Lightweight impact-resistant carbon fiber composite large board and preparation method and application thereof

Abstract

The invention relates to the technical field of plates, in particular to a light-weight impact-resistant carbon fiber composite large plate and a preparation method and application thereof, and the composite large plate comprises a surface carbon fiber rigid composite layer, an internal toughness impact-resistant layer and a light-weight core layer which are sequentially arranged from outside to inside; the surface carbon fiber rigid composite layer is made of epoxy resin carbon fiber cloth prepreg; the internal tough impact-resistant layer is made of epoxy resin ultra-high molecular weight polyethylene prepreg; the lightweight core layer is formed by taking a three-dimensional woven carbon fiber fabric as a framework and adding a filling material in gaps of the three-dimensional woven carbon fiber fabric after reinforcing ribs made of a plurality of carbon fiber hollow square tubes are distributed in the three-dimensional woven carbon fiber fabric; the high-strength and high-modulus carbon fiber composite layer, the ultra-high molecular weight polyethylene composite layer and the light-weight core layer on the surface layer are integrally solidified, so that the technical problems that in the prior art, a foam sandwich plate is insufficient in rigidity and poor in mechanical property, impact resistance and layering resistance are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of plate materials, and in particular to a lightweight impact-resistant carbon fiber composite large plate and a preparation method and application thereof. Background Art

[0002] Traditional shelters use a large plate structure of inner and outer metal skins + middle metal skeleton + interlayer filled polyurethane plates, which has problems such as excessive weight, poor thermal insulation and salt spray corrosion resistance. Since metal materials cannot meet the requirements of lightweight shelters, the application of non-metallic materials in shelters has been promoted. Shelters include special boxes such as special carriages, medical shelters, military shelters, and meteorological shelters. Shelters have higher reliability, electromagnetic compatibility, air tightness, and thermal insulation. At present, shelters used for special purposes pay more attention to the bulletproof performance and maneuverability of the shelters, while the shelter large plates in the existing technology have problems such as heavy weight and poor maneuverability. At the same time, there are also problems such as complex materials and uneconomical production of shelter large plates.

[0003] Chinese patent CN114673296A discloses a large panel for a shelter and a shelter. The large panel for a shelter includes an inner skin, an outer skin, and a bulletproof layer arranged between the inner skin and the outer skin; the bulletproof layer is composed of an aramid plate formed by hot-pressing an aramid plate cloth and a non-woven cloth with a cross-linking agent based on an adhesive. The shelter includes the above-mentioned plurality of large panels for a shelter; the large panels for a shelter are connected and fixed by a plurality of first angle pieces, a plurality of second angle pieces, and a plurality of angle pieces to form a shelter with a closed chamber inside. The bulletproof layer of the large panel for a shelter provided by the present invention is composed of an aramid plate formed by hot-pressing an aramid plate cloth and a non-woven cloth with a cross-linking agent based on an adhesive. The large panel for a shelter adopts an aramid plate with high bulletproof performance, and its weight is reduced by more than 60% compared with steel plate materials; the shelter prepared by using the large panel for a shelter can effectively reduce the energy consumption of the shelter vehicle and improve its maneuverability.

[0004] At present, the large panels of square cabins are mainly foam sandwich panels, which are composed of a foam core layer attached to a skin, and the foam core layer and the skin are glued together. The foam sandwich panels prepared by this process have insufficient overall rigidity, and poor mechanical properties, impact resistance and anti-delamination capabilities. Therefore, it is particularly urgent to develop new composite large panels that can take into account the overall lightweight advantages of foam materials and the excellent performance of composite materials. Summary of the invention

[0005] The purpose of the present invention is to address the deficiencies in the prior art and provide a lightweight, impact-resistant carbon fiber composite large board. Through an integrally cured multi-layer structure, the high-strength and high-modulus carbon fiber composite layer on the surface is used to improve the hardness, strength, rigidity and deformation resistance of the board; an ultra-high molecular weight polyethylene composite layer is used to achieve a certain impact resistance of the board. At the same time, a lightweight core layer with a large thickness ratio is used to achieve a substantial weight reduction, thereby solving the technical problems of insufficient rigidity and poor mechanical properties, impact resistance and anti-delamination ability of foam sandwich panels in the prior art.

[0006] To achieve the above object, the present invention provides the following technical solutions: A lightweight impact-resistant carbon fiber composite large plate, characterized in that it comprises a surface carbon fiber rigid composite layer, an internal tough impact-resistant layer and a lightweight core layer arranged in sequence from the outside to the inside; The surface carbon fiber rigid composite layer is made of epoxy resin carbon fiber cloth prepreg; The internal toughness impact-resistant layer is made of epoxy resin ultra-high molecular weight polyethylene prepreg; The lightweight core layer is composed of a three-dimensional woven carbon fiber fabric as a skeleton, a plurality of reinforcing ribs made of carbon fiber hollow square tubes are distributed in the three-dimensional woven carbon fiber fabric, and a filling material is added in the gaps of the three-dimensional woven carbon fiber fabric.

[0007] As an improvement, the resin matrix in the surface carbon fiber rigid composite layer, the internal tough impact-resistant layer and the filling material in the lightweight core layer is the same tough epoxy resin.

[0008] As an improvement, the filling material of the lightweight core layer is composed of epoxy resin and hollow glass microspheres, and the weight ratio of epoxy resin to hollow glass microspheres is 1:1-1:2.

[0009] As an improvement, the thickness of the carbon fiber composite large board is 15-50mm, and the thickness of the lightweight core layer is 10-30mm.

[0010] Another object of the present invention is to provide a method for preparing a lightweight and impact-resistant carbon fiber composite large board in response to the shortcomings of the prior art. The method comprises sequentially placing a surface epoxy resin carbon fiber cloth prepreg, an epoxy resin ultra-high molecular weight polyethylene prepreg, placing an intermediate core layer skeleton, paving an epoxy resin ultra-high molecular weight polyethylene prepreg and a surface epoxy resin carbon fiber cloth prepreg, introducing epoxy resin and hollow glass microbeads into the intermediate layer by a vacuum method, and finally curing and forming the whole body, thereby solving the technical problems of insufficient stiffness of the foam sandwich panel in the prior art and poor mechanical properties, impact resistance and anti-delamination ability.

[0011] To achieve the above object, the present invention provides the following technical solutions: A method for preparing a lightweight impact-resistant carbon fiber composite large plate, used for preparing a lightweight impact-resistant carbon fiber composite large plate as claimed in any one of claims 1 to 4, characterized in that it comprises the following steps: Step 1: First lay the surface epoxy resin carbon fiber cloth prepreg in the mold, and then lay the epoxy resin ultra-high molecular weight polyethylene prepreg; Step 2: The carbon fiber hollow square tube is made into reinforcing ribs according to the required specifications and placed in the three-dimensional woven carbon fiber fabric as the middle core layer skeleton; Step 3, laying epoxy resin ultra-high molecular weight polyethylene prepreg and surface epoxy resin carbon fiber cloth prepreg in sequence on the middle core layer; Step 4: introducing a low-density casting material composed of epoxy resin and hollow glass microspheres into the middle layer by vacuum method; Step 5: After the mold is closed, vacuum is first used to remove internal bubbles, and then the whole is cured by heating and pressurizing to form a lightweight and impact-resistant carbon fiber composite panel.

[0012] As an improvement, in step five, the heating temperature is 100-120° C., and the curing time is 0.3-1.5 h.

[0013] As an improvement, in step five, the pressurization pressure range is 1-4Mpa.

[0014] As an improvement, in the steps 1 and 3, the epoxy resin carbon fiber cloth prepreg and the epoxy resin ultra-high molecular weight polyethylene prepreg are provided with multiple layers. Another object of the present invention is to address the deficiencies of the prior art and provide a use of a lightweight, impact-resistant carbon fiber composite large plate, so as to achieve special functions under special working conditions through new composite materials.

[0015] To achieve the above object, the present invention provides the following technical solutions: A use of a lightweight impact-resistant carbon fiber composite large plate. The lightweight impact-resistant carbon fiber composite large plate is used to make special cabin plates, refrigerated truck plates or RV plates.

[0016] The beneficial effects of the present invention are: (1) The present invention adopts a multi-layer composite structure integral molding process for the composite large plate, which avoids the delamination of the composite material during long-term use; the surface layer is a high-strength and high-modulus carbon fiber composite layer, which provides the composite plate with high hardness, high strength and stronger rigidity, and improves the overall deformation resistance of the composite material; the interior adopts an ultra-high molecular weight polyethylene composite layer, and since the ultra-high molecular weight polyethylene has super strong impact toughness, it gives the composite plate excellent impact resistance; the core layer is filled with low-density epoxy resin, combined with three-dimensional carbon fiber braided fabric as a reinforcing material, the overall mechanical properties of the composite plate are better. In addition, when producing lightweight impact-resistant square cabin carbon fiber composite large plates, the same resin system is used for one-piece co-curing process molding, and the composite material forms a whole, that is, all the materials in the present invention form a continuum, which improves the overall performance of the composite material.

[0017] (2) The lightweight of the composite large board structure in the present invention depends on the density of the overall structure. The carbon fiber and ultra-high molecular weight fiber in the system are both fibers with relatively low density, especially the ultra-high molecular weight fiber, which has a particularly low density. In particular, the middle core layer is filled with hollow glass microspheres, which makes the overall lightweight effect of the composite board obvious.

[0018] (3) The carbon fiber composite plate structure of the present invention is highly designable, which is mainly reflected in that the thickness and density of the middle core layer can be easily adjusted, and the surface layer structure can be adjusted according to functional requirements. Through optimized design, different functional modules can be matched with the requirements of lightweight, mechanical properties and other requirements of the use conditions.

[0019] In summary, the present invention has the advantages of excellent mechanical properties, light weight, modular design, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the cross-sectional structure of the composite large plate of the present invention. DETAILED DESCRIPTION

[0021] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0022] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0023] Embodiment 1 like Figure 1 As shown, this embodiment provides a lightweight impact-resistant carbon fiber composite large plate, including a surface carbon fiber rigid composite layer 1, an internal tough impact-resistant layer 2 and a lightweight core layer 3 arranged in sequence from the outside to the inside; The surface carbon fiber rigid composite layer 1 is made of epoxy resin carbon fiber cloth prepreg; the high-strength and high-modulus carbon fiber composite layer is used as the surface layer to provide the composite board with high hardness, high strength and stronger rigidity, thereby improving the overall deformation resistance of the composite material; The internal toughness impact-resistant layer 2 is made of epoxy resin ultra-high molecular weight polyethylene prepreg, and the ultra-high molecular weight polyethylene has super strong impact toughness, thus giving the composite board excellent impact resistance; The lightweight core layer 3 is composed of a three-dimensional woven carbon fiber fabric 31 as a skeleton, and a plurality of reinforcing ribs made of carbon fiber hollow square tubes 32 are distributed in the three-dimensional woven carbon fiber fabric 31. Filling material is added to the gaps in the three-dimensional woven carbon fiber fabric 31. Both carbon fiber and ultra-high molecular weight fiber are fibers with low density, especially ultra-high molecular weight fiber has a particularly low density, which greatly reduces the weight of the board.

[0024] It should be noted that the overall molding of the multi-layer composite structure can avoid the problem of delamination of the composite board during use, which would lead to a decrease in the performance of the board.

[0025] A number of carbon fiber hollow square tubes 32 are distributed inside the three-dimensional woven carbon fiber fabric 31, so that the carbon fiber hollow square tubes 32 serve as reinforcing ribs for the core layer and a supporting structure during the molding of the core layer, thereby ensuring the thickness of the lightweight core layer 3 after molding. In addition, carbon fiber and ultra-high molecular weight fiber are both fibers with relatively low density, especially ultra-high molecular weight fiber, which has a particularly low density, and can greatly reduce the weight of the board. The high strength of the carbon fiber three-dimensional woven fabric can be used to greatly improve the strength of the lightweight core layer 3, thereby improving the overall strength of the board.

[0026] In addition, the thickness of the three-dimensional woven carbon fiber fabric 31 is adapted to the carbon fiber hollow square tube 32 , ensuring that the carbon fiber hollow square tube 32 can fully support the three-dimensional woven carbon fiber fabric 31 , thereby ensuring that sufficient filling material can fill the gaps in the three-dimensional woven carbon fiber fabric 31 .

[0027] As an improvement, the resin matrix in the surface carbon fiber rigid composite layer 1, the internal tough impact-resistant layer 2 and the filling material in the lightweight core layer 3 is the same tough epoxy resin, which is made into prepreg by special equipment. The same tough epoxy resin is used in the curing and molding process of the composite large panel, and the same curing process is adopted to improve the performance of the composite large panel after molding.

[0028] As an improvement, the filling material of the lightweight core layer 3 is composed of epoxy resin and hollow glass microspheres, and the weight ratio of epoxy resin to hollow glass microspheres is 1:1-1:2.

[0029] It should be noted that by adding hollow glass microspheres, the density of the composite material can be significantly reduced to achieve a weight reduction effect. The fluidity of the resin in the three-dimensional woven carbon fiber fabric 31 can also be improved, thereby improving the filling fullness of the epoxy resin in the gaps of the three-dimensional woven carbon fiber fabric 31 and ensuring the strength of the composite panel after molding. At the same time, by adding hollow glass microspheres, the stability of the product size is improved to avoid warping of the product after curing.

[0030] At the same time, the hollow structure of hollow glass microspheres is utilized to further improve the heat insulation, sound insulation and other properties of the composite board.

[0031] As an improvement, the thickness of the carbon fiber composite plate is 15-50 mm, and the thickness of the lightweight core layer 3 is 10-30 mm.

[0032] Embodiment 2 This embodiment provides a method for preparing a lightweight impact-resistant carbon fiber composite large plate, which is used to prepare a lightweight impact-resistant carbon fiber composite large plate as described in Example 1, comprising the following steps: Step 1: First lay the surface epoxy resin carbon fiber cloth prepreg in the mold, and then lay the epoxy resin ultra-high molecular weight polyethylene prepreg; Step 2: The carbon fiber hollow square tube 32 is made into reinforcing ribs according to the required specifications and placed in the three-dimensional woven carbon fiber fabric 31 as the middle core layer skeleton; Step 3, laying epoxy resin ultra-high molecular weight polyethylene prepreg and surface epoxy resin carbon fiber cloth prepreg in sequence on the middle core layer; Step 4: introducing a low-density casting material composed of epoxy resin and hollow glass microspheres into the middle layer by vacuum method; Step 5: After the mold is closed, vacuum is first used to remove internal bubbles, and then the whole is cured by heating and pressurizing to form a lightweight and impact-resistant carbon fiber composite panel.

[0033] It should be noted that the composite material is formed into a whole by adopting the same resin system integrated co-curing process, that is, all the materials in the present invention form a continuum, thereby improving the overall performance of the composite material.

[0034] Preferably, in step five, the heating temperature is 100-120° C., and the curing time is 0.3-1.5 h.

[0035] Preferably, in step five, the pressurization pressure ranges from 1 to 4 MPa.

[0036] Preferably, in step 1 and step 3, the epoxy resin carbon fiber cloth prepreg and the epoxy resin ultra-high molecular weight polyethylene prepreg are both provided with multiple layers.

[0037] Embodiment 3 This embodiment provides a method for preparing a lightweight impact-resistant carbon fiber composite plate, comprising the following steps: 1. Lay 3 layers of 400g / m2 in the mold first. 2 Epoxy carbon fiber cloth prepreg, then lay 2 layers of 200g / m 2 Epoxy resin ultra-high molecular weight polyethylene prepreg; 2. Cut the 20*20mm carbon fiber hollow square tube 32 into the required length and seal it, and place it in the three-dimensional woven carbon fiber fabric 31 of corresponding thickness as the middle core layer skeleton reinforcement; 3. 2 layers of 200g / m 2 Epoxy resin ultra-high molecular weight polyethylene prepreg, then paved 3 layers of 400g / m 2 Epoxy carbon fiber cloth prepreg 4. A low-density casting material consisting of 100 parts of epoxy resin and 130 parts of hollow glass microspheres is introduced into the middle layer by vacuum method; 5 After the mold is closed, vacuum is first used to remove internal bubbles, and then a pressure of 2MPa is applied, and the whole is cured at 115℃*0.5h to form a lightweight carbon fiber composite large board.

[0038] Embodiment 4 This embodiment provides a method for preparing a lightweight impact-resistant carbon fiber composite plate, comprising the following steps: 1. Lay 2 layers of 400g / m2 in the mold first. 2 Epoxy carbon fiber cloth prepreg, then lay 3 layers of 200g / m 2 Epoxy resin ultra-high molecular weight polyethylene prepreg; 2. Cut the 25*25mm carbon fiber hollow square tube 32 into the required length and seal it, and place it in the three-dimensional woven carbon fiber fabric 31 of corresponding thickness as the middle core layer skeleton reinforcement; 3 layers of 200g / m 2 Epoxy resin ultra-high molecular weight polyethylene prepreg, then lay 2 layers of 400g / m 2 Epoxy carbon fiber cloth prepreg 4. Introduce a low-density casting material consisting of 100 parts of epoxy resin and 100 parts of hollow glass microspheres into the middle layer by vacuum method; 5 After the mold is closed, vacuum is first used to remove internal bubbles, and then a pressure of 3MPa is applied, and the whole is cured at 110℃*1h to form a lightweight carbon fiber composite large board.

[0039] Comparative Example This embodiment provides a method for manufacturing a large panel of a shelter, which specifically includes the following steps: The large panel of the square cabin consists of an inner skin, an outer skin, and a foam core layer arranged between the inner skin and the outer skin. The inner and outer skins are made of aluminum, and the foam core layer is foamed polyurethane.

[0040] First, a metal frame is prepared by welding to form a metal frame of the large panel of the shelter, which serves as the internal foam core layer support structure; Secondly, the gaps formed in the metal frame are filled with a polyurethane foam layer, which serves as the foam core layer of the large cabin panels, and the thickness is consistent with the metal frame; Next, evenly apply polyurethane glue on one side of the metal aluminum skin as a bonding agent for the inner and outer skins and the foam core layer; Finally, the foam core layer with the metal frame and the skin coated with adhesive are bonded together, and pressure is applied to bond the skin and the core layer into one to form a large cabin panel.

[0041] Carbon fiber composite panel test results: see Table 1.

[0042]

[0043] Embodiment 5 The present embodiment provides a use of a lightweight, impact-resistant carbon fiber composite large panel. The lightweight, impact-resistant carbon fiber composite large panel described in the above embodiment is used to make special cabin panels, refrigerated truck panels or RV panels. Of course, it is not limited to the above application scenarios. The composite large panels recorded in this application can be used in some application scenarios that need to meet special working conditions such as lightweight and impact resistance.

[0044] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A lightweight impact-resistant carbon fiber composite large plate, characterized in that: It comprises a surface carbon fiber rigid composite layer (1), an internal toughness impact-resistant layer (2) and a lightweight core layer (3) which are arranged in sequence from the outside to the inside; The surface carbon fiber rigid composite layer (1) is made of epoxy resin carbon fiber cloth prepreg; The inner tough impact-resistant layer (2) is made of epoxy resin ultra-high molecular weight polyethylene prepreg; The lightweight core layer (3) is composed of a three-dimensional woven carbon fiber fabric (31) as a skeleton, a plurality of reinforcing ribs made of carbon fiber hollow square tubes (32) are distributed in the three-dimensional woven carbon fiber fabric (31), and a filling material is added in the gaps of the three-dimensional woven carbon fiber fabric (31).

2. The lightweight impact-resistant carbon fiber composite board according to claim 1, characterized in that: The resin matrix in the filling material in the surface carbon fiber rigid composite layer (1), the internal tough impact-resistant layer (2) and the lightweight core layer (3) is the same tough epoxy resin.

3. The lightweight impact-resistant carbon fiber composite board according to claim 1, characterized in that: The filling material of the lightweight core layer (3) is composed of epoxy resin and hollow glass microspheres, and the weight ratio of epoxy resin to hollow glass microspheres is 1:1-1:

2.

4. The lightweight impact-resistant carbon fiber composite board according to claim 1, characterized in that: The thickness of the carbon fiber composite plate is 15-50 mm, and the thickness of the lightweight core layer (3) is 10-30 mm.

5. A method for preparing a lightweight impact-resistant carbon fiber composite large plate, used for preparing a lightweight impact-resistant carbon fiber composite large plate as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: Step 1: First lay the surface epoxy resin carbon fiber cloth prepreg in the mold, and then lay the epoxy resin ultra-high molecular weight polyethylene prepreg; Step 2: The carbon fiber hollow square tube (32) is made into reinforcing ribs according to the required specifications and placed in the three-dimensional woven carbon fiber fabric (31) as the middle core layer skeleton; Step 3, laying epoxy resin ultra-high molecular weight polyethylene prepreg and surface epoxy resin carbon fiber cloth prepreg in sequence on the middle core layer; Step 4: introducing a low-density casting material composed of epoxy resin and hollow glass microspheres into the middle layer by vacuum method; Step 5: After the mold is closed, vacuum is first used to remove internal bubbles, and then the whole is cured by heating and pressurizing to form a lightweight and impact-resistant carbon fiber composite panel.

6. A lightweight impact-resistant carbon fiber composite large board and its preparation method and use according to claim 5, characterized in that: In the step 5, the heating temperature is 100-120° C. and the curing time is 0.3-1.5 h.

7. The lightweight impact-resistant carbon fiber composite large board and its preparation method and use according to claim 5, characterized in that: In the step 5, the pressurization pressure ranges from 1 to 4 MPa.

8. The lightweight impact-resistant carbon fiber composite large board and its preparation method and use according to claim 5, characterized in that: In the step 1 and the step 3, the epoxy resin carbon fiber cloth prepreg and the epoxy resin ultra-high molecular weight polyethylene prepreg are both provided with multiple layers.

9. A use of a lightweight impact-resistant carbon fiber composite large plate, characterized in that: The lightweight impact-resistant carbon fiber composite large board described in any one of claims 1 to 4 is used to make special cabin boards, refrigerated truck boards or RV boards.

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