Continuous fiber reinforced thermoplastic prepreg tape and preparation method thereof

Abstract

The invention discloses a continuous fiber reinforced thermoplastic prepreg tape. The continuous fiber reinforced thermoplastic prepreg tape is prepared from the following raw materials in percentage by weight: 36.2-48.7% of thermoplastic resin; 50-60% of continuous fiber; 1.2-2% of a toughening agent; 2-4% of maleic anhydride grafted polyolefin; 0-0.4% of carrier-free color master batch; 0-1.2% of an antioxidant; and 0-1.2% of a UV absorbent. According to the continuous fiber reinforced thermoplastic prepreg tape provided by the invention, the tensile strength, rigidity, thermal deformation temperature and other properties of a product are improved by adding maleic anhydride grafted polyolefin with higher heat-resistant temperature for blending, so that the continuous fiber reinforced thermoplastic prepreg tape can not be softened or deformed in a higher-temperature environment, and the use effect is enhanced.

Description

Technical Field

[0001] This application relates to the technical field of polymer materials, and more particularly to a continuous fiber reinforced thermoplastic prepreg tape and a method for preparing the same. Background Art

[0002] Composite materials have the characteristics of light weight, high strength, and can be made to have multiple functions by adding relevant additives. They are widely used in fields such as automobiles, aviation, and construction. However, the use of a large amount of composite materials will increase the risk of fire. Therefore, it is necessary to carry out flame retardant treatment on composite materials. The existing flame retardant modification treatment of composite materials generally uses halogen-free flame retardants or inorganic flame retardants, but they have a great impact on the physical properties of continuous fiber reinforced thermoplastic prepreg tapes.

[0003] Therefore, there is a need for a continuous fiber reinforced thermoplastic prepreg tape and a method for preparing the same to at least partially solve the above problems. Summary of the Invention

[0004] In the summary of the invention part of this application, a series of simplified concepts are introduced, which will be further elaborated in the detailed implementation part. The summary of the invention part of this application does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the protection scope of the claimed technical solution.

[0005] To at least partially solve the above problems, a first aspect of this application provides a continuous fiber reinforced thermoplastic prepreg tape, which is prepared from the following raw materials by weight percentage:

[0006]

[0007] According to the continuous fiber reinforced thermoplastic prepreg tape of this application, by adding a halogen-containing flame retardant, the flame retardant performance of the continuous fiber reinforced thermoplastic prepreg tape can be significantly improved, preventing the prepreg tape from being burned through and reducing the risk of fire. At the same time, the halogen-containing flame retardant affects the physical properties of the prepreg tape to a lesser extent, thus taking into account both the flame retardant performance and the physical properties of the prepreg tape.

[0008] Optionally, the thermoplastic resin is polypropylene resin.

[0009] Optionally, the continuous fiber is glass fiber.

[0010] Optionally, the compatibilizer is a polyolefin maleic anhydride graft.

[0011] Optionally, the grafting rate of the polyolefin maleic anhydride graft is 0.5 - 2%.

[0012] Optionally, the antioxidant is a hindered phenol phosphite.

[0013] Optionally, the halogen-containing flame retardant includes decabromodiphenylethane and antimony trioxide.

[0014] Optionally, the weight of the decabromodiphenylethane accounts for 63.6 - 71.4% of the weight of the halogen-containing flame retardant, and the weight of the antimony trioxide accounts for 28.6 - 36.4% of the weight of the halogen-containing flame retardant.

[0015] The second aspect of the present application provides a method for preparing a continuous fiber reinforced thermoplastic prepreg tape according to any one of the above technical solutions, including the following steps:

[0016] S10: Mix the following raw materials by weight percentage:

[0017]

[0018] S20: Draw out 50 - 65% of continuous fibers by weight percentage from the creel.

[0019] S30: Melt the mixture in step S10 and compound it with the continuous fibers to obtain the continuous fiber reinforced thermoplastic prepreg tape.

[0020] Optionally, the melting temperature of the material in step S30 is 180 - 240 °C.

[0021] According to the method for preparing a continuous fiber reinforced thermoplastic prepreg tape of the present application, by adding a halogen-containing flame retardant, the flame retardant performance of the continuous fiber reinforced thermoplastic prepreg tape can be significantly improved, preventing the prepreg tape from being burned through and reducing the fire risk. At the same time, the halogen-containing flame retardant affects the physical properties of the prepreg tape to a lesser extent, thus taking into account both the flame retardant performance and the physical properties of the prepreg tape. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The following drawings of the present application are used as a part of the present application to understand the present application. The embodiments and descriptions thereof shown in the drawings are used to explain the principles of the present application.

[0023] In the drawings:

[0024] Figure 1 is the flowchart of the preparation of the continuous fiber reinforced thermoplastic prepreg tape according to the preferred embodiment of the present application;

[0025] Figure 2 is the graph of the burning test results of the prepreg tape in Example 1;

[0026] Figure 3 is the graph of the burning test results of the prepreg tape in Example 2;

[0027] Figure 4 is the graph of the burning test results of the prepreg tape in Example 3;

[0028] Figure 5 The figure shows the burning test results of the prepreg for the comparative example. Detailed implementation manners

[0029] In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present application. However, it will be apparent to one of ordinary skill in the art that the present application may be practiced without one or more of these specific details. In other instances, well-known features have not been described in order to avoid obscuring the present application.

[0030] In order to thoroughly understand the present application, a detailed description will be presented in the following. Obviously, the implementation of the embodiments of the present application is not limited to the specific details familiar to those skilled in the art. The preferred embodiments of the present application are described in detail below. However, in addition to these detailed descriptions, the present application may also have other embodiments.

[0031] It should be noted that the terms used herein are for the purpose of describing specific embodiments only and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular forms are also intended to include the plural forms. In addition, it should be understood that when the terms "comprises" and / or "comprising" are used in this specification, they specify the presence of the stated features, wholes, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or combinations thereof.

[0032] The ordinal numbers such as "first" and "second" cited in the present application are only identifiers and do not have any other meanings, such as a specific order, etc. Moreover, for example, the term "first component" does not imply the existence of a "second component" by itself, and the term "second component" does not imply the existence of a "first component" by itself.

[0033] It should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer" and similar expressions used herein are for illustrative purposes only and are not restrictive.

[0034] Now, exemplary embodiments according to the present application will be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many different forms and should not be construed as being limited only to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of the present application is thorough and complete, and the concepts of these exemplary embodiments are fully conveyed to those of ordinary skill in the art.

[0035] The first aspect of the present application discloses a continuous fiber reinforced thermoplastic prepreg tape. The continuous fiber reinforced thermoplastic prepreg tape is prepared from raw materials in the following weight percentages:

[0036]

[0037] The thermoplastic resin is preferably polypropylene resin. The polypropylene resin is preferably random copolymer polypropylene with a melt flow index of 100 g / 10 min and a melting point of 168 °C. The continuous fiber is preferably glass fiber with good dispersibility. The diameter of the glass fiber is 15 - 20 μm, preferably 16 μm; the linear density of the glass fiber is 2300 - 2500 Tex, preferably 2400 Tex. The compatibilizer is preferably a polyolefin maleic anhydride graft, and the grafting rate of the polyolefin maleic anhydride graft is 0.5 - 2%, preferably 1.5%. The antioxidant is preferably a hindered phenolic phosphite to improve the anti-aging performance of the material. Preferably, the halogenated flame retardant includes decabromodiphenylethane and antimony trioxide. The weight of decabromodiphenylethane accounts for 63.6 - 71.4% of the weight of the halogenated flame retardant, and the weight of antimony trioxide accounts for 28.6 - 36.4% of the weight of the halogenated flame retardant. Further preferably, by weight, the halogenated flame retardant includes 85.6% of decabromodiphenylethane and 14.4% of antimony trioxide.

[0038] For the continuous fiber reinforced thermoplastic prepreg tape according to the present application, by adding a halogenated flame retardant, the flame retardant performance of the continuous fiber reinforced thermoplastic prepreg tape can be significantly improved, preventing the prepreg tape from being burned through and reducing the fire risk. At the same time, the halogenated flame retardant affects the physical properties of the prepreg tape to a lesser extent, thus taking into account both the flame retardant performance and the physical properties of the prepreg tape.

[0039] As Figure 1 shown, the second aspect of the present application discloses a preparation method of a continuous fiber reinforced thermoplastic prepreg tape, including the following steps:

[0040] S10: Mix the following raw materials in the following weight percentages:

[0041]

[0042] The mixing time is 10 - 30 min, preferably 20 min.

[0043] S20: Draw out 50 - 65% of the continuous fiber by weight from the yarn creel.

[0044] S30: Melt the materials mixed in step S10 and then compound them with the continuous fiber to obtain the continuous fiber reinforced thermoplastic prepreg tape. Among them, the melting temperature of the materials is 180 - 240 °C.

[0045] Specifically, in a preferred embodiment, the preparation method of the continuous fiber reinforced thermoplastic prepreg tape is to pour the thermoplastic resin, halogenated flame retardant, compatibilizer, and antioxidant into a mixer according to the above mass proportions, and mix them evenly; wherein the mixing time is 10-30 minutes.

[0046] Put the mixed materials into the hopper of the screw extruder, and do not use suction; the temperature of each section of the screw extruder: Zone 1 170-190℃; Zone 2 180-200℃; Zone 3 190-210℃; Zone 4 200-220℃; Zone 5 210-230℃; Zone 6 220-240℃; the connection between the extruder and the mold is 225-245℃; the hanger mold temperature is 225-245℃; the dipping mold temperature is 225-245℃.

[0047] The continuous fiber yarn roll is placed on the yarn frame, and the continuous fiber enters the impregnation mold cavity through the yarn reed and the yarn spreading roller, and passes through the die head on the other side of the mold cavity.

[0048] Start the screw extruder (speed 35-45r / min) and slowly pull the continuous fiber at the same time; the material put into the screw extruder is sheared and conveyed into the mold cavity by the screw, and the continuous fiber and resin are impregnated to obtain a sheet. The sheet is formed by a cooling roller, a shaping roller, and a flattening roller to obtain the final prepreg tape product.

[0049] The above process is only an example. Unless adverse effects occur, various processing operations can be performed in a different order from the order of the above process. The order of steps in the above process can also be adjusted, combined or deleted according to actual needs.

[0050] According to the preparation method of the continuous fiber reinforced thermoplastic prepreg tape of the present application, the flame retardant properties of the continuous fiber reinforced thermoplastic prepreg tape can be significantly improved by adding a halogenated flame retardant, thereby preventing the prepreg tape from being burned through and reducing the risk of fire. At the same time, the halogenated flame retardant affects the physical properties of the prepreg tape to a lesser extent, thereby taking into account both the flame retardant properties and the physical properties of the prepreg tape.

[0051] Example 1

[0052] Pour 25KG polypropylene resin, 8.75KG halogen flame retardant (6.125KG decabromodiphenylethane and 2.625KG antimony trioxide), 1KG polyolefin maleic anhydride graft, 0.075KG hindered phenol phosphite into the mixer, mix evenly, and the mixing time is 20 minutes. Put the mixed materials into the hopper of the screw extruder, and do not use suction. The temperature of each section of the screw extruder is: Zone 1 180℃; Zone 2 190℃; Zone 3 200℃; Zone 4 210℃; Zone 5 220℃; Zone 6 230℃; 235℃ at the connection between the extruder and the mold; 235℃ for the hanger mold; 235℃ for the impregnation mold.

[0053] Place the glass fiber yarn roll on the yarn rack. The glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation die cavity, and exits from the die head on the other side of the die cavity.

[0054] Start the screw extruder (rotation speed 40 r / min), and at the same time slowly draw the glass fiber; the material put into the screw extruder is sheared and conveyed by the screw and enters the die cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet. The sheet is formed through the cooling roller, the shaping roller, and the flattening roller to obtain the final prepreg tape product. Among them, the mass of the glass fiber is 60% of the total mass of the product.

[0055] Example 2

[0056] Put 25 KG of polypropylene resin, 8.75 KG of halogenated flame retardant (6.125 KG of decabromodiphenylethane and 2.625 KG of antimony trioxide), 1.2 KG of polyolefin maleic anhydride graft, and 0.075 KG of hindered phenolic phosphite into the mixer and mix evenly, with the mixing time being 20 min. Put the mixed material into the hopper of the screw extruder, and do not use suction to inhale. The temperatures of each section of the screw extruder are: section 1 180 °C; section 2 190 °C; section 3 200 °C; section 4 210 °C; section 5 220 °C; section 6 230 °C; the connection between the extruder and the mold 235 °C; the temperature of the hanger die 235 °C; the temperature of the impregnation mold 235 °C.

[0057] Place the glass fiber yarn roll on the yarn rack. The glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation die cavity, and exits from the die head on the other side of the die cavity.

[0058] Start the screw extruder (rotation speed 40 r / min), and at the same time slowly draw the glass fiber; the material put into the screw extruder is sheared and conveyed by the screw and enters the die cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet. The sheet is formed through the cooling roller, the shaping roller, and the flattening roller to obtain the final prepreg tape product. Among them, the mass of the glass fiber is 60% of the total mass of the product.

[0059] Example 3

[0060] Put 25 KG of polypropylene resin, 7.75 KG of halogenated flame retardant (5.425 KG of decabromodiphenylethane and 2.325 KG of antimony trioxide), 1 KG of polyolefin maleic anhydride graft, and 0.075 KG of hindered phenolic phosphite into the mixer and mix evenly, with the mixing time being 20 min. Put the mixed material into the hopper of the screw extruder, and do not use suction to inhale. The temperatures of each section of the screw extruder are: section 1 180 °C; section 2 190 °C; section 3 200 °C; section 4 210 °C; section 5 220 °C; section 6 230 °C; the connection between the extruder and the mold 235 °C; the temperature of the hanger die 235 °C; the temperature of the impregnation mold 235 °C.

[0061] Place the glass fiber yarn roll on the yarn rack. The glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation die cavity, and exits from the die head on the other side of the die cavity.

[0062] Start the screw extruder (rotation speed 40 r / min), and at the same time slowly draw the glass fiber; the material put into the screw extruder is sheared and conveyed by the screw and enters the die cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet. The sheet passes through the cooling roller, the shaping roller, and the flattening roller to form the final prepreg tape product. Among them, the mass of the glass fiber is 60% of the total mass of the product.

[0063] Comparative example

[0064] Put 25 KG of polypropylene resin, 1 KG of polyolefin maleic anhydride graft, and 0.075 KG of hindered phenol phosphite into the mixer and mix evenly, with a mixing time of 20 min. Put the mixed material into the hopper of the screw extruder, and do not use suction to suck it in. The temperatures of each section of the screw extruder are: zone 1 180 °C; zone 2 190 °C; zone 3 200 °C; zone 4 210 °C; zone 5 220 °C; zone 6 230 °C; the connection between the extruder and the mold 235 °C; the temperature of the hanger die 235 °C; the temperature of the impregnation die 235 °C.

[0065] Place the glass fiber yarn roll on the yarn rack. The glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation die cavity, and exits from the die head on the other side of the die cavity.

[0066] Start the screw extruder (rotation speed 40 r / min), and at the same time slowly draw the glass fiber; the material put into the screw extruder is sheared and conveyed by the screw and enters the die cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet. The sheet passes through the cooling roller, the shaping roller, and the flattening roller to form the final prepreg tape product. Among them, the mass of the glass fiber is 60% of the total mass of the product.

[0067] In this application, the sample is burned with a 500 °C flame for 60 s to observe whether the sample is burned through to test the flame retardancy. Sample preparation: Use the hot pressing method to make a plate with a thickness of 1.0 mm from the prepreg tape, and cut it into small square samples of 100 mm * 100 mm.

[0068] The specific formulation design and test data are shown in Table 1.

[0069] Table 1

[0070]

[0071] According to the data in Table 1 and Figures 2 - 5 , it can be seen from the comparison between Example 1 and the comparative example that the addition of the halogenated flame retardant significantly improves the flame retardancy of the prepreg tape, and at the same time affects the physical properties of the prepreg tape to a lesser extent.

[0072] From the comparison between Example 1 and Example 2, it can be seen that the addition amount of the compatibilizer has no effect on the flame retardancy of the prepreg tape and basically has no effect on the properties of the prepreg tape.

[0073] From the comparison between Example 1 and Example 3, it can be seen that the higher the addition amount of the halogen-containing flame retardant, the better the flame retardancy of the prepreg tape, but the physical properties of the prepreg tape will decrease accordingly.

[0074] In summary, by adding an appropriate proportion of halogen-containing flame retardant, the flame retardancy of the continuous fiber reinforced thermoplastic prepreg tape can be improved while minimizing the impact on its physical properties.

[0075] Unless otherwise defined, the technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the technical field of this application. The terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application. The features described in one embodiment herein can be applied to another embodiment alone or in combination with other features, unless the feature is not applicable or otherwise stated in that other embodiment.

[0076] This application has been described through the above embodiments. However, it should be understood that the above embodiments are only for the purpose of illustration and example, and this application is not limited to the above embodiments. According to the teachings of this application, more variations and modifications can be made, and these variations and modifications all fall within the scope claimed by this application.

Claims

1. A continuous fiber reinforced thermoplastic prepreg tape, characterized in that, Prepared from the following raw materials by weight percentage:

2. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, wherein The thermoplastic resin is polypropylene resin.

3. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, wherein The continuous fiber is glass fiber.

4. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, characterized in that, The compatibilizer is a polyolefin maleic anhydride graft.

5. The continuous fiber reinforced thermoplastic prepreg tape according to claim 4, wherein The grafting rate of the polyolefin maleic anhydride graft is 0.5-2%.

6. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, characterized in that The antioxidant is a hindered phenol phosphite.

7. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, wherein The halogenated flame retardant contains decabromodiphenylethane and antimony trioxide.

8. The continuous fiber reinforced thermoplastic prepreg tape according to claim 7, characterized in that The weight of the decabromodiphenylethane accounts for 63.6-71.4% of the weight of the halogenated flame retardant, and the weight of the antimony trioxide accounts for 28.6-36.4% of the weight of the halogenated flame retardant.

9. A method for preparing a continuous fiber reinforced thermoplastic prepreg tape according to any one of the above claims 1-8, characterized in that, Including the following steps: S10: Mix the following raw materials by weight percentage: S20: Draw out 50-65% of the continuous fiber by weight percentage from the yarn creel. S30: Melt the mixture in step S10 and compound it with the continuous fiber to obtain the continuous fiber reinforced thermoplastic prepreg tape.

10. The preparation method according to claim 9, characterized in that, The melting temperature of the material in step S30 is 180-240 °C.

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