Gas-assisted molding polyamide composite material and preparation method thereof

Abstract

The invention discloses a gas-assisted molding polyamide composite material and a preparation method thereof, and the gas-assisted molding polyamide composite material comprises 50-90 parts of polyamide resin, 5-30 parts of carbon fiber, 5-30 parts of various fibers, 10-30 parts of mineral filler, 5-50 parts of metal filler and 5-30 parts of other filler, the various fibers can be glass fibers, aramid fibers, polyester fibers or polypropylene fibers, the mineral filler can be calcium carbonate or talcum powder, the filler is subjected to organic treatment in advance, and the polyamide resin, the carbon fibers, the various fibers, the mineral filler, the metal filler and other fillers are matched with the auxiliaries, so that the composite material is obtained. A proper amount of plasticizer, lubricant or flow promoter can be added to reduce the viscosity of the material and improve the fluidity of the material.

Description

Technical Field

[0001] The invention relates to the technical field of polyamide composite materials, in particular to a polyamide composite material capable of being gas-assisted molded and a preparation method thereof. Background Art

[0002] Polyamide composites are high-performance materials made of polyamide resin (nylon) combined with various reinforcing materials, fillers and other additives. This composite material combines the excellent properties of polyamide resin with the strengthening effect of reinforcing materials, making polyamide composites widely used in many fields.

[0003] However, during the production process, the problem of poor fluidity has always troubled manufacturers. Poor fluidity not only affects the injection molding performance of polyamide composite materials, making it difficult for parts to achieve the expected shape and dimensional accuracy, but also leads to a decrease in the appearance quality and glossiness of the parts. During the injection molding process, poor material flow may cause defects such as ripples and bubbles on the surface of the product, seriously affecting the appearance and performance of the product.

[0004] In addition, polyamide composite materials will also generate residual stress during the injection molding process. The existence of residual stress makes the parts prone to deformation during the cooling process, resulting in dimensional instability. This deformation may manifest as shape defects such as warping and twisting of the parts, and may even cause cracks inside the products. This not only reduces the service life of the parts, but also may cause safety hazards.

[0005] To this end, we propose a gas-assisted moldable polyamide composite material and a preparation method thereof to solve the above problems. Summary of the invention

[0006] One of the purposes of the present invention is to provide a polyamide composite material that can be gas-assisted molded to solve the problem of poor fluidity of the polyamide composite material.

[0007] The second object of the present invention is to provide a method for preparing a polyamide composite material capable of gas-assisted molding to solve the problem of residual stress in the polyamide composite material:

[0008] To achieve one of the above purposes, the embodiment of the present application adopts the following technical solution: a gas-assisted moldable polyamide composite material, including polyamide resin 50-90, carbon fiber 5-30, multiple fibers 5-30, mineral filler 10-30, metal filler 5-50 and other fillers 5-30.

[0009] In the above technical scheme, the embodiment of the present application can add an appropriate amount of plasticizer, lubricant or flow aid to reduce the viscosity of the material and improve its fluidity by pre-organic treatment of the filler and coordination between polyamide resin, carbon fiber, various fibers, mineral filler, metal filler and other fillers and additives.

[0010] In a further embodiment, the polyamide resin is PA6 or PA66.

[0011] In further embodiments, the plurality of fibers may be glass fibers, aramid fibers, polyester fibers, or polypropylene fibers.

[0012] In further embodiments, the mineral filler may be calcium carbonate or talc.

[0013] In a further embodiment, the metal filler may be aluminum powder or copper powder.

[0014] To achieve the second objective, the present application adopts the following technical solution: A method for preparing a polyamide composite material capable of gas-assisted molding, comprising: a preparation stage: preparing a gas-assisted molding machine, material particles, molds and other necessary equipment and materials. At the same time, checking whether the equipment is operating normally and whether the mold is installed correctly.

[0015] Heating and plasticizing: Add the material particles into the hopper of the gas-assisted molding machine, and through the rotation and heating of the screw, the plastic particles are melted into a flowable plastic melt.

[0016] Injection stage: After the molten plastic reaches the appropriate temperature and pressure, the melt is injected into the mold. During the injection process, part of the plastic melt flows into the preset gas channel.

[0017] Gas injection: After the plastic melt fills the mold part, the gas-assisted molding machine injects compressed gas into the mold through the gas channel.

[0018] Cooling and solidification: After the plastic melt and gas are injected into the mold, the mold is cooled and the plastic melt solidifies into a product.

[0019] Opening the mold and taking out the product: After the product is completely cooled and solidified, the mold is opened and the product is taken out.

[0020] Post-processing: As needed, the product can be post-processed, such as trimming, grinding, heat treatment, etc., to further improve its performance or improve its appearance.

[0021] In the above technical scheme, the embodiment of the present application improves the molding performance of the polyamide composite material by vacuum assisted molding, gas assisted molding, etc. These technologies can effectively control the flow and cooling process of the material, reduce the generation of residual stress, and improve the dimensional stability and appearance quality of the product.

[0022] In a further embodiment, when the gas is injected, the pressure and flow rate of the gas need to be precisely controlled to ensure that the plastic melt can be evenly distributed in various parts of the mold.

[0023] In further embodiments, upon cooling and solidification, the gas forms voids within the plastic, reducing the weight of the article and improving its physical properties.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention performs a preliminary organic treatment on the filler, and the polyamide resin, carbon fiber, various fibers, mineral filler, metal filler and other fillers and additives are matched, and an appropriate amount of plasticizer, lubricant or flow aid can be added to reduce the viscosity of the material and improve its fluidity.

[0026] 2. The present invention utilizes vacuum assisted molding, gas assisted molding, etc. to improve the molding performance of polyamide composite materials. These technologies can effectively control the flow and cooling process of the material, reduce the generation of residual stress, and improve the dimensional stability and appearance quality of the product. DETAILED DESCRIPTION

[0027] In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0028] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances. The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. 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.

[0029] 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.

[0030] A polyamide composite material capable of gas-assisted molding according to the present invention comprises

[0031] 1Polyamide resin 50-90.

[0032] 2 Carbon Fiber 5-30.

[0033] 3. Multiple fibers 5-30.

[0034] 4 Mineral fillers 10-30.

[0035] 5 Metal filler 5-50.

[0036] 6 Other fillers 5-30

[0037] The polyamide resin 1 is PA6 or PA66.

[0038] The plurality of fibers 3 may be glass fibers, aramid fibers, polyester fibers or polypropylene fibers.

[0039] The mineral filler 4 may be calcium carbonate or talc.

[0040] The metal filler 5 can be aluminum powder or copper powder.

[0041] The method for preparing the gas-assisted moldable polyamide composite material of the present invention comprises:

[0042] 7 Preparation stage: Prepare the necessary equipment and materials such as gas-assisted molding machine, material particles, molds, etc. At the same time, check whether the equipment is operating normally and whether the mold is installed correctly.

[0043] 8 Heating and plasticizing: Add the material particles into the hopper of the gas-assisted molding machine, and through the rotation and heating of the screw, the plastic particles are melted into a flowable plastic melt.

[0044] 9 Injection stage: After the molten plastic reaches the appropriate temperature and pressure, the melt is injected into the mold. During the injection process, part of the plastic melt flows into the preset gas channel.

[0045] 10 Gas injection: After the plastic melt fills the mold part, the gas-assisted molding machine injects compressed gas into the mold through the gas channel.

[0046] 11 Cooling and solidification: After the plastic melt and gas are injected into the mold, the mold is cooled and the plastic melt solidifies into a product.

[0047] 12 Opening the mold and taking out the product: After the product is completely cooled and solidified, the mold is opened and the product is taken out.

[0048] 13 Post-processing: As needed, the product can be post-processed, such as trimming, grinding, heat treatment, etc., to further improve its performance or improve its appearance.

[0049] When the gas is injected 10, the pressure and flow rate of the gas need to be precisely controlled to ensure that the plastic melt can be evenly distributed in various parts of the mold.

[0050] During cooling and solidification11, the gas forms cavities inside the plastic, reducing the weight of the product and improving its physical properties.

[0051] Example 1

[0052] A polyamide composite material capable of gas-assisted molding and a preparation method thereof of the present invention comprises the following steps:

[0053] Prepare the ingredients:

[0054] Polyamide resin (PA6): 88 parts by weight

[0055] Carbon fiber: 15 parts by weight

[0056] Multiple fibers: 12 parts by weight (the ratio of glass fiber to aramid fiber is 1:1)

[0057] Mineral filler (talc): 20 parts by weight

[0058] Metal filler: 40 (copper powder) parts by weight

[0059] Other fillers: 12 parts by weight Other fillers are (plasticizers, lubricants or flow aids) that reduce the viscosity of the overall material and improve its fluidity, so as to reduce the viscosity of the material and increase its fluidity.

[0060] Preprocessing:

[0061] Make sure all ingredients are dry and clean to avoid problems during processing.

[0062] All fillers undergo pre-treatment, such as grinding, cutting or sieving, to ensure they meet processing requirements.

[0063] mix:

[0064] Polyamide resin (PA6) was placed in a mixer.

[0065] Gradually add carbon fiber, multi-fiber (a mixture of glass fiber and aramid fiber), mineral filler (talc), metal filler and other fillers.

[0066] During the mixing process, make sure all ingredients are evenly distributed to avoid lumps or unevenness.

[0067] Processing:

[0068] The mixed raw materials are fed into appropriate processing equipment, such as extruders, injection molding machines or presses, and processed according to the required final product shape and size. During the processing, attention should be paid to controlling parameters such as temperature, pressure and time to ensure product quality.

[0069] Post-processing:

[0070] Carry out necessary post-processing on the processed products, such as cooling, cutting, grinding or heat treatment, and check the product quality to ensure that it meets the requirements.

[0071] Packaging and storage:

[0072] Qualified products should be packaged and stored properly to prevent moisture, heat or damage.

[0073] Example 2

[0074] A polyamide composite material capable of gas-assisted molding and a preparation method thereof of the present invention comprises the following steps:

[0075] Prepare the ingredients:

[0076] Polyamide resin (PA6): 75 parts by weight

[0077] Carbon fiber: 20 parts by weight

[0078] Multiple fibers: 20 parts by weight (the ratio of glass fiber to aramid fiber is 1:1)

[0079] Mineral filler (calcium carbonate): 20 parts by weight

[0080] Metal filler: 30 (copper powder) parts by weight

[0081] Other fillers: 25 parts by weight Other fillers are (plasticizers, lubricants or flow aids) that reduce the viscosity of the overall material and improve its fluidity, so as to reduce the viscosity of the material and increase its fluidity.

[0082] Preprocessing:

[0083] Make sure all ingredients are dry and clean to avoid problems during processing.

[0084] All fillers undergo pre-treatment, such as grinding, cutting or sieving, to ensure they meet processing requirements.

[0085] mix:

[0086] Polyamide resin (PA6) was placed in a mixer.

[0087] Gradually add carbon fiber, multi-fiber (a mixture of glass fiber and aramid fiber), mineral filler (calcium carbonate), metal filler and other fillers.

[0088] During the mixing process, make sure all ingredients are evenly distributed to avoid lumps or unevenness.

[0089] Processing:

[0090] The mixed raw materials are fed into appropriate processing equipment, such as extruders, injection molding machines or presses, and processed according to the required final product shape and size. During the processing, attention should be paid to controlling parameters such as temperature, pressure and time to ensure product quality.

[0091] Post-processing:

[0092] Carry out necessary post-processing on the processed products, such as cooling, cutting, grinding or heat treatment, and check the product quality to ensure that it meets the requirements.

[0093] Packaging and storage:

[0094] Qualified products should be packaged and stored properly to prevent moisture, heat or damage.

[0095] Example 3

[0096] The material particles are added to the hopper of the gas-assisted molding machine. Through the rotation and heating of the screw, the plastic particles are melted into a flowable plastic melt. After the molten plastic reaches the appropriate temperature and pressure, the melt is injected into the mold. During the injection process, part of the plastic melt flows into the preset gas channel. After the plastic melt fills the mold part, the gas-assisted molding machine injects compressed gas into the mold through the gas channel. After the plastic melt and gas are injected into the mold, the mold is cooled and the plastic melt solidifies into a product. After the product is completely cooled and solidified, the mold is opened and the product is taken out. According to needs, the product can be post-processed, such as trimming, grinding, heat treatment, etc., to further improve its performance or appearance. When the gas is injected, the pressure and flow of the gas need to be precisely controlled to ensure that the plastic melt can be evenly distributed in various parts of the mold. During cooling and solidification, the gas forms cavities inside the plastic, which reduces the weight of the product and improves its physical properties. Through vacuum-assisted molding, gas-assisted molding, etc., the molding performance of polyamide composite materials is improved. These technologies can effectively control the flow and cooling process of the material, reduce the generation of residual stress, and improve the dimensional stability and appearance quality of the parts.

[0097] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be considered exemplary and non-restrictive in all respects, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention.

[0098] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A polyamide composite material capable of gas-assisted molding, characterized in that: In parts by weight, it includes the following components: (1) Polyamide resin 50-90; (2) Carbon fiber 5-30; (3) Various fibers 5-30; (4) Mineral filler 10-30; (5) Metal filler 5-50; (6) Other fillers 5-30.

2. The gas-assisted moldable polyamide composite material according to claim 1, characterized in that: The polyamide resin (1) is PA6 or PA66.

3. The gas-assisted moldable polyamide composite material according to claim 1, characterized in that: The plurality of fibers (3) may be glass fibers, aramid fibers, polyester fibers or polypropylene fibers.

4. The gas-assisted moldable polyamide composite material according to claim 1, characterized in that: The mineral filler (4) may be calcium carbonate or talc.

5. The gas-assisted moldable polyamide composite material according to claim 1, characterized in that: The metal filler (5) may be aluminum powder or copper powder.

6. A method for preparing a polyamide composite material capable of gas-assisted molding according to any one of claims 1 to 6, characterized in that: The following steps are involved: (7) Preparation stage: Prepare the necessary equipment and materials such as gas-assisted molding machine, material particles, molds, etc. At the same time, check whether the equipment is operating normally and whether the mold is installed correctly; (8) Heating and plasticizing: Add the material particles into the hopper of the gas-assisted molding machine, and through the rotation and heating of the screw, the plastic particles are melted into a flowable plastic melt; (9) Injection stage: After the molten plastic reaches the appropriate temperature and pressure, the melt is injected into the mold. During the injection process, part of the plastic melt flows into the preset gas channel; (10) Gas injection: After the plastic melt fills the mold part, the gas-assisted molding machine injects compressed gas into the mold through the gas channel; (11) Cooling and solidification: After the plastic melt and gas are injected into the mold, the mold is cooled and the plastic melt solidifies into a product; (12) Opening the mold and removing the product: After the product is completely cooled and solidified, the mold is opened and the product is removed; (13) Post-processing: As needed, the product can be post-processed, such as trimming, grinding, heat treatment, etc., to further improve its performance or appearance.

7. The method for preparing a polyamide composite material capable of gas-assisted molding according to claim 7, characterized in that: When gas is injected (10), the pressure and flow rate of the gas need to be precisely controlled to ensure that the plastic melt can be evenly distributed in various parts of the mold.

8. The method for preparing a polyamide composite material capable of gas-assisted molding according to claim 7, characterized in that: During cooling and solidification (11), the gas forms cavities inside the plastic, reducing the weight of the product and improving its physical properties.