preferably, the surface layer uses unidirectional or woven carbon fiber impregnated with thermosetting resin to maximize the strength of the board while retaining the carbon fiber texture.

[0012] Preferably, the middle layer uses unidirectional or woven hemp fibers impregnated with thermosetting resin to reduce the amount of carbon fiber used, thereby achieving the purpose of reducing costs and weight, while retaining the strength of the board and achieving low-carbon and environmental protection.

[0013] The present invention also includes a method for manufacturing a thermosetting lightweight carbon fiber composite plate, comprising the following steps:

[0014] S1: The carbon fiber layer and the hemp fiber layer impregnated with thermosetting resin are stacked according to the designed thickness and strength requirements, with the carbon fiber layer placed on the surface and the hemp fiber layer placed in the middle layer;

[0015] S2: Put the stacked materials into a hot pressing mold, press the mold with a hot press, and evacuate the mold. The mold temperature depends on the physical properties of the thermosetting resin used.

[0016] S3: The mold is pressurized and kept at a constant temperature at a set temperature, and vacuum is continuously drawn;

[0017] S4: When the mold reaches the set time, the vacuum is turned off and cooling is started until the sheet in the mold reaches the cooling temperature;

[0018] S5: Open the mold and take out the composite sheet.

[0019] Preferably, the stacking order from bottom to top in S1 is a 3K (3K is the name of carbon fiber woven cloth, and the specific distinction is based on the silk used for the woven cloth) carbon fiber layer impregnated with thermosetting resin, eight woven hemp fiber layers impregnated with thermosetting resin, and a 3K carbon fiber layer impregnated with thermosetting resin.

[0020] Preferably, the thermosetting resin impregnated in S1 is epoxy resin, the temperature of the hot pressing mold in S2 is set to 140° C.-170° C., and the time for pressurizing and maintaining the mold at a constant temperature in S3 is 10 min-15 min.

[0021] Preferably, the cooling temperature of the in-mold composite plate in S4 is set to 50°C-60°C.

[0022] Preferably, a heat press with a vacuum function is required during the processing.

[0023] The beneficial effects of the present invention are:

[0024] 1. The manufacturing method is simple in process, convenient in stacking, and can adjust the thickness of the composite board according to different product requirements.

[0025] 2. The present invention uses carbon fiber layers and hemp fiber layers impregnated with thermosetting resin to reduce the amount of carbon fiber used, and the use of hemp fiber can reduce costs and reduce weight, while also achieving low-carbon and environmental protection, while maintaining the high strength and high modulus (high modulus refers to the ratio of stress to strain of a material under stress) properties of the composite board.

Brief Description of the Drawings

[0026] Figure 1 It is a schematic diagram of the interface of a thermosetting lightweight carbon fiber composite plate of the present invention.

[0027] Figure 2 The present invention is a flowchart of the steps of a method for manufacturing a thermosetting lightweight carbon fiber composite plate. [Specific implementation method]

[0028] In order to further illustrate the technical means and effects adopted by the present invention, the following is a detailed description in conjunction with the embodiments of the present invention and the accompanying drawings.

[0029] The present invention provides a thermosetting lightweight carbon fiber composite plate and a manufacturing method thereof. The thermosetting lightweight carbon fiber composite plate 10 comprises:

[0030] A surface layer 110, wherein the surface layer 110 is a layer of carbon fibers 111 impregnated with thermosetting resin;

[0031] The middle layer 120 is a continuous unidirectional or woven hemp fiber 121 material impregnated with a thermosetting resin, and can be formed into a desired thickness according to usage requirements;

[0032] The surface layer 110 and the middle layer 120 are stacked according to design requirements such as design thickness, size, and strength, and then processed by mixed hot pressing to form the thermosetting lightweight carbon fiber 111 composite board 10.

[0033] The carbon fiber 111 layer used in the surface layer 110 is continuous unidirectional or woven carbon fiber 111 impregnated with a thermosetting resin, which maximizes the strength of the board 10 while retaining the texture of the carbon fiber 111 .

[0034] The middle layer 120 uses unidirectional or woven hemp fibers 121 impregnated with thermosetting resin to reduce the amount of carbon fibers 111 used, thereby reducing costs and weight, while retaining the strength of the board 10 and achieving low carbon and environmental protection.

[0035] The following is an example of using epoxy resin as the thermosetting resin of the thermosetting lightweight carbon fiber 111 composite plate 10 of the present invention to illustrate a method for manufacturing a thermosetting lightweight carbon fiber 111 composite plate 10 of the present invention:

[0036] S1: 111 layers of 3K (3K is the name of carbon fiber 111 woven cloth, and the specific distinction is based on the silk used for the woven cloth) carbon fiber impregnated with epoxy resin, 121 layers of eight-layer woven hemp fiber impregnated with epoxy resin, and 111 layers of 3K carbon fiber impregnated with epoxy resin are laid in a stacking order according to the designed size, thickness and strength;

[0037] S2: The temperature of the hot pressing mold is raised to 140℃-170℃, the stacked materials are fed into the mold of the hot pressing machine, the hot pressing machine presses the mold and evacuates the mold;

[0038] S3: The mold is pressurized and kept at a set temperature of 140℃-170℃ for 10min-15min, and vacuum is continuously drawn;

[0039] S4: When the mold reaches the set time, the vacuum is turned off and cooling is started until the composite sheet 10 in the mold reaches a cooling temperature of 50°C-60°C;

[0040] S5: Open the mold and take out the composite board 10.

[0041] Among them, a hot press with a vacuum function needs to be used in the processing process.

[0042] It should be pointed out that the present invention is not limited to the above-mentioned implementation modes, and any simple modifications, equivalent changes and modifications made to the above-mentioned embodiments by any technician familiar with the profession based on the technical solution of the present invention fall within the protection scope of the present invention.

Claims

1. A thermosetting lightweight carbon fiber composite sheet, characterized in that: include: A surface layer, wherein the surface layer is a carbon fiber layer impregnated with a thermosetting resin; The middle layer is a continuous unidirectional or woven hemp fiber material impregnated with a thermosetting resin and can be formed into a desired thickness according to usage requirements; The surface layer and the middle layer are stacked according to design requirements such as design thickness, size, strength, etc., and then processed by mixed hot pressing to form the thermosetting lightweight carbon fiber composite plate.

2. A thermosetting lightweight carbon fiber composite sheet according to claim 1, characterized in that: The carbon fiber layer used in the surface layer is continuous unidirectional or woven carbon fiber impregnated with thermosetting resin, which maximizes the strength of the board while retaining the carbon fiber texture.

3. The thermosetting lightweight carbon fiber composite sheet according to claim 1, characterized in that: The use of unidirectional or woven hemp fibers impregnated with thermosetting resin reduces the amount of carbon fiber used, thereby achieving the purpose of reducing cost and weight, while retaining the strength of the board and achieving low-carbon and environmental protection.

4. A method for manufacturing a thermosetting lightweight carbon fiber composite sheet, characterized in that: The manufacturing method comprises the following steps: S1: The carbon fiber layer and the hemp fiber layer impregnated with thermosetting resin are stacked according to the designed thickness and strength requirements, with the carbon fiber layer on the surface and the hemp fiber layer in the middle layer; S2: Put the stacked materials into a hot pressing mold, press the mold together with a hot press, and evacuate the mold. The mold temperature depends on the physical properties of the thermosetting resin used. S3: The mold is pressurized and kept at a constant temperature at a set temperature, and vacuum is continuously drawn; S4: When the mold reaches the set time, the vacuum is turned off and cooling is started until the composite sheet in the mold reaches the cooling temperature; S5: Open the mold and take out the composite sheet.

5. The method for manufacturing a thermosetting lightweight carbon fiber composite sheet material according to claim 4, characterized in that: The stacking order from bottom to top in S1 is: 3K carbon fiber layer impregnated with thermosetting resin, eight woven hemp fiber layers impregnated with thermosetting resin, and 3K carbon fiber layer impregnated with thermosetting resin.

6. The method for manufacturing a thermosetting lightweight composite board according to claim 4, characterized in that: The thermosetting resin impregnated in S1 is epoxy resin, the temperature of the hot pressing mold in S2 is set to 140° C.-170° C., and the time for pressurizing and maintaining the mold at a constant temperature in S3 is 10 min-15 min.

7. The method for manufacturing a thermosetting lightweight carbon fiber composite sheet material according to claim 4, characterized in that: The cooling temperature of the in-mold composite plate in S4 is set to 50°C-60°C.

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