Thermoplastic light carbon fiber composite board and manufacturing method thereof

Abstract

The invention relates to a thermoplastic light carbon fiber composite board and a manufacturing method thereof, and the thermoplastic light carbon fiber composite board comprises a surface layer which is an anode aluminum foil; the middle layer is a carbon fiber layer impregnated with thermoplastic resin, and the required thickness can be formed according to the use requirement; the interlayer is made of a foaming material; the surface layer, the middle layer and the interlayer are laid according to design requirements of designed thickness, size, strength and the like and then are processed into the thermoplastic light carbon fiber composite board through mixing and hot pressing. The anode aluminum foil is used as the surface layer of the composite board, the thermoplastic resin impregnated carbon fiber layer is used as the middle layer, the foaming material is used as the interlayer, and the light thermoplastic composite board with the aluminum alloy anode appearance is processed through mixing and hot pressing, so that the metal appearance and light weight of the composite material are realized; and meanwhile, high strength and high modulus performance of the composite board are kept.

Description

Technical Field

[0001] The present invention relates to the technical field of thermoplastic sheets and thermoforming, and in particular to a thermoplastic lightweight carbon fiber composite sheet and a manufacturing method thereof.

Background Art

[0002] With the development of electronic and electrical devices and information devices such as laptop computers, tablet computers, portable phones, portable information terminals or cameras, the market demand for developing thin and light products is increasing. Thin and light products require the composite materials of the product shells to have the advantages of light weight, high strength, high modulus, chemical corrosion resistance, fatigue resistance, and easy integral forming.

[0003] At present, most of the thermoplastic carbon fiber composite products used in products such as electronic appliances, automobiles, and sports equipment are processed and formed using all-carbon fiber or composite sheets mixed with carbon fiber and glass fiber. The density of the thermoplastic all-carbon fiber composite sheet is 1.45 - 1.55 g / cm 3 , but its price is relatively high. While the density of the composite sheet mixed with carbon fiber and glass fiber with a lower price is 1.7 - 1.8 g / cm 3 , although it has a low price, high modulus and high rigidity, the weight of the product is relatively heavy, which does not conform to the current development direction of lightweight.

[0004] In view of this, it is necessary to provide a thermoplastic lightweight carbon fiber composite sheet and a manufacturing method thereof to solve the above problems.

Summary of the Invention

[0005] The technical problem to be solved by the present invention is that the density of the current all-carbon fiber composite sheet is 1.45 - 1.55 g / cm 3 , but its price is relatively high. While the density of the composite sheet mixed with carbon fiber and glass fiber with a lower price is 1.7 - 1.8 g / cm 3 , although it has a low price, high modulus and high rigidity, the weight of the product produced is relatively heavy, which does not conform to the current development direction of lightweight. Therefore, the present invention provides a thermoplastic lightweight carbon fiber composite sheet and a manufacturing method thereof to solve the above problems.

[0006] The solution of the present invention to solve its technical problem is: a thermoplastic lightweight carbon fiber composite sheet, comprising:

[0007] A surface layer, the surface layer being an anodic aluminum foil;

[0008] An intermediate layer, the intermediate layer being a carbon fiber layer impregnated with a thermoplastic resin and having a thickness that can be formed according to the use requirements;

[0009] A sandwich layer, the sandwich layer being a foaming material;

[0010] After the surface layer, the intermediate layer, and the sandwich layer are laid up according to the design requirements such as design thickness, size, strength, etc., they are processed into the thermoplastic lightweight carbon fiber composite board through hybrid hot pressing.

[0011] Preferably, the total thickness of the anodic aluminum foil can be 30 - 200 μm, the thickness of the anodic layer can be 2.5 - 6 μm, and the appearance color of the final product can be anodized according to needs.

[0012] Preferably, the intermediate layer can be continuous unidirectional or woven carbon fibers impregnated with a thermoplastic resin, which maximizes the strength of the board while retaining the carbon fiber texture.

[0013] Preferably, the void diameter of the foaming material can be 3 - 300 μm, and it can be selected according to the design density and strength of the board.

[0014] Preferably, the foaming material can be PP (polypropylene), PET (polyethylene terephthalate), PI (polyimide).

[0015] The present invention also includes a manufacturing method of a thermoplastic lightweight carbon fiber composite board, which includes the following steps:

[0016] S1: Lay up the anodic aluminum foil, the carbon fiber layer impregnated with a thermoplastic resin, and the foaming material according to the design size, thickness, and strength.

[0017] S2: Place the laid-up materials in a hot pressing mold, close the hot press, evacuate, and the mold temperature depends on the physical properties of the thermoplastic resin used.

[0018] S3: Keep the mold at a set temperature for constant pressure and continue to evacuate.

[0019] S4: When the set time is reached, stop evacuating, start cooling until the board in the mold reaches the cooling temperature.

[0020] S5: Open the mold and take out the composite board.

[0021] Preferably, a hot press with a vacuum function is required during the processing.

[0022] The beneficial effect of the present invention is that the present invention uses an anodic aluminum foil as the surface layer of the composite board, a carbon fiber layer impregnated with a thermoplastic resin as the intermediate layer, and a foaming material as the sandwich layer, and processes them into a lightweight thermoplastic composite board with an aluminum alloy anodic appearance through hybrid hot pressing, realizing the metallic appearance and light weight of the composite material, while maintaining the high strength and high modulus performance of the composite board.

Description of the Drawings

[0023] Figure 1 is a schematic diagram of the stacking order from bottom to top of the thermoplastic lightweight carbon fiber composite board in the present invention.

[0024] Figure 2 It is a flow chart of the manufacturing method of the thermoplastic lightweight carbon fiber composite sheet in the present invention.

Specific Embodiments

[0025] To further elaborate on the technical means and effects adopted by the present invention, the following will describe in detail in combination with the embodiments of the present invention and their accompanying drawings.

[0026] The present invention provides a thermoplastic lightweight carbon fiber composite sheet and its manufacturing method, including: The thermoplastic lightweight carbon fiber composite sheet 10 includes:

[0027] A surface layer 20, and the surface layer 20 is an anodic aluminum foil;

[0028] An intermediate layer 30, and the intermediate layer 30 is a carbon fiber layer impregnated with a thermoplastic resin, and can be formed into a required thickness according to usage requirements;

[0029] A sandwich layer 40, and the sandwich layer 40 is a foaming material;

[0030] After the surface layer 20, the intermediate layer 30, and the sandwich layer 40 are stacked according to design requirements such as design thickness, size, and strength, they are processed into the thermoplastic lightweight carbon fiber composite sheet 10 through mixed hot pressing.

[0031] Among them, the total thickness of the anodic aluminum foil can be 30 - 200 um, the thickness of the anodic layer can be 2.5 - 6 um, and the appearance color of the final product can be anodized according to needs.

[0032] Among them, the intermediate layer 30 can be continuous unidirectional or woven carbon fibers impregnated with a thermoplastic resin, which maximizes the strength of the sheet while retaining the carbon fiber texture.

[0033] Among them, the void diameter of the foaming material can be 3 - 300 um, and it can be selected according to the design density and strength of the sheet.

[0034] Among them, the foaming material can be PP (polypropylene), PET (polyethylene terephthalate), PI (polyimide).

[0035] The following takes the example of using a thermoplastic resin as UD carbon fiber impregnated with PC resin and a foaming material as PET to elaborate on the manufacturing method of a thermoplastic lightweight carbon fiber composite sheet of the present invention:

[0036] S1: Cut the anodic aluminum foil, UD carbon fiber impregnated with PC resin, and the foaming layer (PET) into required sizes;

[0037] S2: As shown in Figure 1The bottom-to-top laying sequence shown is UD carbon fiber (0°) 101, UD carbon fiber (90°) 102, foam layer (PET) 103, carbon fiber (90°) 104, UD carbon fiber (0°) 105, anodic aluminum foil 106, which are laid according to their designed dimensions, thicknesses, and strengths;

[0038] S3: Heat the hot pressing mold to 220°C to 240°C;

[0039] S4: Place the laid materials in the hot pressing mold, close the mold and evacuate, and set the mold temperature to 220°C to 240°C;

[0040] S3: Keep the mold at a constant temperature and apply pressure for 200 - 300 s, and continuously evacuate the mold during this process;

[0041] S4: When the set time is reached, stop evacuating the mold and start cooling until the temperature of the plate in the mold cools to 50 - 60°C;

[0042] S5: Open the mold and take out the composite plate 10.

[0043] Among them, the selected incoming material of the anodic aluminum foil is a coil, with a total thickness of 50 μm, an anodic layer thickness of 3 μm, and the anodic color is natural color (silver).

[0044] Among them, one layer of adhesive needs to be laid between every two layers during the laying process. The adhesive needs to be heat-resistant, and an adhesive acrylic adhesive (tolerating 200 - 250°C in the short term and 100 - 120°C in the long term) can be selected.

[0045] Among them, a hot press with a vacuum function needs to be used during the processing.

[0046] The beneficial effects of the present invention are that the present invention uses anodic aluminum foil as the surface layer 20 of the composite plate, a carbon fiber layer impregnated with a thermoplastic resin as the intermediate layer 30, and a foam material as the sandwich layer 40, and is processed into a lightweight thermoplastic composite plate with the appearance of an aluminum alloy anode through hot pressing, realizing the metallic appearance and light weight of the composite material, while maintaining the high strength and high modulus performance of the composite plate.

[0047] It should be noted that the present invention is not limited to the above embodiments. Any simple modifications, equivalent changes, and modifications made by any person skilled in the art to the above embodiments based on the technical solutions of the present invention all fall within the protection scope of the present invention.

Claims

1. A thermoplastic lightweight carbon fiber composite sheet, characterized in that: include: A surface layer, wherein the surface layer is an anode aluminum foil; An intermediate layer, which is a carbon fiber layer impregnated with a thermoplastic resin and can be formed into a desired thickness according to usage requirements; An interlayer, wherein the interlayer is a foaming material; The surface layer, the middle layer and the interlayer are stacked according to design requirements such as design thickness, size, strength, etc., and then processed by mixed hot pressing to form the thermoplastic lightweight carbon fiber composite plate.

2. A thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The total thickness of the anode aluminum foil can be 30-200 um, the thickness of the anode layer can be 2.5-6 um, and the appearance color of the final product can be anodized as needed.

3. A thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The middle layer may be continuous unidirectional or woven carbon fiber impregnated with thermoplastic resin, which maximizes the strength of the board while retaining the carbon fiber texture.

4. A thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The pore diameter of the foaming material may be 3 to 300 um, which may be selected according to the design density and strength of the board.

5. The thermoplastic lightweight carbon fiber composite sheet according to claim 1, characterized in that: The foaming material may be PP (polypropylene), PET (polyethylene terephthalate), or PI (polyimide).

6. A method for manufacturing a thermoplastic lightweight carbon fiber composite sheet, characterized in that: The manufacturing method comprises the following steps: S1: Lay the anode aluminum foil, the carbon fiber layer impregnated with thermoplastic resin, and the foam material according to the designed size, thickness, and strength; S2: placing the stacked materials in a hot pressing mold, closing the hot pressing machine, and evacuating the mold. The mold temperature depends on the physical properties of the thermoplastic resin used. S3: The mold is pressurized at a constant temperature and continuously vacuumed at a set temperature; S4: When the mold reaches the set time, the vacuum pumping stops and cooling starts until the sheet in the mold reaches the cooling temperature; S5: Open the mold and take out the composite sheet.

7. The method for manufacturing a thermoplastic lightweight carbon fiber composite sheet material according to claim 6, characterized in that: A heat press with a vacuum function needs to be used during the processing.

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