Composite material and preparation method thereof

Abstract

The invention discloses a composite material and a preparation method thereof, and relates to the technical field of reinforcing materials. The composite material comprises at least one fiber reinforced layer, wherein the at least one fiber reinforced layer comprises a resin matrix and a continuous fiber layer; the resin matrix is filled in the continuous fiber layer; the resin matrix comprises the following raw materials in parts by weight: 20-50 parts of thermoplastic resin; and 0.2-5 parts by weight of a micro-nano material. According to the composite material, the micro-nano materials are introduced to form a needle-imitating structure similar to needle-punched non-woven fabric so as to play a role of a support, the micro-nano materials are interspersed in the layers and between the layers, stress transfer is facilitated, the mechanical strength, impact toughness and other performance of the composite material are effectively enhanced, and the composite material can be applied to the fields of automobiles, photovoltaics and the like.

Description

Technical Field

[0001] The present application relates to the technical field of reinforced materials, and in particular to a composite material and a preparation method thereof. Background Art

[0002] With the continuous advancement of materials science and manufacturing technology, the research and application of continuous fiber reinforced materials have become increasingly in-depth. This type of material has shown excellent mechanical properties in many engineering applications, making it an important choice to replace traditional metal materials. It has been widely used in the fields of automobiles, photovoltaics, etc.

[0003] However, a notable feature of continuous fiber reinforced materials is anisotropy, that is, their mechanical properties vary significantly in different directions, which makes the mechanical properties of continuous fiber reinforced materials relatively weak in the direction perpendicular to the length of the continuous fiber and in the interface area between layers. In order to further improve the tensile, bending and other mechanical properties of continuous fiber reinforced materials, thereby improving the safety of the use environment, the development of continuous fiber reinforced materials with high glass fiber content is imminent. However, when the fiber content is high, the connection between layers is further weakened, which is prone to mechanical failure due to delamination, and is not conducive to the maintenance of its mechanical properties. Summary of the invention

[0004] In order to solve the above technical problems, the present application aims to provide a composite material and a preparation method thereof, wherein the composite material absorbs and disperses impact energy through a needle-like structure design to improve the strength, toughness and other mechanical properties of the composite material.

[0005] According to a first aspect of the present application, there is provided a composite material comprising at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer;

[0006] The resin matrix fills the layer of the continuous fiber layer;

[0007] The resin matrix includes the following raw materials in parts by weight:

[0008] 20-50 parts by weight of thermoplastic resin;

[0009] 0.2-5 parts by weight of micro-nano material.

[0010] In some embodiments of the present application, when the composite material includes multiple fiber-reinforced layers, multiple single-layer fiber-reinforced layers are laid according to a preset laying rule;

[0011] The resin matrix covers the continuous fiber layer and fills the spaces between the continuous fiber layers.

[0012] In some embodiments of the present application, the weight ratio of the continuous fibers in the continuous fiber layer to the resin matrix is ​​1.00-4.00:1.

[0013] In some embodiments of the present application, the weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer is 1:10.0-16.0.

[0014] In some embodiments of the present application, the thermoplastic resin includes a combination of one or more of polyethylene resin, polypropylene resin, polystyrene resin, and acrylonitrile-butadiene-styrene resin;

[0015] The micro-nano material includes a combination of one or more of micro-nano fibers and micro-nano particles.

[0016] In some embodiments of the present application, the micro-nano fibers include a combination of one or more of chopped glass fibers, zinc oxide nanowires, and carbon nanotubes; the micro-nano particles include a combination of one or more of boron carbide, silicon carbide, and nano-silicon dioxide.

[0017] In some embodiments of the present application, the micro-nano fiber has a length of 5-5000 μm and a diameter of 0.5-100 μm;

[0018] The particle size of the micro-nano particles is 0.5-100 μm.

[0019] In some embodiments of the present application, the resin matrix further includes 0.1-5 parts by weight of a functional additive.

[0020] According to a second aspect of the present application, a method for preparing a composite material is provided, wherein the method for preparing a composite material is used to prepare the composite material as described in any one of the above items, and the method comprises:

[0021] The resin matrix is ​​bonded to the continuous fiber layer and molded under preset conditions to obtain the fiber reinforced layer, and at least one layer of the fiber reinforced layer forms the composite material.

[0022] In some embodiments of the present application, when the fiber-reinforced layer includes multiple layers, after obtaining the fiber-reinforced layer, the preparation method further includes:

[0023] Laying down a plurality of single-layer fiber-reinforced layers according to a preset laying rule to obtain an intermediate material;

[0024] The intermediate material is heated to a preset temperature and pressed under a preset pressure to obtain the composite material.

[0025] The technical solution provided by this application may have the following beneficial effects:

[0026] The present application provides a composite material, which uses a continuous fiber layer as a reinforcement to increase the strength of the composite material; by filling the continuous fiber layer with a resin matrix, the continuous fiber layer can be protected and bonded, which is beneficial to the molding of the composite material; by introducing micro-nano materials, a needle-punched structure similar to a needle-punched nonwoven fabric is formed to play the role of a support, and the micro-nano materials are interspersed within and between layers, which is beneficial to stress transfer, thereby effectively enhancing the mechanical strength and impact toughness and other properties of the composite material.

[0027] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0029] Figure 1 The figure is a schematic diagram showing a layer structure of a composite material including a single fiber-reinforced layer according to an exemplary embodiment.

[0030] Figure 2 The figure is a schematic diagram showing a layer structure of a composite material including multiple fiber-reinforced layers according to an exemplary embodiment.

[0031] Figure 3 The present invention is a flow chart of a method for preparing a composite material according to an exemplary embodiment.

[0032] Figure 4 The present invention is a flow chart showing a method for preparing a composite material including a plurality of single-layer fiber-reinforced layers according to an exemplary embodiment.

[0033] Description of reference numerals:

[0034] 1. Fiber reinforcement layer; 11. Continuous fiber layer; 12. Resin matrix. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme of the present application will be clearly and completely described below in combination with the embodiments of the present application and the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without making creative work are within the scope of protection of the present application. It should be noted that, in the absence of conflict, the embodiments in the present application and the features in the embodiments can be arbitrarily combined with each other.

[0036] The present application provides a composite material, comprising at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer, wherein the resin matrix is ​​filled in the layer of the continuous fiber layer; the resin matrix comprises the following raw materials in parts by weight: 20-50 parts by weight of thermoplastic resin; 0.2-5 parts by weight of micro-nano material. The continuous fiber layer is used as a reinforcement to increase the strength of the composite material; by filling the resin matrix into the layer of the continuous fiber layer, the continuous fiber layer is protected and bonded, which is beneficial to the molding of the composite material; by introducing the micro-nano material, a needle-punched structure similar to a needle-punched nonwoven fabric is formed to play the role of a support, and the micro-nano material is interspersed in and between the layers, which is beneficial to stress transmission, thereby effectively enhancing the mechanical strength and impact toughness of the composite material.

[0037] Some specific implementation modes described below are intended to facilitate those skilled in the art to understand the present embodiment, and the present embodiment is not limited to some specific implementation modes described below.

[0038] like Figure 1 As shown, an exemplary embodiment of the present application provides a composite material, including at least one fiber reinforced layer 1, the at least one fiber reinforced layer 1 includes a resin matrix 12 and a continuous fiber layer 11; the resin matrix 12 fills the layer of the continuous fiber layer 11; the resin matrix 12 includes the following raw materials in parts by weight: 20-50 parts by weight of thermoplastic resin; 0.2-5 parts by weight of micro-nano material.

[0039] In this embodiment, "inside the layer" refers to the area inside a single continuous fiber layer 11, that is, the resin matrix 12 can be filled into the inside of the continuous fiber layer 11 to reduce the pores in the composite material; by using the continuous fiber layer 11 as a reinforcement, the strength of the composite material is increased, and by filling the resin matrix 12 into the layer of the continuous fiber layer 11, the continuous fiber layer 11 is protected and bonded, and the needle-like structure design is used to absorb and disperse impact energy, so as to improve the strength, toughness and other mechanical properties of the composite material. The composite material in this embodiment may include: Figure 1 The single fiber reinforced layer 1 shown may also include Figure 2 The multi-layer fiber reinforced layer 1 shown, wherein Figure 2 The cross-section lines in different directions in the figure indicate that the continuous fiber layer 11 in the multi-layer fiber reinforcement layer 1 can be laid at different angles. It should be noted that Figure 1 and Figure 2It is only for the convenience of illustration to show the interlayer relationship between the resin matrix 12 and the continuous fiber layer 11. However, in actual products, the boundary between the resin matrix 12 and the continuous fiber layer 11 is not necessarily clear, and part of the resin matrix 12 will be filled into the layer of the continuous fiber layer 11 to fill the gaps in the continuous fiber layer 11, and the other part of the resin matrix 12 will be coated on the surface of the continuous fiber layer 11.

[0040] Among them, the continuous fiber layer 11 can be composed of continuous fibers arranged neatly in a uniaxial direction. The continuous fiber is a fiber with a continuous length, including continuous glass fiber, continuous carbon fiber, continuous aramid fiber, etc. The above continuous fiber materials can provide good mechanical properties such as mechanical strength and stiffness.

[0041] In this embodiment, the thickness of the fiber reinforced layer 1 is 0.15-0.90 mm. For example, the thickness of the fiber reinforced layer 1 is 0.15 mm, 0.30 mm, 0.50 mm, 0.70 mm or 0.90 mm.

[0042] Although the composite material with the continuous fiber layer 11 as reinforcement has good mechanical properties, it has a notable feature of anisotropy, that is, its mechanical properties vary significantly in different directions, which makes the mechanical properties of the composite material relatively weak in the direction perpendicular to the length of the continuous fibers and in the interface area between layers, resulting in certain limitations in the interlayer performance, impact performance and performance perpendicular to the fiber direction of the composite material, especially for reinforced materials with high continuous fiber content, the above situation will be more obvious.

[0043] In order to solve the above problems, for composite materials containing a single-layer fiber reinforcement layer 1, micro-nano materials are introduced into the thermoplastic resin so that randomly oriented micro-nano materials can be bridged between the continuous fiber layers 11 arranged in the axial direction to improve the anisotropy of the composite material, thereby improving the mechanical strength and toughness of the composite material. For composite materials containing multiple layers of fiber reinforcement layers 1, randomly oriented micro-nano materials can be interspersed in and between the layers of the multiple layers of continuous fiber layers 11, and the structure is similar to that of needle-punched nonwoven fabrics to play the role of a support. The micro-nano materials are interspersed in and between the layers, which is conducive to stress transfer, thereby effectively enhancing the mechanical strength and impact toughness of the composite material.

[0044] Exemplarily, in one embodiment, the resin matrix 12 includes the following raw materials in parts by weight:

[0045] 20 parts by weight of thermoplastic resin;

[0046] 0.2 parts by weight of micro-nano materials.

[0047] In one embodiment, the resin matrix 12 includes the following raw materials in parts by weight:

[0048] 35 parts by weight of thermoplastic resin;

[0049] 2.5 parts by weight of micro-nano materials.

[0050] In one embodiment, the resin matrix 12 includes the following raw materials in parts by weight:

[0051] 50 parts by weight of thermoplastic resin;

[0052] 5 parts by weight of micro-nano materials.

[0053] In order to solve the problem that the mechanical properties of composite materials have significant differences in different directions due to the anisotropy of continuous fibers, for composite materials containing multiple fiber reinforced layers 1, in addition to adjusting the formulation of the resin matrix 12 to improve the anisotropy of the single-layer fiber reinforced layer 1, the layup structure of the composite material can also be adjusted so that each fiber reinforced layer 1 is arranged in a different layup manner to improve the anisotropy of the composite material.

[0054] Based on this, in an exemplary embodiment, when the composite material includes multiple fiber-reinforced layers 1 , the multiple fiber-reinforced layers 1 are laid out according to a preset laying rule; the resin matrix 12 covers the continuous fiber layer 11 and fills the spaces between the continuous fiber layers 11 .

[0055] In this embodiment, "interlayer" may refer to the area between multiple continuous fiber layers 11, or may refer to the area between layers of each fiber reinforced layer 1. The multiple fiber reinforced layers 1 may be laid out according to a preset laying rule so that the resin matrix 12 covers the continuous fiber layer 11 and fills the space between the fiber layers to reduce the stratification phenomenon of each layer and improve the mechanical properties of the composite material.

[0056] The preset laying rules may be 0° / 90° / 90° / 0°, 0° / 90° / 0°, 0° / 90° / +45° / -45° / 90° / 0°, 0° / 20° / +45° / -45° / 20° / 0°, 30° / 60° / 90° / 90° / 60° / 30°, 0° / 25° / 80° / 20° / 75° / 0°, etc. By laying layers at different angles, the mechanical strength and toughness of the composite material can be improved.

[0057] In an exemplary embodiment, the weight ratio of the continuous fibers in the continuous fiber layer 11 to the resin matrix 12 is 1.00-4.00:1.

[0058] In this embodiment, by controlling the weight ratio of the continuous fiber layer 11 and the resin matrix 12 to be 1.00-4.00:1, the composite material can be improved to have good mechanical properties, processing properties, and production costs. Exemplarily, the weight ratio of the continuous fibers in the continuous fiber layer 11 to the resin matrix 12 is 1.00:1, 2.00:1, 2.85:1, or 4.00:1.

[0059] In an exemplary embodiment, the weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer 11 is 1:10.0-16.0.

[0060] In this embodiment, the mechanical strength and toughness of the composite material can be further improved by controlling the weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer 11 to 1:10.0-16.0. For example, the weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer 11 is 1:10.0, 1:13.0 or 1:16.0.

[0061] In an exemplary embodiment, the thermoplastic resin includes a combination of one or more of polyethylene resin, polypropylene resin, polystyrene resin, and acrylonitrile-butadiene-styrene resin; the micro-nano material includes a combination of one or more of micro-nano fibers and micro-nano particles; the micro-nano fibers include a combination of one or more of chopped glass fibers, zinc oxide nanowires, and carbon nanotubes; the micro-nano particles include a combination of one or more of boron carbide, silicon carbide, and nano-silicon dioxide.

[0062] In this embodiment, polyethylene resin (PE), polypropylene resin (PP), polystyrene resin (PS), and acrylonitrile-butadiene-styrene resin (ABS) have good mechanical strength. Using a combination of one or more of the above resins as the thermoplastic resin material in the resin matrix 12 can provide the composite material with better mechanical properties and bonding properties.

[0063] Micro-nano materials include micro-nano fibers, micro-nano particles or a combination of the two. Micro-nano fibers refer to fiber materials with a micro-nano diameter. After the resin matrix 12 is coated with the continuous fiber layer 11, randomly oriented micro-nano fibers are interspersed within or between the layers of the continuous fiber layer 11 to act as a support, thereby enhancing the mechanical properties of the composite material such as impact resistance; wherein the micro-nano fibers include a combination of one or more of chopped glass fibers, zinc oxide nanowires, and carbon nanotubes (CNTs).

[0064] Micro-nano particles refer to particle materials with a particle size of micro-nano level. Due to their small particle size, when the resin matrix 12 covers the continuous fiber layer 11, the micro-nano particles with a smaller particle size are dispersed in or between the layers of the continuous fiber layer 11. The continuously distributed micro-nano particles can also bridge between the continuous fiber layers 11 to enhance the toughness of the composite material. Among them, the micro-nano particles include a combination of one or more of boron carbide, silicon carbide, and nano silicon dioxide.

[0065] In an exemplary embodiment, the length of the micro-nano fibers is 5-5000 μm and the diameter is 0.5-100 μm; the particle size of the micro-nano particles is 0.5-100 μm.

[0066] In this embodiment, by controlling the length and diameter of the micro-nano fibers and the particle size of the micro-nano particles, the micro-nano fibers can be dispersed in the pores of the continuous fiber layer 11 to enhance the composite material. For example, the length of the micro-nano fibers is 5 μm, 100 μm, 500 μm or 1000 μm, and the diameter is 0.5 μm, 10 μm, 50 μm or 100 μm; the particle size of the micro-nano particles is 0.5 μm, 10 μm, 50 μm or 100 μm.

[0067] In an exemplary embodiment, the resin matrix 12 further includes 0.1-5 parts by weight of a functional additive.

[0068] In order to give the composite material other properties, 0.1-5 parts by weight of functional performance additives may be added to the resin matrix 12. The functional additives may be, for example, anti-ultraviolet agents, light stabilizers, antioxidants, antistatic agents, etc. The amount of the functional additives may be 0.1 parts by weight, 1 part by weight, 3 parts by weight, or 5 parts by weight.

[0069] like Figure 3 As shown, an exemplary embodiment of the present application provides a method for preparing a composite material, the preparation method comprising:

[0070] S110, bonding the resin matrix to the continuous fiber layer, and molding under preset conditions to obtain a fiber reinforced layer, wherein at least one fiber reinforced layer forms a composite material.

[0071] In step S110, the raw materials of the resin matrix 12 are mixed evenly and then put into an extruder; the extruder heats the resin matrix 12 to make it melt; the molten resin matrix 12 is then extruded through the extruder and evenly adhered to the continuous fiber layer 11, and after being cooled and shaped by a roller, a fiber reinforced layer 1 can be obtained. When the composite material is a single-layer fiber reinforced layer 1, the fiber reinforced layer 1 is a composite material.

[0072] like Figure 4As shown, an exemplary embodiment of the present application provides a method for preparing a composite material. When the fiber reinforced layer includes multiple layers, the preparation method further includes:

[0073] S210, bonding the resin matrix to the continuous fiber layer, and molding under preset conditions to obtain a fiber reinforced layer.

[0074] The implementation of step S210 is the same as that of step S110 and will not be described again.

[0075] S220, laying out a plurality of single-layer fiber-reinforced layers according to a preset laying rule to obtain an intermediate material.

[0076] In step S220, the preset laying rule can be 0° / 90° / 90° / 0°, 0° / 90° / 0°, 0° / 90° / +45° / -45° / 90° / 0°, 0° / 20° / +45° / -45° / 20° / 0°, 30° / 60° / 90° / 90° / 60° / 30°, 0° / 25° / 80° / 20° / 75° / 0°, etc.

[0077] S230, heating the intermediate material to a preset temperature, and pressing it under a preset pressure to obtain a composite material.

[0078] In step S230, the obtained intermediate material is sent to a press for heating. After being heated to 150-280°C, the resin matrix 12 in the fiber-reinforced layer 1 will melt again to form an amorphous region, and the randomly oriented micro-nano material can be interspersed in and between the layers of the continuous fiber layer 11. Then, a pressure of 2-5 bar is applied to the intermediate material by a pressure roller, and the intermediate material is cooled at a temperature of 10-60°C. The randomly oriented micro-nano material can serve as a third phase to play a supporting role between and within the layers of the continuous fiber layer 11, making the material structure similar to that of a needle-punched nonwoven, which is conducive to stress transfer, thereby obtaining a composite material with improved impact toughness.

[0079] The heating temperature can be set according to the melting temperature of the thermoplastic resin in the resin matrix 12, for example, the heating temperature can be 150°C, 180°C, 230°C or 280°C. The pressure can be 2 bar, 3.5 bar, 5 bar. The cooling temperature can be 10°C, 30°C or 60°C, for example.

[0080] The specific implementation methods of the present application are further described below in conjunction with preferred embodiments, and examples of preferred value ranges of each component in the composite material provided in the present application are explained in detail.

[0081] Preferred Example 1

[0082] A composite material comprises at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer, wherein the resin matrix fills the continuous fiber layer;

[0083] The weight ratio of the continuous fiber layer to the resin matrix is ​​1.00-4.00:1.

[0084] Preferred Example 2

[0085] A composite material comprises at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer, wherein the resin matrix fills the continuous fiber layer;

[0086] Wherein, the weight ratio of the continuous fiber layer to the resin matrix is ​​1.00-4.00:1;

[0087] The resin matrix includes the following raw materials in parts by weight:

[0088] 20-50 parts by weight of thermoplastic resin;

[0089] 0.2-5 parts by weight of micro-nano material.

[0090] Preferred Example 3

[0091] A composite material comprises at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer, wherein the resin matrix fills the continuous fiber layer;

[0092] Wherein, the weight ratio of the continuous fiber layer to the resin matrix is ​​1.00-4.00:1;

[0093] The resin matrix includes the following raw materials in parts by weight:

[0094] 20-50 parts by weight of thermoplastic resin;

[0095] 0.2-5 parts by weight of micro-nano material;

[0096] The weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer is 1:10.0-16.0.

[0097] Preferred Example 4

[0098] A composite material comprises at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer, wherein the resin matrix fills the continuous fiber layer;

[0099] Wherein, the weight ratio of the continuous fiber layer to the resin matrix is ​​1.50-2.33:1;

[0100] The resin matrix includes the following raw materials in parts by weight:

[0101] 25-35 parts by weight of thermoplastic resin;

[0102] 0.2-5 parts by weight of micro-nano material;

[0103] The weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer is 1:10.0-16.0.

[0104] Preferred Example 5

[0105] A composite material comprises at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer, wherein the resin matrix fills the continuous fiber layer;

[0106] Wherein, the weight ratio of the continuous fiber layer to the resin matrix is ​​1.86-2.33:1;

[0107] The resin matrix includes the following raw materials in parts by weight:

[0108] 25-35 parts by weight of thermoplastic resin;

[0109] 3-5 parts by weight of micro-nano material;

[0110] The weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer is 1:13.0-14.0.

[0111] In order to more clearly explain the technical solution of the present application, the present application lists specific examples of the preparation method of the composite material, and the beneficial effects of selecting the above-mentioned range of the content of each component will be explained by giving specific experimental data through specific examples.

[0112] It should be noted that the composite materials in the following embodiments are described by taking multiple fiber-reinforced layers as an example, and the number of layers, thickness and laying method of the fiber-reinforced layers in each embodiment are the same.

[0113] The thermoplastic resin is polyethylene resin; the amount of the functional additive is 3% of the weight of the thermoplastic resin.

[0114] Example

[0115] Embodiment 1: A method for preparing a composite material, comprising the following steps:

[0116] (1) A thermoplastic resin, a micro-nano material and a functional additive are uniformly mixed in a mixer to obtain a resin matrix; wherein the weight of the thermoplastic resin (including the functional additive) is 49.8 kg, and the weight of the micro-nano material is 0.2 kg.

[0117] (2) The resin matrix is ​​put into an extruder and heated by the extruder to make it melt; then the molten resin matrix is ​​extruded through the extruder and evenly bonded to the continuous fiber layer, and after being cooled and shaped by a pressing roller, a fiber reinforcement layer can be obtained; wherein the continuous fiber in the continuous fiber layer is continuous glass fiber, and the weight of the continuous glass fiber is 60 kg.

[0118] (3) Laying down multiple fiber-reinforced layers according to a preset laying rule to obtain an intermediate material, wherein the number of laid fiber-reinforced layers is 8 and the thickness of a single fiber-reinforced layer is 2 mm.

[0119] (4) The obtained intermediate material is sent to a press and heated to 180° C., and a pressure of 5 bar is applied to the intermediate material using a press roller, and then cooled at a temperature of 40° C. to obtain a composite material.

[0120] In order to more clearly explain the technical solution of the present application, the present application also lists Examples 2-44 of the preparation method of the composite material, wherein the formulas of Examples 2-44 are shown in Table 1.

[0121] Table 1 shows a specific embodiment of the method for preparing the composite material in the present application. It should be noted that, except for the parameters listed in Table 1, other parameters of Examples 2-44 and Example 1 are substantially the same.

[0122] Wherein, the ratio C1 is the weight ratio of continuous fiber to resin matrix (including functional additives);

[0123] The ratio C2 is the weight ratio of the micro-nano material to the continuous fiber.

[0124] Table 1 Raw material ratio of the composite material of the embodiment

[0125]

[0126] Comparative Example

[0127] Comparative Example 1: The main difference between this comparative example and Example 1 is the raw material ratio of the composite material, including: 60 kg of continuous glass fiber and 40 kg of thermoplastic resin (including functional additives).

[0128] Comparative Example 2: The main difference between this comparative example and Example 1 is the raw material ratio of the composite material, including: 65 kg of continuous glass fiber and 35 kg of thermoplastic resin (including functional additives).

[0129] Comparative Example 3: The main difference between this comparative example and Example 1 lies in the raw material ratio of the composite material, including: 70 kg of continuous glass fiber and 30 kg of thermoplastic resin (including functional additives).

[0130] Comparative Example 4: The main difference between this comparative example and Example 1 is the raw material ratio of the composite material, including: 80 kg of continuous glass fiber and 20 kg of thermoplastic resin (including functional additives).

[0131] Performance Testing

[0132] Composite materials were prepared according to the methods of Examples 1-44 and Comparative Examples 1-3, respectively. The 0° tensile strength, 0° flexural strength, 90° tensile strength, and 90° flexural strength of the composite materials were tested, and the test results are recorded in Table 2.

[0133] Table 2 Performance test table of the composite materials of the embodiments and comparative examples

[0134]

[0135] Continuous fiber reinforced materials have strong anisotropy within the layer and weak interlayer bonding, especially continuous fibers with high glass fiber content as reinforcement materials. Their 90° tensile strength and 90° bending strength are significantly lower than the 0° tensile strength and 0° bending strength, making it easy to be damaged perpendicular to the fiber direction, causing the material to fail.

[0136] Combining the data in Table 1 and Table 2, it can be seen that by adding micro-nano materials to the raw materials of composite fibers, the chance of bridging between fibers can be increased. When cracks occur, the end bridging can effectively organize crack diffusion, thereby increasing the toughness, impact resistance and other mechanical properties of the material, and can significantly improve the tensile strength and bending strength of the composite material at 0° and 90°, reduce anisotropy, and improve the mechanical properties of the composite material to a certain extent.

[0137] In addition, the weight ratio of continuous fiber and resin matrix (including functional additives) in the composite material (i.e., ratio C1) and the weight ratio of micro-nano material to continuous fiber (i.e., ratio C2) also have an important influence on the mechanical properties of the composite material. Within a certain range, with the increase in the amount of continuous fiber and micro-nano material, the tensile strength and bending strength of the composite material can be improved. However, when the content of continuous fiber and micro-nano material is too high, the composite material cannot provide sufficient bonding strength in the thermoplastic resin, resulting in a decrease in the interlayer bonding force of the continuous fiber, which in turn leads to a decrease in the mechanical properties of the composite material.

[0138] Among them, among the raw materials of the composite material, the thermoplastic resin is 25-35 parts by weight, the micro-nano material is 3-5 parts by weight, and the continuous fiber is 60-70 parts by weight. The weight ratio of the continuous fiber to the resin matrix is ​​1.86-2.33:1, and the weight ratio of the micro-nano material to the continuous fiber is 1:13.0-14.0. The composite material has significant improvements in 0° tensile strength, 90° tensile strength, 0° flexural strength, and 90° flexural strength.

[0139] It should be noted that, in this article, the terms "comprises", "includes" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.

[0140] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application is described in detail with reference to the above embodiments, a person skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some of the technical features can be replaced by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A composite material, characterized in that: The invention comprises at least one fiber-reinforced layer, wherein the at least one fiber-reinforced layer comprises a resin matrix and a continuous fiber layer; The resin matrix fills the layer of the continuous fiber layer; The resin matrix includes the following raw materials in parts by weight: 20-50 parts by weight of thermoplastic resin; 0.2-5 parts by weight of micro-nano material.

2. The composite material according to claim 1, characterized in that When the composite material includes multiple fiber-reinforced layers, multiple single fiber-reinforced layers are laid according to a preset laying rule; The resin matrix covers the continuous fiber layer and fills the spaces between the continuous fiber layers.

3. The composite material according to claim 1, characterized in that The weight ratio of the continuous fibers in the continuous fiber layer to the resin matrix is ​​1.00-4.00:

1.

4. The composite material according to claim 1, characterized in that The weight ratio of the micro-nano material to the continuous fibers in the continuous fiber layer is 1:10.0-16.

0.

5. The composite material according to claim 1, characterized in that The thermoplastic resin includes a combination of one or more of polyethylene resin, polypropylene resin, polystyrene resin, and acrylonitrile-butadiene-styrene resin; The micro-nano material includes a combination of one or more of micro-nano fibers and micro-nano particles.

6. The composite material according to claim 5, characterized in that The micro-nano fibers include a combination of one or more of chopped glass fibers, zinc oxide nanowires, and carbon nanotubes; the micro-nano particles include a combination of one or more of boron carbide, silicon carbide, and nano-silicon dioxide.

7. The composite material according to claim 6, characterized in that The micro-nano fibers have a length of 5-5000 μm and a diameter of 0.5-100 μm; The particle size of the micro-nano particles is 0.5-100 μm.

8. The composite material according to claim 1, characterized in that The resin matrix further comprises 0.1-5 parts by weight of a functional additive.

9. A method for preparing a composite material, characterized in that: The method for preparing the composite material is used to prepare the composite material according to any one of claims 1 to 8, and the method for preparing the composite material comprises: The resin matrix is ​​bonded to the continuous fiber layer and molded under preset conditions to obtain the fiber reinforced layer, and at least one layer of the fiber reinforced layer forms the composite material.

10. The method for preparing a composite material according to claim 9, characterized in that: When the fiber reinforced layer includes multiple layers, after obtaining the fiber reinforced layer, the preparation method further includes: Laying down a plurality of single-layer fiber-reinforced layers according to a preset laying rule to obtain an intermediate material; The intermediate material is heated to a preset temperature and pressed under a preset pressure to obtain the composite material.

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