Carbon fiber composite material and method for manufacturing the same

Abstract

The present application relates to a kind of carbon fiber composite material and its preparation method, carbon fiber composite material includes the metal energy-absorbing layer, thermosetting resin layer, carbon fiber layer, thermoplastic resin layer arranged in turn, the raw material of metal energy-absorbing layer includes foamed metal, carbon fiber and foaming resin, the raw material of thermosetting resin layer includes thermosetting resin, curing agent and elastomer, the raw material of carbon fiber layer includes carbon fiber, the raw material of thermoplastic resin layer includes thermoplastic resin.The carbon fiber composite material provided by the present application, by the way of metal energy-absorbing layer, thermosetting resin layer, carbon fiber layer, thermoplastic resin layer layer layer toughening, effectively improve the energy-absorbing performance of carbon fiber composite material, effectively support carbon fiber, give carbon fiber cushioning effect, prevent the damage caused by ultra-high strength impact, prolong the service life of material;Carbon fiber composite material is used in energy-absorbing noise reduction field, carbon fiber composite material has better impact resistance and tensile strength, preparation process is pollution-free, it is convenient for large-scale production.

Description

Technical Field

[0001] This invention belongs to the field of carbon fiber composite material preparation, specifically relating to a carbon fiber composite material and its preparation method. Background Technology

[0002] With the continuous evolution of technology and changes in market demand, energy-absorbing materials will continue to move towards higher performance, greater intelligence, and greater eco-friendliness. The superior performance of these materials is particularly crucial in fields such as aerospace, automobiles, sports equipment, and civil buildings, where they provide shock absorption, impact protection, and noise absorption. In order to meet the needs of the rapid development of my country's energy absorption and noise reduction field, it is urgent to develop high-performance energy-absorbing and earthquake-resistant materials to serve social development.

[0003] Carbon fiber materials have wide applications in energy absorption and noise reduction, spanning numerous fields including aerospace, automotive, sporting goods, and civil construction. Carbon fiber possesses characteristics such as lightweight, high specific strength, high specific modulus, high temperature resistance, corrosion resistance, and fatigue resistance, giving it superior energy absorption properties under dynamic loads. Despite its excellent strength and stiffness, carbon fiber-reinforced composites can exhibit brittleness in certain situations, potentially fracturing or cracking under impact or severe deformation. Combining porous materials with carbon fiber materials can improve the toughness of the carbon fiber, altering its brittleness and compensating for the shortcomings of the base material.

[0004] For example, patent CN113276523B discloses a PBO fiber / aramid fiber reinforced composite material and its preparation method. The face of the composite material is a PBO fiber reinforced thermosetting resin composite material, and the back plate is an aramid fiber reinforced thermoplastic resin composite material. It relies on the properties of aramid itself to absorb energy, which can lead to material fatigue or damage, resulting in a decline in the performance of the material in various aspects. Summary of the Invention

[0005] The purpose of this invention is to provide an improved carbon fiber composite material with excellent impact resistance, high strength, and long service life.

[0006] The present invention also provides a method for preparing the above-mentioned carbon fiber composite material, which has a simple preparation process.

[0007] To achieve the above objectives, the present invention employs the following technical solution:

[0008] A carbon fiber composite material includes a metal energy-absorbing layer, a thermosetting resin layer, a carbon fiber layer, and a thermoplastic resin layer arranged sequentially. The raw materials of the metal energy-absorbing layer include foamed metal, carbon fiber, and foamed resin. The raw materials of the thermosetting resin layer include thermosetting resin, curing agent, and elastomer. The raw materials of the carbon fiber layer include carbon fiber. The raw materials of the thermoplastic resin layer include thermoplastic resin.

[0009] In some preferred embodiments of the present invention, the foamed metal is selected from one or more combinations of foamed aluminum, foamed copper, foamed nickel, foamed aluminum, and foamed magnesium. Compared with general sintered porous metals, foamed metal has a higher porosity. The foamed metal refers to a metallic material containing foam-like pores. Since foamed metal is a two-phase composite material composed of a continuous phase of a metal matrix framework and a dispersed or continuous phase of pores, its properties depend on the metal matrix used, the porosity, and the pore structure, and are also affected by the preparation process.

[0010] According to some specific aspects of the present invention, the foamed metal is preferably foamed aluminum, which can satisfy excellent mechanical properties and energy absorption effect as well as compatibility with foaming resin.

[0011] According to some specific aspects of the present invention, the porosity of the foamed metal is 30-80%, wherein the porosity refers to the percentage of pore volume in a bulk material to the total volume of the material in its natural state, and the porosity is tested according to the GB / T10799-2008 standard.

[0012] According to some specific aspects of the present invention, the porosity of the foam metal is preferably 40-80%. The mechanical properties of the foam metal decrease with the increase of porosity. When it is subjected to pressure, the foam metal has excellent impact energy absorption characteristics due to the increase of the stress area caused by the collapse of the pores and the strain hardening effect of the material.

[0013] According to some specific aspects of the present invention, the average pore size of the foam metal is 1-10 mm, and the average pore size is the cross-sectional diameter of the pores in the foam metal layer, which is obtained by scanning electron microscopy of the cross-section.

[0014] According to some specific aspects of the present invention, the average pore size of the foam metal is preferably 1-5 mm, which allows the material filled into the foam metal layer to be mixed uniformly.

[0015] According to certain aspects of the present invention, the bulk density of the foamed metal is 0.1-1.5 g / cm³. 3 Bulk density refers to the mass of a material per unit volume (including the material itself and its open and closed pores) in its natural state. It is commonly known as bulk density. The more pores per unit volume, the lower the bulk density.

[0016] According to certain aspects of the present invention, the bulk density of the foamed metal is preferably 0.5-1.0 g / cm³. 3 The material is lighter.

[0017] According to some specific aspects of the present invention, the thickness of the foam metal is 1-50 mm, and the thickness is measured by a thickness gauge. The average value of the thickness at 9 different locations on the foam metal layer is taken as the thickness of the foam metal layer.

[0018] According to some specific aspects of the present invention, the thickness of the foamed metal is preferably 1-30 mm, and the composite material has better impact resistance and lightweight properties.

[0019] According to certain aspects of the present invention, the tensile strength of the foamed metal is 1-15 MPa. The tensile strength is tested according to GB / T 1040.1-2018.

[0020] According to some specific aspects of the present invention, the tensile strength of the foamed metal is preferably 5-12 MPa, and the tensile strength of the composite material is even better.

[0021] In some preferred embodiments of the present invention, the carbon fiber raw material of the metal energy-absorbing layer is powder, and the average fiber length of the carbon fiber in the metal energy-absorbing layer is 0.1-5 mm. Carbon fiber powder is obtained by surface treatment, grinding, microscopic identification, screening, and high-temperature drying of high-strength, high-modulus carbon fiber filaments using special techniques. It retains many excellent properties of carbon fiber, and its small size and clean surface make it easy to be wetted and uniformly dispersed by resin, making it a high-performance composite filler. Fiber length refers to the distance between the two ends of a fiber when it is straightened without external force. Generally, under the same fiber volume fraction and fiber length distribution, the larger the fiber length, the higher the mechanical properties of the composite material, such as elastic modulus, strength, and fracture toughness.

[0022] According to some specific aspects of the present invention, the average fiber length of the carbon fiber in the metal energy-absorbing layer is preferably 0.5-3.5 mm, and it exhibits good mixing uniformity and mechanical properties.

[0023] In some preferred embodiments of the present invention, the foaming resin is a combination selected from one or more of polystyrene, polyurethane, polyvinyl chloride, and polyethylene. The foaming resin is a material that has been processed to produce a microporous structure, which endows the material with properties such as lightweight, heat insulation, sound absorption, and shock absorption.

[0024] According to some specific aspects of the present invention, the foaming resin is preferably polyurethane, which has good stability and energy absorption properties.

[0025] In some preferred embodiments of the present invention, the raw material of the thermosetting resin layer includes a thermosetting resin, which has a large number of polar groups and is used to bond the metal energy-absorbing layer and the carbon fiber layer. The thermosetting resin is selected from one or more combinations of thermosetting epoxy resin, thermosetting unsaturated polyester resin, thermosetting polyurethane resin, thermosetting phenolic resin, thermosetting urea-formaldehyde resin, thermosetting silicone resin, and thermosetting melamine-formaldehyde resin.

[0026] According to some specific aspects of the present invention, the thermosetting resin is selected from one or more combinations of thermosetting epoxy resin and thermosetting unsaturated polyester resin, which can ensure the excellent strength of the composite material.

[0027] According to some specific aspects of the present invention, the thermosetting epoxy resin is selected from one or more combinations of bisphenol A type epoxy resin, bisphenol A type epoxy resin, bisphenol F type epoxy resin, polyphenol type glycidyl ether epoxy resin, aliphatic glycidyl ether epoxy resin, glycidyl ester type epoxy resin, glycidyl amine type epoxy resin, epoxidized olefin compound, heterocyclic epoxy resin, and mixed type epoxy resin.

[0028] According to some specific aspects of the present invention, the thermosetting unsaturated polyester resin is selected from one or more combinations of bisphenol A type vinyl unsaturated polyester, isophthalic acid type vinyl unsaturated resin, and styrene / butadiene copolyunsaturated polyester.

[0029] According to certain aspects of the present invention, the thermosetting resin is preferably a combination of one or more of bisphenol A type epoxy resin and isophthalic acid type vinyl unsaturated resin. This is beneficial to the adhesion between the thermosetting resin layer and the metal energy-absorbing layer, as well as the mechanical strength and service life of the prepared composite material.

[0030] In some preferred embodiments of the present invention, the curing agent is a polyamide curing agent, and the content of the polyamide curing agent is 5-15 parts by weight relative to 100 parts by weight of the thermosetting resin.

[0031] According to some specific aspects of the present invention, the polyamide curing agent is present in a content of 5-10 parts by weight, which ensures sufficient curing and reduces the preparation time of the composite material.

[0032] According to some specific aspects of the present invention, the elastomer comprises a polyamide elastomer, wherein the content of the polyamide elastomer is 5-15 parts by weight relative to 100 parts by weight of the thermosetting resin, such that the thermosetting resin layer has better toughness.

[0033] According to some specific aspects of the present invention, the polyamide elastomer is one or more selected from polyether block amide elastomer (PEBA), polyether ester amide (PEEA) elastomer and polyester amide (PEA) block copolymer elastomer.

[0034] According to some specific aspects of the present invention, the content of the polyether ester type polyamide elastomer (PEEA) is preferably 5-10 parts by weight, which has good toughening effect and low cost.

[0035] In some preferred embodiments of the present invention, the carbon fiber of the carbon fiber layer is selected from one or more of carbon fiber paper, carbon fiber cloth, carbon fiber felt, and carbon fiber woven fabric.

[0036] According to some specific aspects of the present invention, the carbon fibers of the carbon fiber layer are preferably carbon fiber braided fabrics, which have good bonding strength with the thermosetting resin layer and the thermoplastic resin layer.

[0037] According to some specific aspects of the present invention, the thickness of the carbon fiber layer is 0.1-1.5 mm. The thickness is measured by a thickness gauge, and the average value is taken after measuring the thickness at 9 different locations on the carbon fiber layer.

[0038] According to some specific aspects of the present invention, the tensile strength of the carbon fiber layer is greater than 3500 MPa, and the tensile strength is tested according to GB / T 1040.1-2018. The thicker the material, the stronger its tensile strength.

[0039] According to some specific aspects of the present invention, the thickness of the carbon fiber layer is preferably 0.1-1.0 mm, and its tensile strength is greater than 4000 MPa, which meets the strength requirements while being low in cost.

[0040] In some preferred embodiments of the present invention, the thermoplastic resin is selected from one or more combinations of polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamide, polyoxymethylene, polycarbonate, polyphenylene ether, polysulfone, rubber, and polyester.

[0041] According to some specific aspects of the present invention, the thermoplastic resin is preferably a polyamide resin, which has good adhesion to the carbon fiber layer.

[0042] According to some specific aspects of the present invention, the polyamide resin is a polymeric material containing repeating amide groups (-CO-NH-) structural units, and the polyamide resin is selected from aliphatic polyamides, semi-aromatic polyamides, and aromatic polyamides.

[0043] According to some specific aspects of the present invention, the aliphatic polyamide is selected from one or more combinations of poly(hexamethylene adipamide), poly(hexamethylene adipamide), poly(hexamethylene sebacate), poly(hexamethylene dodecyl diamide), and poly(hexamethylene sebacate).

[0044] According to some specific aspects of the present invention, the semi-aromatic polyamide is selected from one or more combinations of poly(terephthalamide butylene diamine), poly(furan dibutylene diamine), poly(terephthalamide pentanediamine), poly(furan dipentanediamine), poly(terephthalamide hexamethylenediamine), poly(furan dipentanediamine), poly(terephthalamide nonadiamine), poly(furan dipentanediamine), poly(terephthalamide decanediamine), poly(furan dipentanediamine), poly(terephthalamide hexamethylenediamine decanediamine), poly(terephthalamide furandicarboxylate decanediamine), poly(terephthalamide furandicarboxylate decanediamine), poly(terephthalamide furandicarboxylate pentanediamine), and poly(terephthalamide furandicarboxylate decanediamine).

[0045] According to some specific aspects of the present invention, the aromatic polyamide is selected from one or more combinations of poly(p-phenylene terephthalamide), poly(p-phenylene furanyl dimethyl terephthalamide), and poly(p-phenylene furanyl dimethyl terephthalamide).

[0046] According to certain aspects of the present invention, the polyamide is preferably a semi-aromatic polyamide. More preferably, it is a combination of one or more of poly(decanediamine terephthalamide) and poly(hexamethylene adipamide terephthalamide), which exhibit temperature resistance and low water absorption to maintain the composite material's long service life.

[0047] Another technical solution provided by this invention:

[0048] A method for preparing the above-mentioned carbon fiber composite material, the method comprising:

[0049] (1) Prepare a metal energy-absorbing layer, a thermosetting resin layer, and a thermoplastic resin layer respectively, wherein,

[0050] In preparing the metal energy-absorbing layer: foam metal and carbon fiber are mixed and placed in molten foaming resin, and then foamed to obtain the metal energy-absorbing layer;

[0051] In preparing the thermosetting resin layer: the thermosetting resin, curing agent, and elastomer are mixed and hot-pressed into the thermosetting resin layer.

[0052] (2) The metal energy-absorbing layer, thermosetting resin layer, carbon fiber layer and thermoplastic resin layer are sequentially arranged and then hot-pressed and cured to prepare the carbon fiber composite material.

[0053] According to some specific aspects of the present invention, in step (1), when preparing the metal energy-absorbing layer: the foam metal is placed in the carbon fiber powder and then placed in an ultrasonic vibrator to be fully vibrated with ultrasound; at the same time, the foaming resin is melted at 150-250°C; then the mixture of foam metal and carbon fiber powder is placed in the molten foaming resin, and finally foaming is carried out using supercritical fluid to obtain the metal energy-absorbing layer.

[0054] According to some specific aspects of the present invention, the foaming parameters are as follows: first soaking in supercritical CO2 at 100-250°C and 10-20 MPa for 1-3 hours, and then foaming under steam at 100°C.

[0055] According to some specific aspects of the present invention, in step (1), when preparing the thermosetting resin layer, the thermosetting resin, curing agent and elastomer are mixed in a high-speed ball mill for 1-3 hours, and then hot-pressed at 30-60°C and 0.5-2MPa for 10-30 minutes to obtain the thermosetting resin layer.

[0056] According to some specific aspects of the present invention, a carbon fiber composite material is obtained by vacuum hot pressing and curing the prepared metal energy-absorbing layer, thermosetting resin layer, carbon fiber layer, and thermoplastic resin layer.

[0057] In some preferred and specific aspects of the present invention, in step (2), the thermoplastic resin layer is first heated to 200-250°C, and then the carbon fiber layer is attached to the thermoplastic resin layer. Subsequently, it is hot-pressed at 200-250°C and 0.5-2.0 MPa for 5-15 minutes. Then, a thermosetting resin layer and a metal energy-absorbing layer are sequentially composited on the carbon fiber layer. Finally, it is hot-pressed at 100-150°C and 3-10 MPa for 30-60 minutes. After cooling, the carbon fiber composite material is obtained.

[0058] Due to the application of the above-mentioned technical solution, the present invention has the following advantages compared with the prior art:

[0059] 1. Combining foamed metal with foamed resin results in well-developed pores, which synergistically enhances the seismic performance of carbon fiber composite materials.

[0060] 2. By using the interlayer toughening method of metal energy-absorbing layer, thermosetting resin layer, carbon fiber layer and thermoplastic resin layer, the energy absorption performance of carbon fiber composite material is effectively improved, the carbon fiber is effectively supported, the carbon fiber is given a shock-absorbing effect, the damage caused by ultra-high strength impact is prevented, and the service life of the material is extended.

[0061] 3. Foamed metal, foamed resin, and carbon fiber are lightweight materials, and the carbon fiber composite material prepared is lightweight and has high strength.

[0062] 4. Carbon fiber composites are used in the field of energy absorption and noise reduction. Carbon fiber composites have good impact resistance and tensile strength, and the preparation process is pollution-free, making it easy to mass-produce. Detailed Implementation

[0063] The present invention will be further described below with reference to the embodiments shown.

[0064] The raw materials used in Examples 1-11 and Comparative Examples 1-7 are as follows.

[0065]

Foam Metal

[0066] A1: Aluminum foam, TMAX-Aluminum foam-02 produced by Xiamen Tianmeifu Machinery Equipment Co., Ltd., with a porosity of 68-78%, an average pore size of 1.6mm, and a bulk density of 0.60-0.85g / cm³. 3 It has a thickness of 5-6mm and a tensile strength of 8MPa.

[0067] A2: Foamed aluminum, produced by Shanghai Yinfu Hardware Products Co., Ltd., with a porosity of 60-70%, an average pore size of 3mm, and a bulk density of 0.4-0.5g / cm³. 3 It has a thickness of 5-6mm and a tensile strength of 4MPa.

[0068] Carbon fiber with a metallic energy-absorbing layer

[0069] B1: Carbon fiber powder, T700 short-cut carbon fiber produced by Toray Industries, Inc. of Japan, with a fiber length of 2mm.

[0070] B2: Carbon fiber powder, MLD-300 carbon fiber powder produced by Toray Industries, Inc. of Japan, with a fiber length of 130μm.

[0071] Foaming resin

[0072] C1: Polyethylene, LD100AC polyethylene produced by Sinopec Shanghai Petrochemical Co., Ltd.

[0073] C2: Polyurethane, GMB FP3039D6 polyether polyurethane.

[0074] The metal energy-absorbing layer (M1) was prepared according to the formulation described in Table 1. Foamed metal was placed in carbon fiber powder and subjected to full vibration and ultrasonication to obtain a mixture of foamed metal and carbon fiber. Then, the foaming resin was heated to 130°C, and the mixture of foamed metal and carbon fiber was placed in the molten foaming resin. It was then immersed in supercritical CO2 at 130°C and 15MPa for 2 hours, and then foamed under steam at 100°C. After cooling, the metal energy-absorbing layer was obtained.

[0075] The metal energy-absorbing layer (M2-M4) is prepared according to the formulation described in Table 1. Foamed metal is placed in carbon fiber powder and subjected to full vibration and ultrasonication to obtain a mixture of foamed metal and carbon fiber. Then, the foaming resin is heated to 200°C, and the mixture of foamed metal and carbon fiber is placed in the molten foaming resin. The mixture is then immersed in supercritical CO2 at 200°C and 15MPa for 2 hours, and then foamed under steam at 180°C. After cooling, the metal energy-absorbing layer is obtained.

[0076] The metal energy-absorbing layer (M6) is prepared according to the formulation described in Table 1. The foamed metal is placed in the molten foaming resin, soaked in supercritical CO2 at 200°C and 15MPa for 2 hours, and then foamed under steam at 180°C. After cooling, the metal energy-absorbing layer is obtained.

[0077] The metal energy-absorbing layer (M7) is prepared according to the formulation described in Table 1. Foamed metal is placed in carbon fiber powder and subjected to full vibration and ultrasonication to obtain a mixture of foamed metal and carbon fiber. Then, the foaming resin is heated to 200°C, and the mixture of foamed metal and carbon fiber is placed into the molten foaming resin. After cooling, the metal energy-absorbing layer is obtained.

[0078] Table 1 Formulation of Metal Energy Absorbing Layer

[0079] M1 A1 B1 C1 M2 A2 B1 C1 M3 A2 B2 C1 M4 A2 B1 C2 M5 A2 - - M6 A2 - C1 M7 A2 B1 C1 (C1 unfoamed)

[0080] Thermosetting resins

[0081] D1: Thermosetting epoxy resin, EPICLON3050 bisphenol A type epoxy resin manufactured by Dai Nippon Ink Co., Ltd.

[0082] D2: Thermosetting unsaturated polyester resin, TZ-470 isophthalic acid type vinyl unsaturated resin produced by Jinan Changhua Resin Chemical Co., Ltd.

[0083]

Curing agent

[0084] E: Polyamide curing agent, H300 polyamide curing agent produced by Wuxi Pinhua Chemical Co., Ltd.

[0085] Elastomers

[0086] F: Polyamide elastomer, Arkema PEBAX 7233SP01 polyether ester type polyamide elastomer.

[0087] Thermosetting resin layers (N1-N6) are prepared by weighing thermosetting resin, polyamide curing agent, and polyamide elastomer according to the formula shown in Table 2. The thermosetting resin, polyamide curing agent, and polyamide elastomer are then mixed using a high-speed ball mill for 0.5-1.5 hours. Subsequently, the mixture is hot-pressed at 30-60℃ and 0.5-2MPa for 10-30 minutes to obtain the thermosetting resin layers.

[0088] Table 2 Formulations of thermosetting resin layers (N1-N6)

[0089]

[0090]

[0091]

Carbon fiber layer

[0092] G1: Carbon fiber woven fabric, Mitsubishi Chemical TRK510 M carbon fiber woven fabric, with a thickness of 0.57mm and a tensile strength of 4500MPa.

[0093] G2: Carbon fiber woven fabric, Mitsubishi Chemical TR3110 M carbon fiber woven fabric, with a thickness of 0.23mm and a tensile strength of 3800MPa.

[0094] Thermoplastic resin

[0095] H1: Poly(decaphthalamide) terephthalamide, produced by Kingfa Science & Technology. 62G30HST2 Poly(terephthalamide) decanediamine.

[0096] H2: Poly(hexamethylene adipamide terephthalamide decanediamine), produced by Kingfa Science & Technology. 42G30HS Poly(hexamethylene adipate) terephthalamide decanediamine.

[0097] The formulations of Examples 1-11 and Comparative Examples 1-7 are shown in Table 3 below.

[0098] Table 3 Formulations of carbon fiber composite materials in Examples 1-11 and Comparative Examples 1-7

[0099]

[0100]

[0101] Examples 1-11 and Comparative Examples 5-7: According to the formulations described in Table 3, the thermoplastic resin layer was heated to 200°C in a mold.

[0102] At 250℃, the carbon fiber layer is then attached to the thermoplastic resin layer and hot-pressed at 200-250℃ and 0.5-2.0MPa for 5-15 minutes. Subsequently, a thermosetting resin layer and a metal energy-absorbing layer are sequentially laminated onto the carbon fiber layer, and then hot-pressed at 100-150℃ and 3-10MPa for 30-60 minutes. After cooling, a carbon fiber composite material with a thickness of 10±0.5mm is obtained.

[0103] Comparative Example 1: Following the formulation described in Table 3, the thermoplastic resin layer was heated to 200-250°C in a mold, and then the carbon fiber layer was attached to the thermoplastic resin layer. The mixture was then hot-pressed at 200-250°C and 0.5-2.0 MPa for 5-15 minutes. A thermosetting resin layer was then laminated onto the carbon fiber layer, and the mixture was hot-pressed again at 100-150°C and 3-10 MPa for 30-60 minutes. After cooling, a carbon fiber composite material with a thickness of 5±0.5 mm was obtained.

[0104] Comparative Example 2: Following the formulation in Table 3, the thermoplastic resin layer was heated to 200-250℃ in a mold, and then the carbon fiber layer was attached to the thermoplastic resin layer. The mixture was then hot-pressed at 200-250℃ and 0.5-2.0MPa for 5-15 minutes. A metal energy-absorbing layer was then composited onto the carbon fiber layer. The mixture was then hot-pressed at the same temperature for 30-60 minutes at a pressure of 3-10MPa. After cooling, a carbon fiber composite material with a thickness of 10±0.5mm was obtained.

[0105] Comparative Example 3: According to the formulation in Table 3, the thermoplastic resin layer was heated to 200-250℃ in a mold, and then the thermosetting resin layer was attached to the thermoplastic resin layer. The mixture was hot-pressed at 200-250℃ and 0.5-2.0MPa for 5-15 minutes. A composite metal energy-absorbing layer was then applied to the thermosetting resin layer, and the mixture was hot-pressed at 100-150℃ and 3-10MPa for 30-60 minutes. After cooling, a carbon fiber composite material with a thickness of 10±0.5mm was obtained.

[0106] Comparative Example 4 was prepared according to the formulation in Table 3, with carbon fiber layer, thermosetting resin layer and metal energy-absorbing layer compounded in sequence, and hot-pressed at 100-150℃ for 30-60 min at a pressure of 3-10 MPa. After cooling, a carbon fiber composite material with a thickness of 10±0.5 mm was obtained.

[0107] Performance testing

[0108] The carbon fiber composites of Examples 1-11 and Comparative Examples 1-7 were subjected to the following tests. Unless otherwise specified, all tests were conducted at 25°C. The main indicators are as follows:

[0109] 1. Breaking Impact Strength: Tested according to ASTM D7136-2007. An Instron 9350 fully automatic drop hammer impact testing machine was used. The total mass of the drop hammer was 1 ± 0.05 kg, and the diameter of the impact head was 3 ± 0.1 mm. Each group of specimens was tested starting with a kinetic energy of 100 J, with increments of 10 J, until the specimen broke to obtain the breaking impact strength.

[0110] 2. Tensile strength: Tested according to GB / T 1040.1-2018, the specimen is stretched at a rate of 5 mm / min, and the specimen size is 100 mm × 10 mm.

[0111] 3. Interlaminar shear failure stress: Tested according to the test method of GB / T28889-2012, with the specimen stretched at a rate of 5 mm / min.

[0112] Table 4 Performance test data of carbon fiber composite materials in Examples 1-11 and Comparative Examples 1-7

[0113]

[0114] As shown in Table 4, compared with Comparative Examples 1-2 and 5-7, the carbon fiber composite material of Example 1 exhibits superior breaking impact strength, tensile strength, and interlaminar shear stress. Compared with Comparative Examples 3-4, the carbon fiber composite material of Example 1 exhibits superior breaking impact strength, tensile strength, and interlaminar shear stress.

[0115] In summary, compared with the composite materials of Examples 1-11 and Comparative Examples 1-7, the composite materials prepared in Examples 1-11 have better impact resistance and tensile strength; the composite materials prepared in Examples 1-11 have superior performance and the preparation process is pollution-free, making it easy for large-scale production.

[0116] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A carbon fiber composite material, characterized in that, It includes a metal energy-absorbing layer, a thermosetting resin layer, a carbon fiber layer, and a thermoplastic resin layer arranged sequentially. The raw materials of the metal energy-absorbing layer include foamed metal, carbon fiber, and foaming resin. The raw materials of the thermosetting resin layer include thermosetting resin, curing agent, and elastomer. The raw materials of the carbon fiber layer include carbon fiber. The raw materials of the thermoplastic resin layer include thermoplastic resin. In preparing the metal energy-absorbing layer: foam metal and carbon fiber are mixed and then added to molten foaming resin, and then foamed to obtain the metal energy-absorbing layer; The carbon fiber raw material of the metal energy-absorbing layer is powder, and the average fiber length of the carbon fiber in the metal energy-absorbing layer is 0.1-5mm; The elastomer includes a polyamide elastomer, wherein the content of the polyamide elastomer is 5-15 parts by weight relative to 100 parts by weight of the thermosetting resin; the curing agent includes a polyamide curing agent, and the content of the polyamide curing agent is 5-15 parts by weight relative to 100 parts by weight of the thermosetting resin.

2. The carbon fiber composite material according to claim 1, characterized in that, The foamed metal is selected from one or more of foamed aluminum, foamed copper, foamed nickel, and foamed magnesium.

3. The carbon fiber composite material according to claim 1, characterized in that, The porosity of the foamed metal is 30-80%; and / or the bulk density of the foamed metal is 0.1-1.5 g / cm³. 3 The thickness of the foamed metal is 1-50 mm; and the tensile strength of the foamed metal is 1-15 MPa.

4. The carbon fiber composite material according to claim 1, characterized in that, The foaming resin is selected from one or more of polystyrene, polyurethane, polyvinyl chloride, and polyethylene.

5. The carbon fiber composite material according to claim 1, characterized in that, The thermosetting resin is selected from one or more of thermosetting polyurethane resin, thermosetting phenolic resin, thermosetting urea-formaldehyde resin, thermosetting silicone resin, and thermosetting melamine-formaldehyde resin.

6. The carbon fiber composite material according to claim 1, characterized in that, The thermoplastic resin is selected from one or more of polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamide, polyoxymethylene, polycarbonate, polyphenylene ether, polysulfone, rubber, and polyester.

7. The carbon fiber composite material according to claim 1, characterized in that, The carbon fiber in the carbon fiber layer is selected from one or more of carbon fiber paper, carbon fiber cloth, carbon fiber felt, and carbon fiber woven fabric; the thickness of the carbon fiber layer is 0.1-1.5mm, and its tensile strength is greater than 3500MPa.

8. A method for preparing a carbon fiber composite material according to any one of claims 1 to 7, characterized in that, The preparation method includes: (1) Prepare a metal energy-absorbing layer, a thermosetting resin layer, a thermoplastic resin layer, and a carbon fiber layer respectively. When preparing the metal energy-absorbing layer, the foam metal and carbon fiber are mixed and then added to the molten foaming resin, and then foamed to obtain the metal energy-absorbing layer. When preparing the thermosetting resin layer, the thermosetting resin, curing agent, and elastomer are mixed and hot-pressed to form the thermosetting resin layer. (2) The metal energy-absorbing layer, thermosetting resin layer, carbon fiber layer and thermoplastic resin layer are sequentially arranged and then hot-pressed and cured to prepare the carbon fiber composite material.

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