Thermoplastic light carbon fiber composite board and manufacturing method thereof

Abstract

The invention relates to a thermoplastic light carbon fiber composite board and a manufacturing method thereof, and the thermoplastic light carbon fiber composite board comprises a surface layer which is a carbon fiber layer impregnated with thermoplastic resin; the middle layer is made of a thermoplastic resin impregnated material with uncompacted non-woven long carbon fibers with holes, 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 thermoplastic light carbon fiber composite board through mixed hot pressing, and 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, and the production cost is reduced. Meanwhile, the use amount of the non-woven long carbon fibers impregnated with the thermoplastic resin can be reduced, the cost is saved, low carbon and environmental protection are achieved, and meanwhile the use requirements of light weight, high strength, high rigidity and the like can be met.

Description

[Technical field]

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

[0002] With the development of electronic and electrical equipment and information equipment such as laptops, tablets, mobile phones, portable information terminals or cameras, the market demand for the development of thin and lightweight products is increasing. Thin and light products require that the outer shell or internal components of the product 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 manufacture 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 outer shells of electronic and electrical equipment and information equipment such as laptops, tablets, mobile phones, portable information terminals or cameras, playing a role in making the outer shell thinner and reducing the weight of the equipment.

[0003] At present, most thermoplastic carbon fiber composite products used in electronic appliances, automobiles, sports equipment and other products are processed and formed using all-carbon fiber or carbon fiber and glass fiber mixed composite sheets. The density of thermoplastic all-carbon fiber composite sheets is 1.45-1.55g / cm 3 The density of the composite board made of carbon fiber and glass fiber, which is relatively cheap, is 1.7-1.8 g / cm 3 Although its price is low and its modulus and rigidity are high enough, the weight of the product is heavy, which does not conform to the current development direction of lightweighting.

[0004] In view of this, it is necessary to provide a thermoplastic 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 the price of full carbon fiber composite sheet is too high, and the composite sheet of carbon fiber mixed with glass fiber with lower price has high modulus and rigidity, but the weight of the product is too heavy and does not conform to the current development direction of lightweight. Therefore, the present invention provides a thermoplastic lightweight carbon fiber composite sheet and its manufacturing method to solve the above problems.

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

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

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

[0009] The middle layer is a thermoplastic resin-impregnated material with hollow, uncompacted non-woven long carbon fibers, 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 thermoplastic lightweight carbon fiber composite plate.

[0011] Preferably, the carbon fiber layer used in the surface layer is continuous unidirectional or woven carbon fiber impregnated with thermoplastic resin, which maximizes the strength of the board while retaining the carbon fiber texture.

[0012] Preferably, the middle layer uses non-woven long carbon fibers impregnated with thermoplastic resin, the density of the non-woven long carbon fiber layer depends on the final required board density, and the middle layer does not need to be compacted, but needs to be fully impregnated and retain pores.

[0013] Preferably, the long carbon fiber can be recycled carbon fiber with a fiber length of 10 mm to 100 mm, so as to reduce the usage of continuous carbon fiber and achieve the purpose of reducing cost and weight.

[0014] Preferably, the long carbon fibers are bonded together with the carbon fiber layer by an adhesive, and the adhesive needs to be resistant to high temperatures, such as a tackified acrylic adhesive (short-term resistance of 200-250° C., long-term resistance of 100-120° C.).

[0015] Preferably, the thermoplastic resin may be polycarbonate (PC), polyamide (PA), polyphenylene sulfide (PPS), polypropylene (PP) or the like.

[0016] The present invention also includes a method for manufacturing a thermoplastic lightweight carbon fiber composite plate, comprising the following steps:

[0017] S1: A carbon fiber layer impregnated with thermoplastic resin is used as a surface layer, and a non-woven long carbon fiber layer impregnated with thermoplastic resin is used as an intermediate layer, and the layers are stacked according to the designed size, thickness and strength;

[0018] S2: placing the stacked materials in a hot pressing mold, pressing the mold with a hot pressing machine, and evacuating the mold. The mold temperature depends on the physical properties of the thermoplastic resin used;

[0019] S3: The mold is pressurized and kept at a constant temperature at a set temperature, and vacuum is continuously drawn;

[0020] 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;

[0021] S5: Open the mold and take out the composite sheet.

[0022] Preferably, the stacking order from bottom to top in S1 is a 0° unidirectional carbon fiber layer impregnated with thermoplastic resin, a 90° unidirectional carbon fiber layer impregnated with thermoplastic resin, a thermoplastic resin layer impregnated with adhesive and an intermediate layer (thermoplastic resin + long carbon fiber) and adhesive and a thermoplastic resin layer impregnated with thermoplastic resin, a 90° unidirectional carbon fiber layer impregnated with thermoplastic resin, and a 0° unidirectional carbon fiber layer impregnated with thermoplastic resin.

[0023] Preferably, the temperature of the hot pressing mold in S2 is set to 180°C to 260°C.

[0024] Preferably, the time of pressurizing and maintaining the constant temperature of the mold in S4 is 200 to 300 seconds, and the cooling temperature of the composite plate in the mold is set to 50° C. to 60° C.

[0025] Preferably, the carbon fiber board processing process requires the use of a conventional hot press machine, and the mold uses a flat steel plate.

[0026] The beneficial effects of the present invention are:

[0027] 1. The manufacturing method is simple in process, easy to lay up, and the thickness of the composite board can be adjusted according to different product requirements.

[0028] 2. The present invention uses non-woven long carbon fibers impregnated with thermoplastic resin to reduce the amount of carbon fibers used, save costs, and be low-carbon and environmentally friendly, while also meeting the requirements of light weight, high strength, and high rigidity.

[0029] 3. The hot pressing process is simple, and the entire process can be carried out using conventional hot pressing equipment.

Brief Description of the Drawings

[0030] Figure 1 It is a schematic cross-sectional view of a thermoplastic lightweight carbon fiber composite plate of the present invention.

[0031] Figure 2 The present invention is a flowchart of the steps of a method for manufacturing a thermoplastic lightweight carbon fiber composite plate.

[0032] Figure 3 It is a schematic diagram of the stacking sequence of the thermoplastic lightweight carbon fiber composite plate from bottom to top in the present invention. [Specific implementation method]

[0033] 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.

[0034] The present invention provides a thermoplastic lightweight carbon fiber composite plate and a manufacturing method thereof. The thermoplastic lightweight carbon fiber composite plate 10 comprises:

[0035] A surface layer 20, wherein the surface layer 20 is a carbon fiber layer impregnated with a thermoplastic resin;

[0036] The middle layer 30 is a thermoplastic resin-impregnated material with hollow, uncompacted non-woven long carbon fibers 110, and can be formed into a desired thickness according to usage requirements;

[0037] The surface layer 20 and the middle layer 30 are stacked according to design requirements such as design thickness, size, strength, etc., and then processed by mixed hot pressing to form the thermoplastic lightweight carbon fiber composite plate.

[0038] The carbon fiber layer used in the surface layer 20 is continuous unidirectional or woven carbon fiber impregnated with thermoplastic resin, which maximizes the strength of the board 10 while retaining the carbon fiber texture.

[0039] The middle layer 30 uses non-woven long carbon fibers 110 impregnated with thermoplastic resin, and the density of the non-woven long carbon fiber layer depends on the final required density of the board 10. The middle layer 30 does not need to be compacted, but needs to be fully impregnated and retain pores.

[0040] The long carbon fiber may be recycled carbon fiber with a fiber length of 10 mm to 100 mm, thereby reducing the amount of continuous carbon fiber used and achieving the purpose of reducing cost and weight.

[0041] The long carbon fibers are bonded together with the carbon fiber layer by adhesive 105, and the adhesive 105 needs to be resistant to high temperatures, such as tackified acrylic adhesive (short-term resistance of 200-250°C, long-term resistance of 100-120°C).

[0042] The thermoplastic resin may be polycarbonate (PC), polyamide (PA), polyphenylene sulfide (PPS), polypropylene (PP) or the like.

[0043] The following is an example of using polycarbonate (PC) as the thermoplastic resin of the thermoplastic lightweight carbon fiber composite sheet 10 of the present invention to illustrate a method for manufacturing a thermoplastic lightweight carbon fiber composite sheet of the present invention:

[0044] S1: According to Figure 3 The stacking order of the PC film 102 and the carbon fiber (0°) 103, the PC film 102 and the carbon fiber (90°) 104, the PC film 102 and the adhesive 105 and the middle layer (thermoplastic resin + long carbon fiber) 106 and the adhesive 105 and the PC film 102, the carbon fiber (90°) 104 and the PC film 102, and the carbon fiber (0°) 103 and the PC film 102 is stacked according to the designed size, thickness and strength;

[0045] S2: Place the stacked materials in a hot pressing mold, press the mold with a hot pressing machine, evacuate the mold, and set the mold temperature to 180°C to 260°C;

[0046] S3: The mold is pressurized and kept at a set temperature for 200 to 300 seconds, during which the mold is continuously vacuumed;

[0047] S4: When the mold reaches the set time, turn off the vacuum and start cooling until the sheet in the mold reaches the cooling temperature of 50-60°C;

[0048] S5: Open the mold and take out the composite board 10.

[0049] The carbon fiber board processing process requires the use of a conventional hot press machine, and the mold uses a flat steel plate.

[0050] The beneficial effects of the present invention are:

[0051] 1. The manufacturing method is simple in process, easy to lay up, and the thickness of the composite board can be adjusted according to different product requirements.

[0052] 2. The present invention uses non-woven long carbon fibers impregnated with thermoplastic resin to reduce the amount of carbon fibers used, save costs, and be low-carbon and environmentally friendly, while also meeting the requirements of light weight, high strength, and high rigidity.

[0053] 3. The hot pressing process is simple, and the entire process can be carried out using conventional hot pressing equipment.

[0054] 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 thermoplastic lightweight carbon fiber composite sheet, characterized in that: include: A surface layer, wherein the surface layer is a carbon fiber layer impregnated with a thermoplastic resin; The middle layer is a thermoplastic resin-impregnated material with hollow, uncompacted, non-woven long carbon fibers, 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 thermoplastic lightweight carbon fiber composite plate.

2. A thermoplastic 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 thermoplastic resin, which maximizes the strength of the board while retaining the carbon fiber texture.

3. A thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The middle layer uses non-woven long carbon fibers impregnated with thermoplastic resin. The density of the non-woven long carbon fiber layer depends on the final required board density. The middle layer does not need to be compacted, but needs to be fully impregnated and retain pores.

4. A thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The long carbon fiber can be recycled carbon fiber with a fiber length of 10 mm to 100 mm, thereby reducing the amount of continuous carbon fiber used and achieving the purpose of reducing cost and weight.

5. The thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The long carbon fibers are bonded together with the carbon fiber layer by an adhesive, and the adhesive needs to be resistant to high temperatures, such as a tackified acrylic adhesive (short-term resistance of 200-250° C., long-term resistance of 100-120° C.).

6. A thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The thermoplastic resin may be polycarbonate (PC), polyamide (PA), polyphenylene sulfide (PPS), polypropylene (PP), or the like.

7. A method for manufacturing a thermoplastic lightweight carbon fiber composite sheet, characterized in that: The manufacturing method comprises the following steps: S1: A carbon fiber layer impregnated with thermoplastic resin is used as a surface layer, and a non-woven long carbon fiber layer impregnated with thermoplastic resin is used as an intermediate layer, and the layers are stacked according to the designed size, thickness and strength; S2: placing the stacked materials in a hot pressing mold, pressing the mold with a hot pressing machine, and evacuating the mold. The mold temperature depends on the physical properties of the thermoplastic 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 sheet in the mold reaches the cooling temperature; S5: Open the mold and take out the composite sheet.

8. The method for manufacturing a thermoplastic lightweight carbon fiber composite sheet material according to claim 7, characterized in that: The stacking order from bottom to top in S1 is a 0° unidirectional carbon fiber layer impregnated with thermoplastic resin, a 90° unidirectional carbon fiber layer impregnated with thermoplastic resin, a thermoplastic resin layer impregnated with adhesive and an intermediate layer (thermoplastic resin + long carbon fiber) and adhesive and a thermoplastic resin layer impregnated with thermoplastic resin, a 90° unidirectional carbon fiber layer impregnated with thermoplastic resin, and a 0° unidirectional carbon fiber layer impregnated with thermoplastic resin.

9. The method for manufacturing a thermoplastic lightweight carbon fiber composite sheet material according to claim 7, characterized in that: The temperature of the hot pressing mold in S2 is set to 180°C to 260°C.

10. The method for manufacturing a thermoplastic lightweight carbon fiber composite sheet material according to claim 7, characterized in that: The time of pressurizing and maintaining the constant temperature of the mold in S4 is 200 to 300 seconds, and the cooling temperature of the composite plate in the mold is set to 50° C. to 60° C.

11. The method for manufacturing a thermoplastic lightweight carbon fiber composite sheet material according to claim 7, characterized in that: The carbon fiber board processing process needs to use a conventional hot press machine, and the mold uses a flat steel plate.

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