High-toughness carbon-glass hyper-hybrid composite material, preparation method and application

Abstract

This invention discloses a high-toughness carbon-glass hyperhybrid composite material, its preparation method, and its applications. Carbon fiber and glass fiber broadened filaments obtained from an ultra-thin carbon fiber spreading device are hyperhybridized and filamentized, and then molded using a vacuum-assisted resin transfer molding process to prepare a carbon-glass hyperhybrid composite material with superior reinforcement and toughening effects. This invention improves upon existing hybridization methods, solving problems such as poor hybridization design, low fiber hybridization degree, and unsatisfactory toughening effects in interlaminar hybridization methods. The resulting carbon-glass hyperhybrid composite material exhibits better reinforcement and toughening effects. At the same carbon-glass volume ratio, the carbon-glass hyperhybrid composite material has higher tensile modulus, elongation at break, and loss factor. Drop-weight impact tests show greater energy absorption and smaller damage area. In summary, the carbon-glass hyperhybrid composite material exhibits better reinforcement and toughening effects, improves the mechanical properties of the composite material, and is overall superior to interlaminar hybrid composite materials.

Description

Technical Field

[0001] This invention relates to the field of preparation and performance technology of a high-toughness carbon-glass hybrid composite material, particularly its application in the inner panel skeleton of automobile doors. Background Technology

[0002] The inner frame of the car door (such as) Figure 1 As shown, the main structural components are made of high-strength steel, aluminum alloy, or composite materials. As a secondary load-bearing component of the vehicle, the inner frame of the car door provides support and protects the vehicle from impacts during driving. The properties of the materials used play a decisive role in the safety performance and overall strength of the vehicle. Currently, high-strength steel, aluminum alloy, and composite materials are the preferred choices for automakers because they not only possess excellent strength and rigidity but also exhibit good corrosion resistance.

[0003] During the production process, manufacturers precisely select appropriate materials based on the characteristics of the vehicle model and target market, such as sedans, SUVs, or trucks, as well as the vehicle's operating environment and cost budget. The choice of automotive frame materials also affects the vehicle's weight, which in turn affects fuel economy. Therefore, selecting the right automotive door inner panel frame material is crucial for improving vehicle performance and economic efficiency. This not only concerns driver safety but also operational costs.

[0004] Against the backdrop of national advocacy for energy conservation and emission reduction, carbon fiber composites, with their lightweight and high strength, have been widely used in many fields, gradually replacing some metallic materials. Especially in the automotive, high-end sporting goods, and aerospace industries, carbon fiber composites are playing an increasingly important role. However, the high cost and low toughness of carbon fiber composites are two factors limiting their wider application. To address these issues, the main optimization method currently used is fiber hybridization. A common approach is to blend low-cost, high-toughness polymer fibers or other fibers with carbon fiber to prepare hybrid fiber composites, thereby reducing costs and enhancing toughness.

[0005] Due to its advantages of low cost and high toughness, glass fiber has become the mainstream fiber material for hybridization with carbon fiber. Currently, the main hybridization method is interlayer hybridization, which involves alternating layers of carbon fiber woven fabric and glass fiber woven fabric (carbon-glass interlayer hybridization). However, because the woven fabric is usually thick, it suffers from problems such as limited design flexibility and low degree of hybridization between carbon fiber and glass fiber, resulting in the inability to fully utilize the advantages of both fibers. In view of this, the present invention provides a high-toughness carbon-glass ultrahybrid composite material for use in the inner panel frame of automotive doors. Summary of the Invention

[0006] To address the problems of limited designability, low degree of carbon-glass hybridization, and poor toughening effect in carbon-glass interlayer hybrid composites, this invention provides a high-toughness carbon-glass ultrahybrid composite material and its preparation method. The method involves ultrahybridizing and spinning carbon fiber and glass fiber broadened filaments obtained from an ultra-thin carbon fiber spreading device, followed by vacuum-assisted resin transfer molding to prepare a carbon-glass ultrahybrid composite material with superior reinforcement and toughening effects. This invention produces composite materials with different carbon-glass volume ratios and degrees of hybridization, all exhibiting enhanced reinforcement and toughening effects, and applies them to the inner panel frame of a car door.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0008] A method for preparing a high-toughness carbon-glass hybrid composite material includes the following steps:

[0009] (1) Preparation of carbon-glass hyperhybrid woven fabric

[0010] (a) Preparation of ultra-hybrid fiber spread filaments: Carbon fiber spread filaments (i.e., 12K T700 carbon fiber bundles spread to 24mm, which is 1.4 times the width of traditional mechanical spread filaments, and its thickness is only 0.02mm, which is 60% less than that of traditional mechanical spread filaments) obtained by airflow perturbation carbon fiber spread filament equipment (ZL202111589981.4) and glass fiber spread filaments (i.e., 20K T300 glass fiber bundles spread to 15mm, which is 1.5 times the width of traditional mechanical spread filaments, and its thickness is only 0.03mm, which is 40% less than that of traditional mechanical spread filaments) are mixed according to different carbon-glass volume ratios. The fibers are then fused together using parallel rollers, and then fused together as a whole using other rollers to obtain ultra-hybrid fiber spread filaments.

[0011] (b) Preparation of woven fabric: Carbon-glass ultra-hybrid woven fabric is prepared by weaving the ultra-hybrid fiber spread filaments using a weaving device, with a thickness between 0.04 mm and 0.08 mm.

[0012] (2) Preparation of carbon-glass hyperhybrid composite materials

[0013] (A) Layup design: Since the two types of fibers have already been super-mixed within the bundle in the super-hybrid fiber braid, the super-hybrid fiber braid is directly laid up. The optimal thickness range of the super-hybrid fiber braid after layup is 1.0-1.4 mm.

[0014] (B) Vacuum-assisted resin transfer molding: The laid-up super hybrid fiber woven fabric is placed on a smooth stainless steel template. After the epoxy resin is completely impregnated into the fiber woven fabric, it is sealed and cured to obtain a carbon-glass super hybrid composite material with a thickness between 2.6mm and 2.8mm.

[0015] Furthermore, in step (a), the carbon fiber and glass fiber broadened filaments after integral spinning interpenetrate and cross each other in the thickness direction due to the presence of tension, and further broaden, thereby obtaining a wider broadening.

[0016] Furthermore, in step (a), the volume ratios of carbon fiber spread filaments and glass fiber spread filaments are 2:1, 1:1, and 1:2, respectively.

[0017] Furthermore, SCGC carbon-glass hybrid woven fabric, SCG carbon-glass hybrid woven fabric, and SGCG carbon-glass hybrid woven fabric were prepared when the volume ratio of carbon fiber spread filament to glass fiber spread filament was 2:1, 1:1, and 1:2, respectively.

[0018] In step (A), laying 10 layers of SCGC fiber woven fabric, 15 layers of SCG fiber woven fabric, and 10 layers of SGCG fiber woven fabric respectively can prepare super hybrid layup structures with carbon-glass volume ratios of 2:1 (SCGC), 1:1 (SCG), and 1:2 (SGCG).

[0019] The specific preparation method of the carbon-glass hybrid composite material in step (B) is as follows: Place the laid-up hybrid fiber woven fabric on a smooth stainless steel template coated with a release agent and anti-stick film. Place a release cloth, a flow guide net, absorbent cotton, a threaded tube, and a vacuum bag sequentially on top of the woven fabric, and then adhere them around the fabric using 3M sealant. Connect and fix the suction pipe and the glue inlet pipe to the threaded tube. Connect the suction pipe in series with the buffer tank and the vacuum pump, lock the glue inlet, and turn on the vacuum pump to create a vacuum. When the vacuum pump pressure reaches one atmosphere, check... To check for leaks, after confirming that the entire apparatus is leak-free, connect the inlet tube to the beaker containing degassed epoxy resin. Then, open the inlet, and the epoxy resin enters the sealed mold cavity under the action of the vacuum pump. After the epoxy resin completely impregnates the fiber woven fabric, seal the inlet and the evacuation port, and cure at room temperature for 24 hours. Then, place it in an oven and cure at 60°C for 2 hours. After removing it, remove the hybrid composite material from the mold, remove the release cloth, guide net, and vacuum bag to obtain the carbon-glass ultrahybrid composite material.

[0020] Furthermore, the preparation method of epoxy resin adhesive is as follows: Epoxy resin and curing agent are mixed in a mass ratio of 3:1 and stirred evenly. The mixed epoxy resin contains a large number of air bubbles. At this time, the epoxy resin needs to be placed in a vacuum drying oven to remove air for 10-12 minutes. After the air is removed, the epoxy resin is transparent, clear and uniform inside without air bubbles.

[0021] The present invention also provides a high-toughness carbon-glass hybrid composite material prepared by the preparation method described above.

[0022] The application of the high-toughness carbon-glass hybrid composite material described in this invention in the inner panel skeleton of automobile doors, compared with interlaminar hybrid composite materials, shows that the high-toughness carbon-glass hybrid composite material with three volume ratios of carbon and glass has the highest tensile modulus of 55 MPa, which is 19.5% higher; the highest elongation at break of 1.9%, which is 10.4% higher; the highest flexural strain of 2.66%, which is 39.2% higher; the highest loss factor of 0.595, which is 6.63% higher; the lowest damage area after impact testing of 4.2%, which is 14.2% lower; and the highest absorbed energy of 24.8 J, which is 4.6% higher.

[0023] The beneficial effects of this invention are as follows: It improves upon existing hybridization methods, solving problems such as poor hybridization design, low fiber hybridization degree, and unsatisfactory toughening effect in interlayer hybridization methods. The resulting carbon-glass hyperhybrid composite material exhibits better reinforcement and toughening effects. Specifically, under the same carbon-glass volume ratio, the carbon-glass hyperhybrid composite material has higher tensile modulus, elongation at break, and loss factor. Drop hammer impact tests show greater energy absorption and smaller damage area. The application of the high-toughness carbon-glass hyperhybrid composite material described in this invention in the inner panel skeleton of automotive doors, compared to interlayer hybrid composite materials, shows that the hyperhybrid composite materials with the three carbon-glass volume ratios have a maximum tensile modulus of 55 MPa, an increase of 19.5%; a maximum elongation at break of 1.9%, an increase of 10.4%; a maximum flexural strain of 2.66%, an increase of 39.2%; a maximum loss factor of 0.595, an increase of 6.63%; a minimum damage area of ​​4.2% after impact testing, a reduction of 14.2%; and a maximum absorbed energy of 24.8 J, an increase of 4.6%.

[0024] In summary, the carbon-glass hybrid composite material exhibits better reinforcement and toughening effects, improves the mechanical properties of the composite material, and is superior to interlaminar hybrid composite materials overall, making it an excellent alternative. Applying the high-toughness carbon-glass hybrid composite material of this invention to the inner panel frame of automobile doors can demonstrate excellent strength and toughness. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of the inner panel of a car door.

[0027] Figure 2 The preparation process of ultra-hybrid fiber broadening filaments with three different carbon-glass volume ratios.

[0028] Figure 3 Designs for ultra-hybrid woven fabric lay-ups: (a) SCGC, (b) SCG, (c) SGCG.

[0029] Figure 4 Designs for interlayer mixed woven fabric lay-up: (a) LCGC, (b) LCG, (c) LGCG.

[0030] Figure 5 This is a flowchart of the preparation process for ultrahybrid composite materials.

[0031] Figure 6 The tensile modulus is the composite material obtained in Examples 1-3 and Comparative Examples 1-3.

[0032] Figure 7 Elongation at break of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3.

[0033] Figure 8 Bending limit strain of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3.

[0034] Figure 9 Loss factors of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3.

[0035] Figure 10 Impact test absorbed energy data of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3.

[0036] Figure 11 Damage ratios of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3.

[0037] Figure 12 Storage modulus of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3.

[0038] Figure 13 The ultrasonic nondestructive testing results of the composite materials obtained in Examples 1-3 and Comparative Examples 1-3 are as follows: (a) SCGC, (b) SCG, (c) SGCG, (d) LCGC, (e) LCG, (f) LGCG.

[0039] Figure 14 Schematic diagram of vacuum-assisted resin transfer molding. Detailed Implementation

[0040] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0041] The carbon fiber and glass fiber spreaders used in this invention are both prepared using an airflow-turbulent carbon fiber spreading device (authorized patent: ZL202111589981.4). The carbon fiber spreader is made by spreading 12K T700 carbon fiber bundles to 24mm, which is 1.4 times the width of traditional mechanical spreading, and its thickness is only 0.02mm, which is 60% less than that of traditional mechanical spreading. The glass fiber spreader is made by spreading 20K T300 glass fiber bundles to 15mm, which is 1.5 times the width of traditional mechanical spreading, and its thickness is only 0.03mm, which is 40% less than that of traditional mechanical spreading.

[0042] Carbon fiber and glass fiber spreaders obtained using an airflow-induced carbon fiber spreading apparatus (ZL202111589981.4) are used to prepare carbon-glass hybrid fiber spreaders, such as... Figure 2 The table shows the preparation process of three different carbon-glass volume ratios of ultrahybrid fiber broadening filaments. Examples 1-3 are three ultrahybrid composite materials SCGC, SCG, and SGCG, and Comparative Examples 1-3 are three interlaminar hybrid composite materials LCGC, LCG, and LGCG, as shown in Table 1.

[0043] Table 1 Hybrid Composite Materials

[0044]

[0045] Example 1

[0046] The preparation method of the high-toughness carbon-glass hybrid composite material in this embodiment is as follows:

[0047] (1) Preparation of ultra-hybrid spreadable filaments: Carbon fiber spreadable filaments (i.e., 12K T700 carbon fiber bundles spread to 24mm, which is 1.4 times the width of traditional mechanical spreadable filaments, and its thickness is only 0.02mm, which is 60% less than that of traditional mechanical spreadable filaments) and glass fiber spreadable filaments (i.e., 20K T300 glass fiber bundles spread to 15mm, which is 1.5 times the width of traditional mechanical spreadable filaments, and its thickness is only 0.03mm, which is 40% less than that of traditional mechanical spreadable filaments) are prepared using an airflow-turbulent carbon fiber spreadable equipment (authorized patent: ZL202111589981.4) and glass fiber spreadable filaments (i.e., 20K T300 glass fiber bundles spread to 15mm, which is 1.5 times the width of traditional mechanical spreadable filaments, and its thickness is only 0.03mm, which is 40% less than that of traditional mechanical spreadable filaments). Then, carbon-glass ultra-hybrid fiber spreadable filaments are prepared, such as... Figure 2 The image shows the preparation process of ultra-hybrid fiber broadening filaments with three different carbon-glass volume ratios.

[0048] exist Figure 2In (a), ① and ② are carbon fiber broadened filaments and glass fiber broadened filaments prepared by the mechanical vibration-airflow disturbance synergistic broadening method, respectively. ① and ② are filaments fused together using three parallel rollers, and then fused together as a whole using a fourth roller. Due to the tension, the carbon fiber broadened filaments and glass fiber broadened filaments after fusion permeate and cross each other in the thickness direction and are further broadened, resulting in ③, which is a more uniform carbon-glass hybrid, i.e., a super hybrid broadened filament (SCGC) with a carbon-glass volume ratio of 2:1.

[0049] (2) Preparation of woven fabric: The super hybrid spread yarn (SCGC) is woven by a weaving device to prepare a super hybrid fiber woven fabric (SCGC) with a thickness between 0.04 mm and 0.08 mm.

[0050] (3) Layup Design: Since the two types of fibers are already super-hybridized within the bundle in the super-hybrid fiber braid, the super-hybrid fiber braid (SCGC) is directly laid up, and the optimal total layup thickness is 1.0-1.4 mm. Specifically, laying up 10 layers of SCGC fiber braid can prepare a super-hybrid layup structure with a carbon-glass volume ratio of 2:1 (SCGC).

[0051] (4) Vacuum-assisted resin transfer molding: First, mix epoxy resin and curing agent in a mass ratio of 3:1 and stir evenly. The mixed epoxy resin contains a large number of air bubbles. At this time, the epoxy resin needs to be placed in a vacuum drying oven to remove air. After about ten minutes, the epoxy resin after removing air is transparent and has a clear, uniform interior without air bubbles.

[0052] Place the laid-up fiber woven fabric on a smooth stainless steel template coated with release agent and anti-stick film. Place release cloth, guide net, absorbent cotton, threaded tube, and vacuum bag on top of the woven fabric in sequence, and secure them around the edges with 3M sealant. Connect and secure the suction pipe and glue inlet pipe to the threaded tube. Connect the suction pipe in series with the buffer tank and vacuum pump, lock the glue inlet, and turn on the vacuum pump to create a vacuum. Once the vacuum pump pressure reaches one atmosphere, check for leaks. After confirming that the entire system is leak-free, connect the glue inlet pipe to a beaker containing epoxy resin. Then open the glue inlet, allowing the epoxy resin to enter the sealed mold cavity under the vacuum pump. After the epoxy resin completely impregnates the fiber woven fabric, seal the glue inlet and suction port, and allow it to cure at room temperature for 24 hours. Then, the mold is placed in an oven and cured at 60°C for two hours. After removal, the hybrid composite material is removed from the mold, and the release cloth, guide net, and vacuum bag are removed to obtain carbon-glass hybrid composite materials with different volume ratios and thicknesses between 2.6mm and 2.8mm.

[0053] When the carbon-glass volume ratio is 2:1 (SCGC), the carbon fiber volume fraction is 66%. Tensile tests, bending tests, DMA performance tests, drop hammer impact tests, and ultrasonic non-destructive testing were performed on the super hybrid composite material. The specific data are shown in Table 2.

[0054] Table 2 Test data of superhybrid composite materials with a carbon-to-glass ratio of 2:1

[0055]

[0056] Example 2

[0057] The preparation method of the high-toughness carbon-glass hybrid composite material in this embodiment is as follows:

[0058] (1) Preparation of ultra-hybrid spreadable filaments: Carbon fiber spreadable filaments and glass fiber spreadable filaments (authorized patent: an airflow disturbance type carbon fiber spreadable device, ZL 202111589981.4) are used to prepare carbon-glass ultra-hybrid fiber spreadable filaments, such as... Figure 2 The image shows the preparation process of ultra-hybrid fiber broadening filaments with three different carbon-glass volume ratios.

[0059] exist Figure 2 In (b), two parallel rollers are used to spin ① and ② together, and then they are passed through a third roller. Due to the tension, the spun carbon fiber and glass fiber filaments interpenetrate and cross each other in the thickness direction and continue to spread, resulting in ④, which is a more uniform carbon-glass hybrid filament with a carbon-glass volume ratio of 1:1 (SCG).

[0060] (2) Preparation of woven fabric: The super hybrid fiber woven fabric (SCG) is prepared by weaving the super hybrid spread filament (SCG) with a thickness between 0.04 mm and 0.08 mm using a weaving device.

[0061] (3) Layup design: The super hybrid fiber woven fabric (SCG) is directly laid up, and the total layup thickness is the same as in Example 1 (between 1.0-1.4 mm). Among them, laying up 15 layers of SCG fiber woven fabric can prepare a super hybrid layup structure with a carbon-glass volume ratio of 1:1 (SCG).

[0062] (4) Vacuum-assisted resin transfer molding: Same as in Example 1.

[0063] When the carbon-glass volume ratio is 1:1 (SCG), the carbon fiber volume fraction is 50%. Tensile tests, bending tests, DMA performance tests, drop hammer impact tests, and ultrasonic non-destructive testing were performed on the super-hybrid composite material. The specific data are shown in Table 3.

[0064] Table 3 Test data of 1:1 carbon-glass ratio superhybrid composite materials

[0065]

[0066] Example 3

[0067] The preparation method of the high-toughness carbon-glass hybrid composite material in this embodiment is as follows:

[0068] (1) Preparation of ultra-hybrid spreadable filaments: Carbon fiber spreadable filaments and glass fiber spreadable filaments (authorized patent: an airflow disturbance type carbon fiber spreadable device, ZL202111589981.4) are used to prepare carbon-glass ultra-hybrid fiber spreadable filaments, such as... Figure 2 The image shows the preparation process of ultra-hybrid fiber broadening filaments with three different carbon-glass volume ratios.

[0069] exist Figure 2 In (c), three parallel rollers are used to spin ②①② together, and then the fibers are passed through a fourth roller. Due to the tension, the spun carbon fiber and glass fiber fibers interpenetrate and cross each other in the thickness direction and continue to spread, resulting in ⑤, which is a super hybrid spread fiber (SGCG) with a carbon-glass volume ratio of 1:2, which is more uniformly mixed with carbon and glass.

[0070] (2) Preparation of woven fabric: The super hybrid spread yarn (SGCG) is woven by a weaving device to prepare a super hybrid fiber woven fabric (SGCG) with a thickness between 0.04 mm and 0.08 mm.

[0071] (3) Layup design: The super hybrid fiber woven fabric (SGCG) was directly laid up, and the total layup thickness was the same as in Example 1 (between 1.0-1.4 mm). Specifically, laying up 10 layers of SGCG fiber woven fabric can prepare a super hybrid layup structure with a carbon-glass volume ratio of 1:2 (SGCG);

[0072] (4) Vacuum-assisted resin transfer molding: Same as in Example 1.

[0073] When the carbon-glass volume ratio is 1:2 (SGCG), the carbon fiber volume fraction is 33%. Tensile tests, bending tests, DMA performance tests, drop hammer impact tests, and ultrasonic non-destructive testing were performed on the super-hybrid composite material. The specific data are shown in Table 4.

[0074] Table 4 Test data of superhybrid composite materials with a carbon-to-glass ratio of 1:2

[0075]

[0076]

[0077] Comparative Example 1

[0078] The preparation method of this comparative example interlaminar hybrid composite material (carbon-glass volume ratio of 2:1) is as follows:

[0079] (1) Preparation of single fiber woven fabric: carbon fiber woven fabric and glass fiber woven fabric are woven into carbon fiber woven fabric and glass fiber woven fabric respectively (the same as in the example, after being stretched using authorized equipment).

[0080] (2) Layup Design: In order to compare with the layup structure of ultra-hybrid woven fabrics, in Figure 4 In this example, carbon fiber woven fabric and glass fiber woven fabric are laid up in a hybrid manner with the same carbon-glass volume ratio as the 2:1 carbon-glass volume ratio super hybrid layup. The total thickness of the layup is the same as in Example 1 (between 1.0-1.40 mm). When the carbon-glass volume ratio is 2:1 (LCGC), the interlayer hybrid layup structure with a carbon-glass volume ratio of 2:1 (LCGC) is prepared by alternating layers in the pattern C3G3C6G3C6G3C6G3C3 (C represents carbon fiber woven fabric, G represents glass fiber woven fabric, and the subscripts 3 and 6 indicate the number of woven fabric layers), for a total of 36 layers (each layer is about 0.03 mm).

[0081] (3) Vacuum-assisted resin transfer molding: Same as step (4) in Example 1.

[0082] When the carbon-glass volume ratio is 2:1 (LCGC), the carbon fiber volume fraction is 66%. Tensile tests, bending tests, DMA performance tests, drop hammer impact tests, and ultrasonic non-destructive testing were performed on the interlaminar hybrid composite material. The specific data are shown in Table 5.

[0083] Table 5 Test data of interlaminar hybrid composites with a carbon-to-glass ratio of 2:1

[0084]

[0085] Comparing the ultrahybrid and interlaminar composites at the same carbon-glass ratio (i.e., a carbon-glass volume ratio of 2:1, comparing Tables 2 and 5), it can be found that in tensile testing, the tensile modulus of the ultrahybrid composite (Table 2) is 19.5% higher than that of the interlaminar composite, and the elongation at break of the ultrahybrid composite is 1.3% higher. In bending testing, the flexural limit strain of the ultrahybrid composite is 12.3% higher than that of the interlaminar composite. In DMA performance testing, the loss factor of the ultrahybrid composite is 8.47% higher than that of the interlaminar composite. In drop hammer impact testing, the ultrahybrid composite absorbs 3.8% more energy than the interlaminar composite. In ultrasonic nondestructive testing, the damaged area of ​​the ultrahybrid composite is 10.8% smaller than that of the interlaminar composite.

[0086] Comparative Example 2

[0087] The preparation method of this comparative example interlaminar hybrid composite material (carbon-glass volume ratio of 1:1) is as follows:

[0088] (1) Preparation of single fiber woven fabric: carbon fiber woven fabric and glass fiber woven fabric are woven into carbon fiber woven fabric and glass fiber woven fabric respectively.

[0089] (2) Layup Design: In order to compare with the layup structure of ultra-hybrid woven fabrics, in Figure 4 In this example, carbon fiber and glass fiber woven fabric are laid up in a hybrid manner with the same carbon-glass volume ratio as the 1:1 carbon-glass volume ratio super hybrid layup. The total thickness of the layup is the same as in Example 2 (between 1.0-1.4 mm). When the carbon-glass volume ratio is 1:1 (LCG), the interlayer hybrid layup structure with a carbon-glass volume ratio of 1:1 (LCG) can be prepared by alternating layups in the pattern of C3G6C6G6C6G6C3, for a total of 36 layers (each layer is about 0.03 mm).

[0090] (3) Vacuum-assisted resin transfer molding: Same as step (4) in Example 1.

[0091] When the carbon-glass volume ratio is 1:1 (LCG), the carbon fiber volume fraction is 50%. Tensile tests, bending tests, DMA performance tests, drop hammer impact tests, and ultrasonic non-destructive testing were performed on the interlaminar hybrid composite material. The specific data are shown in Table 6.

[0092] Table 6 Test data of interlaminar hybrid composite materials with a carbon-to-glass ratio of 1:1

[0093]

[0094]

[0095] Comparing the ultrahybrid and interlaminar composites at the same carbon-glass ratio (i.e., a carbon-glass volume ratio of 1:1, comparing Tables 3 and 6), it can be found that in tensile testing, the tensile modulus of the ultrahybrid composite (Table 3) is 22.7% higher than that of the interlaminar composite, and the elongation at break of the ultrahybrid composite is 5.5% higher. In bending testing, the flexural limit strain of the ultrahybrid composite is 26.3% higher than that of the interlaminar composite. In DMA performance testing, the loss factor of the ultrahybrid composite is 7.33% higher than that of the interlaminar composite. In drop hammer impact testing, the ultrahybrid composite absorbs 1.9% more energy than the interlaminar composite. In ultrasonic nondestructive testing, the damaged area of ​​the ultrahybrid composite is 6.3% smaller than that of the interlaminar composite.

[0096] Comparative Example 3

[0097] The preparation method of this comparative example interlaminar hybrid composite material (carbon-glass volume ratio 1:2) is as follows:

[0098] (1) Preparation of single fiber woven fabric: carbon fiber woven fabric and glass fiber woven fabric are woven into carbon fiber woven fabric and glass fiber woven fabric respectively.

[0099] (2) Layup Design: In order to compare with the layup structure of ultra-hybrid woven fabrics, in Figure 4 In this case, carbon fiber and glass fiber woven fabric were designed with interlayer hybrid layup according to the same carbon-glass volume ratio as the 1:2 carbon-glass volume ratio super hybrid layup, and the total layup thickness was the same as in Example 3 (between 1.0-1.4 mm). When the carbon-glass volume ratio is 1:2 (LGCG), the interlayer hybrid layup structure with a carbon-glass volume ratio of 1:2 (LGCG) can be prepared by alternating layup in the manner of C3G6C2G6C2G6C2G6C3, for a total of 36 layers (each layer is about 0.03 mm).

[0100] (3) Vacuum-assisted resin transfer molding: Same as step (4) in Example 1.

[0101] When the carbon-glass volume ratio is 1:2 (LGCG), the carbon fiber volume fraction is 33%. Tensile tests, bending tests, DMA performance tests, drop hammer impact tests, and ultrasonic non-destructive testing were performed on the interlaminar hybrid composite material. The specific data are shown in Table 7.

[0102] Table 7 Test data of interlaminar hybrid composites with a carbon-to-glass ratio of 1:2

[0103]

[0104] Comparing the ultrahybrid and interlaminar composites at the same carbon-glass ratio (i.e., a carbon-glass volume ratio of 1:2, comparing Tables 4 and 7), it can be found that in tensile testing, the tensile modulus of the ultrahybrid composite (Table 4) is 11% higher than that of the interlaminar composite, and the elongation at break of the ultrahybrid composite is 10.4% higher. In bending testing, the flexural limit strain of the ultrahybrid composite is 39.2% higher than that of the interlaminar composite. In DMA performance testing, the loss factor of the ultrahybrid composite is 6.63% higher than that of the interlaminar composite. In drop hammer impact testing, the ultrahybrid composite absorbs 4.6% more energy than the interlaminar composite. In ultrasonic nondestructive testing, the damaged area of ​​the ultrahybrid composite is 14.2% smaller than that of the interlaminar composite.

[0105] In summary, the three embodiments and comparative examples are compared as follows (specific data are shown in the figure). Figure 6-13 (As shown in Table 8):

[0106] Table 8 Energy Absorbed by Composite Materials

[0107]

[0108] (1) In terms of tensile modulus, when the carbon-glass volume ratios are 2:1, 1:1 and 1:2, the tensile modulus of the super-hybrid composite material is increased by 19.5%, 22.7% and 11% respectively compared with the interlaminar hybrid composite material. It can be seen that the tensile modulus of the super-hybrid composite material is significantly better than that of the interlaminar hybrid composite material, and it plays a better role in reinforcement.

[0109] (2) Regarding elongation at break, when the carbon-glass volume ratios were 2:1, 1:1, and 1:2, the elongation at break of the ultrahybrid composite material was increased by 1.3%, 5.5%, and 10.4% respectively compared to the interlaminar composite material. It can be seen that the elongation at break of the ultrahybrid composite material is higher than that of the interlaminar composite material. The improvement effect is more obvious when the carbon fiber content is lower, indicating that the more uniform carbon-glass hybrid effect of the ultrahybrid fiber composite material allows the carbon fiber and glass fiber to play a better synergistic role, thereby producing a strengthening and toughening effect.

[0110] (3) Regarding the flexural ultimate strain, when the carbon-glass volume ratios are 2:1, 1:1, and 1:2, the flexural ultimate strain of the hyperhybrid composite material is increased by 12.3%, 26.3%, and 39.2% respectively compared to the interlaminar composite material. It can be seen that the flexural ultimate strain of the hyperhybrid composite material is significantly higher than that of the interlaminar composite material, indicating that the hyperhybrid composite material exhibits a better toughening effect under flexural load.

[0111] (4) Regarding the loss factor results in the DMA performance test, when the carbon-glass volume ratios were 2:1, 1:1, and 1:2, the loss factor of the hyperhybrid fiber composite was higher than that of the interlaminar composite, indicating that the hyperhybrid fiber composite had greater damping. In the hyperhybrid composite, the mixing of carbon fiber and glass fiber was more uniform than that of the interlaminar composite. The carbon fiber reinforcement and glass fiber toughening worked synergistically, resulting in greater damping and dissipating more energy during deformation, thus exhibiting a better energy absorption effect.

[0112] (5) In the drop hammer impact test, when the carbon-glass volume ratios were 2:1, 1:1, and 1:2, the energy absorbed by the hyperhybrid composite material was 3.8%, 1.9%, and 4.6% higher than that of the interlaminar composite material, respectively. The energy absorbed by the hyperhybrid material was higher than that of the interlaminar composite material. This indicates that the fibers in the hyperhybrid composite material are more uniformly dispersed, resulting in a better energy absorption effect.

[0113] (6) In terms of the proportion of damaged area, when the carbon-glass volume ratios are 2:1, 1:1 and 1:2, the damaged area of ​​the super hybrid composite material is reduced by 10.8%, 6.3% and 14.2% respectively compared with the interlaminar hybrid composite material, indicating that the super hybrid material has better impact resistance.

[0114] The above results show that the super-hybrid composite material prepared by the present invention overcomes the defects of poor interlayer hybrid design, low fiber hybridization degree and poor toughening effect of the existing materials. It achieves more uniform hybridization within carbon fiber and glass fiber bundles, enabling the two to better synergize with each other and give full play to their own advantages, exhibiting better reinforcement and toughening effect, and improving the mechanical properties of the composite material.

[0115] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages.

[0116] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a high-toughness carbon-glass hyperhybrid composite material, characterized in that... Includes the following steps: (1) Preparation of carbon-glass hybrid woven fabric; (2) Preparation of carbon-glass hybrid composite materials; The preparation of the carbon-glass hybrid woven fabric in step (1) includes the following steps: (a) Preparation of ultra-hybrid fiber spreader: The carbon fiber spreader and glass fiber spreader obtained by airflow disturbance carbon fiber spreader are mixed according to different carbon-glass volume ratios. The fibers are then fused together using parallel rollers and then fused together as a whole through other rollers to obtain ultra-hybrid fiber spreader. (b) Preparation of woven fabric: Carbon-glass ultra-hybrid woven fabric is prepared by weaving the ultra-hybrid fiber broadened filaments using a weaving device; In step (a), the carbon fiber and glass fiber broadened filaments after integral spinning interpenetrate and cross each other in the thickness direction due to the tension, and further broaden, thereby obtaining a wider broadening. In step (a), the volume ratios of carbon fiber spread filaments and glass fiber spread filaments are 2:1, 1:1, and 1:2, respectively. The preparation of the carbon-glass hybrid composite material in step (2) includes the following steps: (A) Layup design: Since the two types of fibers have been super-mixed within the bundle in the super-hybrid fiber braid, the super-hybrid fiber braid is directly laid up, and the thickness of the super-hybrid fiber braid after layup is 1.0-1.4 mm. (B) Vacuum-assisted resin transfer molding: The laid-up super hybrid fiber woven fabric is placed on a smooth stainless steel template. After the epoxy resin is completely impregnated into the fiber woven fabric, it is sealed and cured to obtain carbon-glass super hybrid composite material. The high-toughness carbon-glass hybrid composite material has a fracture elongation of 1.9%, a flexural limit strain of 2.66%, a loss factor of 0.595, a damage area of ​​4.2% after impact testing, and an absorbed energy of 24.8 J.

2. The method for preparing the high-toughness carbon-glass hybrid composite material according to claim 1, characterized in that, When the volume ratio of carbon fiber spread filament to glass fiber spread filament is 2:1, 1:1, and 1:2, respectively, SCGC carbon-glass super hybrid woven fabric, SCG carbon-glass super hybrid woven fabric and SGCG carbon-glass super hybrid woven fabric are prepared.

3. The method for preparing the high-toughness carbon-glass hybrid composite material according to claim 1, characterized in that, The specific preparation method of the carbon-glass hyperhybrid composite material in step (B) is as follows: The laid-up hyperhybrid fiber woven fabric is placed on a smooth stainless steel template coated with a release agent and anti-stick film. Release cloth, a flow guide net, absorbent cotton, a threaded tube, and a vacuum bag are then placed sequentially on top of the woven fabric. Using 3... M sealant is applied around the perimeter; the suction pipe and the glue inlet pipe are connected and fixed to the threaded pipe, the suction pipe is connected in series with the buffer tank and the vacuum pump, the glue inlet is locked, the vacuum pump is turned on to evacuate the vacuum, and when the vacuum pump pressure reaches one atmosphere, check for leaks. After confirming that the whole set of equipment is leak-free, the glue inlet pipe is connected to a beaker containing degassed epoxy resin. Then the glue inlet is opened, and the epoxy resin enters the sealed mold cavity under the action of the vacuum pump. After the epoxy resin completely impregnates the fiber weave, the glue inlet and the suction port are sealed, and it is cured at room temperature for 24 hours. Then it is placed in an oven and cured at 60°C for 2 hours. After removal, the hybrid composite material is removed from the mold, and the release cloth, guide net and vacuum bag are removed to obtain the carbon glass ultra-hybrid composite material.

4. The method for preparing the high-toughness carbon-glass hybrid composite material according to claim 3, characterized in that, The preparation method of epoxy resin adhesive is as follows: Mix epoxy resin and curing agent in a mass ratio of 3:1 and stir evenly. The mixed epoxy resin contains a large number of air bubbles. At this time, the epoxy resin needs to be placed in a vacuum drying oven to remove air for 10-12 minutes. After the air is removed, the epoxy resin is transparent, clear and uniform inside without air bubbles.

5. The high-toughness carbon-glass hybrid composite material prepared by any one of the preparation methods according to claims 1-4.

6. The application of the high-toughness carbon-glass hybrid composite material according to claim 5 in the inner panel skeleton of automobile doors.

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