Wave-transparent composite material with high surface flatness and low surface roughness and forming method

Abstract

The invention relates to a wave-transparent composite material with high surface flatness and low surface roughness and a forming method. The wave-transparent composite material comprises a fiber reinforced resin-based wave-transparent composite material main body layer, an ultrathin fiber cloth reinforced resin-based wave-transparent material transition layer and a thermoplastic film surface layer which are arranged in sequence. The forming method of the wave-transparent composite material comprises the following steps: sequentially laying the fiber reinforced resin prepreg (prepreg A), the ultrathin fiber cloth reinforced resin prepreg (prepreg B) and the thermoplastic polymer film on a mold, and then integrally hot-pressing, curing and forming. The wave-transparent composite material is compact and uniform in surface, high in flatness and low in roughness.

Description

Technical Field

[0001] The present invention belongs to the technical field of wave-transmitting composite materials, and in particular relates to a wave-transmitting composite material with high surface flatness and low surface roughness and a molding method thereof. Background Art

[0002] Fiber-reinforced resin-based wave-transparent composite materials are typical structural / functional integrated materials, mainly used in the preparation of radar antenna covers. On the one hand, they ensure that electromagnetic signals can pass through the cover efficiently and with low loss, and on the other hand, they prevent direct contact between the external environment and the radar system, providing a suitable working environment for the radar. In the future, as the technical indicators of radar systems continue to rise and the service environment becomes more complicated, TXZ will be required to have multifunctional integration such as stealth, lightning resistance, anti-static, and rain erosion resistance. To achieve the above requirements, it is generally necessary to construct different functional structures and coatings on the surface of the composite material. However, the original surface of fiber-reinforced resin-based wave-transparent composite materials usually contains various defects such as micropores, broken fibers, and poor glue, which cannot achieve high-quality construction of functional coatings and structures. Therefore, the composite material needs to be surface modified.

[0003] Although the surface quality of composite materials can be improved by grinding, polishing, scraping putty and other treatment methods, grinding is likely to cause fiber breakage and damage, affecting the reliability of the material; scraping putty can improve the surface flatness, but the surface roughness is high, and the putty layer has poor adhesion to the composite surface. In summary, there is currently a lack of methods for directly forming wave-transmitting composite materials with high surface quality. Summary of the invention

[0004] In order to solve the problems existing in the prior art, the present invention provides a wave-transmitting composite material with high surface flatness and low surface roughness and a molding method.

[0005] In a first aspect, the present invention relates to a wave-transmitting composite material with high surface flatness and low surface roughness, wherein the wave-transmitting composite material comprises a fiber-reinforced resin-based wave-transmitting composite material main body layer, an ultra-thin fiber cloth-reinforced resin-based wave-transmitting material transition layer and a thermoplastic film surface layer arranged in sequence.

[0006] The fibers in the main layer include but are not limited to quartz fibers, glass fibers, basalt fibers, PBO fibers, polyimide fibers and other wave-transmitting fibers, and the forms of the fibers include but are not limited to short fibers, long fibers, fiber cloth and the like.

[0007] The resin in the resin-based wave-transparent material of the main layer and the transition layer is the same, and the types of resin include but are not limited to epoxy resin, cyanate resin, phenolic resin, phthalonitrile resin, polyarylacetylene resin, polyimide resin, etc.

[0008] The ultra-thin fiber cloth in the transition layer includes ultra-thin quartz fiber cloth and ultra-thin glass cloth, and the thickness of the ultra-thin fiber cloth is not greater than 0.05 mm.

[0009] The surface layer of the thermoplastic film adopts thermoplastic polymer film, including polyphenol oxide film, polyurethane film, polystyrene film, polyaryletherketone film, polysulfone film, polyimide film, etc. The temperature resistance of the film must match the temperature resistance of the above-mentioned resin base, and the thickness of the film is not more than 0.02mm.

[0010] In a second aspect, the present invention discloses an integrated molding method of a wave-transmitting composite material having high surface flatness and low surface roughness, wherein the integrated molding method of the wave-transmitting composite material specifically comprises the following steps:

[0011] 1) Preparing a prepreg A of a fiber-reinforced resin-based wave-transmitting composite material main layer and a prepreg B of an ultra-thin fiber cloth-reinforced resin-based wave-transmitting material transition layer;

[0012] 2) Spreading prepreg A on the mold surface according to product design requirements;

[0013] 3) Laying prepreg B on the prepreg A;

[0014] 4) attaching a thermoplastic polymer film to the prepreg B;

[0015] 5) The structure comprising the prepreg A, the prepreg B and the thermoplastic polymer film is integrally cured and molded to obtain a wave-transmitting composite material with high surface flatness and low surface roughness.

[0016] In step 1), the prepreg A is composed of a composite of fibers and resins, wherein the fibers include but are not limited to quartz fibers, glass fibers, basalt fibers, PBO fibers, polyimide fibers and other wave-transmitting fibers, the forms of the fibers include but are not limited to chopped fibers, long fibers, fiber cloth, etc., and the types of the resins include but are not limited to epoxy resins, cyanate resins, phenolic resins, phthalonitrile resins, polyarylacetylene resins, polyimide resins, etc.

[0017] In step 1), the prepreg B is composited with ultra-thin fiber cloth and resin, wherein the ultra-thin fiber cloth includes ultra-thin quartz fiber cloth and ultra-thin glass cloth, the thickness of the ultra-thin fiber cloth is not more than 0.05 mm, the resin is the same as the resin used in prepreg A, and the number of layers of the prepreg B in step 3) is 1 to 3 layers.

[0018] In step 4), the thermoplastic polymer film includes polyphenol oxide film, polyurethane film, polystyrene film, polyaryletherketone film, polysulfone film, polyimide film, etc. The temperature resistance of the film must match the temperature resistance of the above-mentioned resin base. The thickness of the film is not more than 0.02mm, and the number of film layers is 1.

[0019] In step 5), the curing method is vacuum bag curing, autoclave curing, compression molding curing, etc., and the curing conditions are matched with the resin used.

[0020] The beneficial effects of the present invention are as follows:

[0021] The wave-transmitting composite material of the present invention is composed of a fiber-reinforced resin-based wave-transmitting composite material main body layer, an ultra-thin fiber cloth-reinforced resin-based wave-transmitting material transition layer and a thermoplastic film surface layer. The surface of the wave-transmitting composite material is dense, uniform, high in flatness and low in roughness. The transition layer can repair the large hole defects caused by the fiber weaving pattern of the main body layer and improve the surface flatness; the surface layer can reduce the surface roughness and improve the surface uniformity. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of a wave-transmitting composite material with high surface flatness and low surface roughness of the present invention.

[0023] Figure 2 This is a scanning electron microscope photograph of the wave-transmitting composite material in Example 1.

[0024] Figure 3 This is a three-dimensional profile scanning photo of the wave-transmitting composite material in Example 1.

[0025] Figure 4 This is a scanning electron microscope photograph of the wave-transmitting composite material in Comparative Example 1.

[0026] Figure 5 This is a three-dimensional profile scanning photo of the wave-transmitting composite material in Comparative Example 1. DETAILED DESCRIPTION

[0027] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below through specific embodiments and drawings.

[0028] The structure of the wave-transmitting composite material with high surface flatness and low surface roughness of the present invention is as follows Figure 1 As shown, the wave-transmitting composite material comprises a fiber-reinforced resin-based wave-transmitting composite material main body layer 1, an ultra-thin fiber cloth-reinforced resin-based wave-transmitting material transition layer 2 and a thermoplastic film surface layer 3 which are arranged in sequence.

[0029] Embodiment 1:

[0030] The surface of the stainless steel flat mold is cleaned and a release agent is applied; then 10 layers of glass fiber / epoxy resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat mold; then 1 layer of ultra-thin glass cloth / epoxy resin prepreg (prepreg B) is laid on the above prepreg A, and then a thermoplastic polyphenol oxide film is pasted on the prepreg B, and the film thickness is 10 μm; finally, vacuum bag pressing and curing is used to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. Figure 2 This is a scanning electron microscope photo of the wave-transmitting composite material. Figure 3 This is a three-dimensional profile scanning photo of the wave-transmitting composite material. The surface roughness of the wave-transmitting composite material is 0.4 μm.

[0031] Embodiment 2:

[0032] The surface of the stainless steel flat mold is cleaned and a release agent is applied; then 10 layers of quartz fiber cyanate resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat mold; then 2 layers of ultra-thin quartz cloth / cyanate resin prepreg (prepreg B) are laid on the above prepreg A, and then a thermoplastic polyaryletherketone film is pasted on prepreg B, with a film thickness of 15 μm; finally, a hot autoclave is used for curing to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. The surface roughness of the wave-transmitting composite material is 0.3 μm.

[0033] Embodiment 3:

[0034] Clean the surface of the stainless steel flat mold and apply a release agent; then 10 layers of quartz fiber / polyimide resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat mold; then 3 layers of ultra-thin quartz cloth / polyimide resin prepreg (prepreg B) are laid on the above prepreg A, and then a thermoplastic polyimide film is pasted on prepreg B, with a film thickness of 20 μm; finally, hot molding and curing are used to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. The surface roughness of the wave-transmitting composite material is 0.3 μm.

[0035] Embodiment 4:

[0036] The surface of the stainless steel flat mold is cleaned and a release agent is applied; then 10 layers of PBO fiber / cyanate resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat mold; then 3 layers of ultra-thin quartz cloth / cyanate resin prepreg (prepreg B) are laid on the above prepreg A, and then a thermoplastic polyaryletherketone film is pasted on prepreg B, with a film thickness of 10 μm; finally, a hot autoclave is used for curing to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. The surface roughness of the wave-transmitting composite material is 0.5 μm.

[0037] Comparative Example 1:

[0038] The surface of the stainless steel flat mold was cleaned and a release agent was applied; then 10 layers of glass fiber / epoxy resin prepreg (prepreg A) were sequentially laid on the surface of the stainless steel flat mold; finally, vacuum bag pressing and curing were performed to obtain a wave-transmitting composite material. Figure 4 This is a scanning electron microscope photo of the wave-transmitting composite material. Figure 5 This is a three-dimensional profile scanning photo of the wave-transmitting composite material. The surface roughness of the wave-transmitting composite material is 2.9 μm.

[0039] Comparative Example 2:

[0040] The surface of the stainless steel flat plate mold is cleaned and a release agent is applied; then 10 layers of quartz fiber cyanate resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat plate mold; finally, a hot-pressing tank is used for curing to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. The surface roughness of the wave-transmitting composite material is 3.2 μm.

[0041] Comparative Example 3:

[0042] The surface of the stainless steel flat mold is cleaned and a release agent is applied; then 10 layers of quartz fiber / polyimide resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat mold; finally, hot molding and curing are performed to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. The surface roughness of the wave-transmitting composite material is 4.5 μm.

[0043] Comparative Example 4:

[0044] The surface of the stainless steel flat mold is cleaned and a release agent is applied; then 10 layers of PBO fiber / cyanate resin prepreg (prepreg A) are sequentially laid on the surface of the stainless steel flat mold; finally, a hot-pressing tank is used for curing to obtain the wave-transmitting composite material with high surface flatness and low surface roughness. The surface roughness of the wave-transmitting composite material is 2.3 μm.

[0045] The specific embodiments of the present invention disclosed above are intended to help understand the content of the present invention and implement it accordingly. It can be understood by those skilled in the art that various replacements, changes and modifications are possible without departing from the spirit and scope of the present invention. The present invention should not be limited to the contents disclosed in the embodiments of this specification, and the scope of protection of the present invention shall be subject to the scope defined in the claims.

Claims

1. A wave-transmitting composite material with high surface flatness and low surface roughness, characterized in that: It comprises a fiber reinforced resin-based wave-transmitting composite material main body layer, an ultra-thin fiber cloth reinforced resin-based wave-transmitting material transition layer and a thermoplastic film surface layer which are arranged in sequence.

2. The wave-transmitting composite material according to claim 1, characterized in that: The fibers in the main layer of the fiber-reinforced resin-based wave-transmitting composite material include at least one of the following: quartz fiber, glass fiber, basalt fiber, PBO fiber, polyimide fiber; the form of the fibers includes at least one of the following: chopped fiber, long fiber, fiber cloth.

3. The wave-transmitting composite material according to claim 1, characterized in that: The fiber-reinforced resin-based wave-transparent composite material main layer and the ultra-thin fiber cloth reinforced resin-based wave-transparent material transition layer have the same resin type, and the resin type includes at least one of the following: epoxy resin, cyanate resin, phenolic resin, phthalonitrile resin, polyarylacetylene resin, and polyimide resin.

4. The wave-transmitting composite material according to claim 1, characterized in that: The ultra-thin fiber cloth in the ultra-thin fiber cloth reinforced resin-based wave-transmitting material transition layer is an ultra-thin quartz fiber cloth or an ultra-thin glass cloth, and the thickness of the ultra-thin fiber cloth is not greater than 0.05 mm.

5. The wave-transmitting composite material according to claim 1, characterized in that: The surface layer of the thermoplastic film is made of a thermoplastic polymer film, and the thermoplastic polymer film includes at least one of the following: polyphenol oxide film, polyurethane film, polystyrene film, polyaryletherketone film, polysulfone film, polyimide film; the temperature resistance of the thermoplastic polymer film matches the temperature resistance of the resin base, and the thickness of the thermoplastic polymer film is not more than 0.02mm.

6. A method for forming a wave-transmitting composite material with high surface flatness and low surface roughness, characterized in that: The following steps are involved: Preparing a prepreg A for a fiber-reinforced resin-based wave-transmitting composite material main layer and a prepreg B for an ultra-thin fiber cloth-reinforced resin-based wave-transmitting material transition layer; Spreading prepreg A on the mold surface; Laying prepreg B on prepreg A; attaching a thermoplastic polymer film to the prepreg B; The prepreg A, the prepreg B and the thermoplastic polymer film are integrally cured and molded to obtain a wave-transmitting composite material with high surface flatness and low surface roughness.

7. The molding method according to claim 6, characterized in that: The prepreg A is composited with fibers and resins, wherein the fibers include at least one of the following: quartz fibers, glass fibers, basalt fibers, PBO fibers, and polyimide fibers, and the fiber forms include at least one of the following: chopped fibers, long fibers, and fiber cloth; and the types of the resins include at least one of the following: epoxy resins, cyanate resins, phenolic resins, phthalonitrile resins, polyarylene resins, and polyimide resins.

8. The molding method according to claim 6, characterized in that: The prepreg B is composited with ultra-thin fiber cloth and resin, wherein the ultra-thin fiber cloth is ultra-thin quartz fiber cloth or ultra-thin glass cloth, the thickness of the ultra-thin fiber cloth is not more than 0.05 mm, the resin is the same as the resin used in prepreg A, and the number of layers of the prepreg B is 1 to 3 layers.

9. The molding method according to claim 6, characterized in that: The thermoplastic polymer film includes at least one of the following: polyphenol oxide film, polyurethane film, polystyrene film, polyaryletherketone film, polysulfone film, polyimide film, the temperature resistance of the thermoplastic polymer film matches the temperature resistance of the resin base, the thickness of the thermoplastic polymer film is not more than 0.02mm, and the number of layers of the thermoplastic polymer film is 1.

10. The molding method according to claim 6, characterized in that: The curing is at least one of the following: vacuum bag curing, autoclave curing, and compression curing.

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