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: 38-47% of thermoplastic resin; 50-60% of continuous fiber; 1.5%-1.9% of a toughening agent; 0.4 to 0.6 percent of a compatilizer; and 0-0.4% of color master batch. According to the continuous fiber reinforced thermoplastic prepreg tape, the flexibilizer and the compatilizer are added, so that the thickness of the prepreg tape can be reduced, the fiber content is increased, and the product performance is further improved. Specifically, by adding the flexibilizer, the toughness of the prepreg tape can be improved, and the prepreg tape is prevented from cracking in the processing process of the subsequent working procedure; and by adding the compatilizer, the compatibility of the continuous fibers and the thermoplastic resin can be improved, so that the mechanical property of the prepreg tape is improved.

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] The continuous fiber reinforced thermoplastic prepreg tape is prepared by impregnating continuous fibers with thermoplastic resin. Currently, the common continuous fiber reinforced thermoplastic prepreg tape is affected by the physical properties of the matrix resin, with poor toughness, which makes the subsequent processing of the product difficult, and the prepreg tape has a relatively thick thickness and a low fiber content, severely restricting the use of the material.

[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, adding a toughening agent and a compatibilizer can reduce the thickness of the prepreg tape and increase the fiber content, thereby improving the product performance. Specifically, adding a toughening agent can improve the toughness of the prepreg tape and prevent the prepreg tape from cracking during the subsequent processing; adding a compatibilizer can improve the compatibility between the continuous fiber and the thermoplastic resin, thereby improving the mechanical properties of the prepreg tape.

[0008] Optionally, the thermoplastic resin is styrene-acrylonitrile copolymer.

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

[0010] Optionally,

[0011] the diameter of the glass fiber is 15 - 20 μm, and / or

[0012] the linear density of the glass fiber is 1100 - 1300 Tex.

[0013] Optionally, the toughening agent is a maleic anhydride grafted hydrogenated styrene-butadiene block copolymer.

[0014] Optionally, the compatibilizer is a maleic anhydride-styrene random copolymer.

[0015] Optionally, the addition amount of the compatibilizer is less than or equal to 1.5% of the addition amount of the thermoplastic resin.

[0016] 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:

[0017] S10: Mix the following raw materials by weight percentage:

[0018] Thermoplastic resin 38 - 47%;

[0019] Toughening agent 1.5 - 1.9%;

[0020] Compatibilizer 0.4 - 0.6%;

[0021] S20: Draw out 50 - 60% of continuous fibers by weight percentage from the creel;

[0022] S30: Melt the mixture in step S10 and compound it with the continuous fibers to obtain the continuous fiber reinforced thermoplastic prepreg tape.

[0023] Optionally, the mixing time in step S10 is 20 - 30 min.

[0024] Optionally, the melting temperature of the material in step S30 is 210 - 290 °C.

[0025] According to the method for preparing a continuous fiber reinforced thermoplastic prepreg tape of the present application, by adding a toughening agent and a compatibilizer, the thickness of the prepreg tape can be reduced and the fiber content can be increased, thereby improving the product performance. Specifically, by adding a toughening agent, the toughness of the prepreg tape can be improved to prevent the prepreg tape from cracking during the processing of subsequent processes; by adding a compatibilizer, the compatibility between the continuous fibers and the thermoplastic resin can be improved, thereby improving the mechanical properties of the prepreg tape. Description of the Drawings

[0026] 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 principle of the present application.

[0027] In the drawings:

[0028] Figure 1 is the preparation flow chart of the continuous fiber reinforced thermoplastic prepreg tape of the preferred embodiment of the present application. Detailed Embodiments

[0029] In the following description, numerous specific details are given 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 details. In other instances, well-known technical features have not been described to avoid obscuring the present application.

[0030] To thoroughly understand the present application, a detailed description will be presented in the following. Apparently, 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 have other embodiments.

[0031] It should be noted that the terms used herein are only for describing specific embodiments 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 "comprising" and / or "including" 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 merely identifiers and do not have any other meanings, such as a specific order, etc. Moreover, for example, the term "first component" itself does not imply the existence of a "second component", and the term "second component" itself does not imply the existence of a "first component".

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

[0034] Now, the 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 concept of these exemplary embodiments is 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 the following raw materials by weight percentage:

[0036] Thermoplastic resin 38 - 47%;

[0037]

[0038] The thermoplastic resin is preferably styrene-acrylonitrile copolymer (SAN), and the density of the SAN resin is 1.06-1.08 g / cm 3 ; the melt index is 58 g / 10 min (220 °C, 10 kg). The continuous fiber is preferably glass fiber, the diameter of the glass fiber is 15-20 μm, and the linear density is 1100-1300 Tex. The toughening agent is preferably maleic anhydride grafted hydrogenated styrene-butadiene block copolymer. The addition of the rubber phase can improve the toughness of the product and prevent the product from cracking during the processing of the subsequent process. The compatibilizer is preferably maleic anhydride and styrene binary random copolymer.

[0039] For the continuous fiber reinforced thermoplastic prepreg tape according to the present application, by adding a toughening agent and a compatibilizer, the thickness of the prepreg tape can be reduced and the fiber content can be increased, thereby improving the product performance. Specifically, by adding a toughening agent, the toughness of the prepreg tape can be improved, and the prepreg tape can be prevented from cracking during the processing of the subsequent process; by adding a compatibilizer, the compatibility between the continuous fiber and the thermoplastic resin can be improved, thereby improving the mechanical properties of the prepreg tape.

[0040] As Figure 1 shown, the second aspect of the present application discloses a method for preparing a continuous fiber reinforced thermoplastic prepreg tape, including the following steps:

[0041] S10: Mix the following raw materials by weight percentage:

[0042] Thermoplastic resin 38-47%;

[0043] Toughening agent 1.5-1.9%;

[0044] Compatibilizer 0.4-0.6%.

[0045] The mixing time is 20-30 min.

[0046] S20: Draw out 50-60% of the continuous fiber by weight percentage from the yarn frame.

[0047] S30: Melt the mixture in step S10 and then compound it with the continuous fiber to obtain a continuous fiber reinforced thermoplastic prepreg tape. Among them, the melting temperature of the material is 210-290 °C.

[0048] Specifically, in the preferred embodiment, the method for preparing the continuous fiber reinforced thermoplastic prepreg tape is to pour the thermoplastic resin, the toughening agent, and the compatibilizer into a mixer according to the above mass ratio and mix them evenly; the mixing duration is 20-30 min.

[0049] Put the mixed materials into the hopper of the extruder. The temperatures of each section of the extruder are as follows: Zone 1: 200 - 220 °C; Zone 2: 220 - 240 °C; Zone 3: 230 - 250 °C; Zone 4: 240 - 260 °C; Zone 5: 240 - 260 °C; Zone 6: 250 - 270 °C; Zone 7: 260 - 280 °C; Zone 8: 270 - 290 °C; Zone 9: 270 - 290 °C; Zone 10: 270 - 290 °C; The connection area between the barrel and the die: 280 - 290 °C; The hanger die area: 280 - 290 °C; The impregnation die area: 280 - 300 °C.

[0050] Place the continuous fiber yarn roll on the yarn rack. The continuous fiber passes through the heddle, yarn spreading roller and enters the impregnation die cavity, and exits from the die head on the other side of the die cavity.

[0051] Start the extruder (rotation speed 50 - 60 r / min), and at the same time slowly draw the continuous fiber. The resin is sheared, conveyed by the screw, passed through the melt pump and the runner, and finally enters the die cavity to complete the impregnation of the continuous fiber and the resin, obtaining a sheet. The sheet is formed by the shaping roller and the cooling roller (the temperature of the cooling roller is 30 - 50 °C) to obtain the final prepreg tape product.

[0052] The above process is only an example. Unless adverse effects occur, various processing operations can be carried out in an order different from the order of the above process. The order of the steps of the above process can also be adjusted, combined or deleted according to actual needs.

[0053] According to the method for preparing the continuous fiber reinforced thermoplastic prepreg tape of the present application, by adding a toughening agent and a compatibilizer, the thickness of the prepreg tape can be reduced and the fiber content can be increased, thereby improving the product performance. Specifically, by adding a toughening agent, the toughness of the prepreg tape can be improved to prevent the prepreg tape from cracking during the processing of subsequent processes; by adding a compatibilizer, the compatibility between the continuous fiber and the thermoplastic resin can be improved, thereby improving the mechanical properties of the prepreg tape.

[0054] Example 1

[0055] Pour 25 Kg of SAN resin, 1 Kg of maleic anhydride-grafted hydrogenated styrene-butadiene block copolymer, 0.25 g of maleic anhydride, and styrene binary random copolymer into a mixer and mix evenly for 25 minutes; put the mixed material into the hopper of the extruder; the temperatures of each section of the extruder are: the first section is 210 °C; the second section is 230 °C; the third section is 240 °C; the fourth section is 250 °C; the fifth section is 250 °C; the sixth section is 260 °C; the seventh section is 270 °C; the eighth section is 280 °C; the ninth section is 280 °C; the tenth section is 280 °C; the connection area between the barrel and the mold is 285 °C; the hanger die area is 290 °C; the impregnation mold area is 290 °C. Place the glass fiber yarn roll on the yarn rack, and the continuous glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation mold cavity, and exits from the die head on the other side of the mold cavity. Start the extruder (rotation speed 55 r / min), and at the same time slowly draw the glass fiber; the resin passes through the screw shear, conveying, melt pump, and runner and finally enters the mold cavity to complete the impregnation of the glass fiber and the resin to obtain a sheet; the sheet is formed by a shaping roller and a cooling roller (the temperature of the cooling roller is 40 °C) to obtain the final prepreg tape product. Among them, the mass of the continuous glass fiber is 60% of the total mass of the product.

[0056] Example 2

[0057] Pour 25 Kg of SAN resin, 1 Kg of maleic anhydride-grafted hydrogenated styrene-butadiene block copolymer, 0.375 g of maleic anhydride, and styrene binary random copolymer into a mixer and mix evenly for 25 minutes; put the mixed material into the hopper of the extruder; the temperatures of each section of the extruder are: the first section is 210 °C; the second section is 230 °C; the third section is 240 °C; the fourth section is 250 °C; the fifth section is 250 °C; the sixth section is 260 °C; the seventh section is 270 °C; the eighth section is 280 °C; the ninth section is 280 °C; the tenth section is 280 °C; the connection area between the barrel and the mold is 285 °C; the hanger die area is 290 °C; the impregnation mold area is 290 °C. Place the glass fiber yarn roll on the yarn rack, and the continuous glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation mold cavity, and exits from the die head on the other side of the mold cavity. Start the extruder (rotation speed 55 r / min), and at the same time slowly draw the glass fiber; the resin passes through the screw shear, conveying, melt pump, and runner and finally enters the mold cavity to complete the impregnation of the glass fiber and the resin to obtain a sheet; the sheet is formed by a shaping roller and a cooling roller (the temperature of the cooling roller is 40 °C) to obtain the final prepreg tape product. Among them, the mass of the continuous glass fiber is 60% of the total mass of the product.

[0058] Example 3

[0059] Pour 25 Kg of SAN resin, 2 Kg of maleic anhydride grafted hydrogenated styrene-butadiene block copolymer, 0.375 g of maleic anhydride, and styrene binary random copolymer into a mixer and mix evenly for 25 min. Feed the mixed material into the hopper of the extruder. The temperatures of each section of the extruder are as follows: Zone 1: 210 °C; Zone 2: 230 °C; Zone 3: 240 °C; Zone 4: 250 °C; Zone 5: 250 °C; Zone 6: 260 °C; Zone 7: 270 °C; Zone 8: 280 °C; Zone 9: 280 °C; Zone 10: 280 °C; The connection area between the barrel and the mold: 285 °C; The hanger die area: 290 °C; The impregnation mold area: 290 °C. Place the glass fiber yarn roll on the yarn rack. The continuous glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation mold cavity, and exits from the die head on the other side of the mold cavity. Start the extruder (rotation speed 55 r / min), and at the same time, slowly draw the glass fiber. The resin is sheared, conveyed by the screw, passes through the melt pump and the runner, and finally enters the mold cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet. The sheet is formed by a shaping roller and a cooling roller (the temperature of the cooling roller is 40 °C) to obtain the final prepreg tape product. The mass of the continuous glass fiber is 60% of the total mass of the product.

[0060] Comparative Example 1

[0061] Pour 12.5 Kg of acrylonitrile-styrene-butadiene copolymer (ABS) resin and 25 Kg of SAN resin into a mixer and mix evenly for 25 min. Feed the mixed material into the hopper of the extruder. The temperatures of each section of the extruder are as follows: Zone 1: 230 °C; Zone 2: 240 °C; Zone 3: 250 °C; Zone 4: 260 °C; Zone 5: 270 °C; The connection area between the barrel and the mold: 270 °C; The hanger die area: 270 °C; The impregnation mold area: 270 °C. Place the glass fiber yarn roll on the yarn rack. The continuous glass fiber passes through the yarn reed and the yarn spreading roller and enters the impregnation mold cavity, and exits from the die head on the other side of the mold cavity. Start the extruder (rotation speed 55 r / min), and at the same time, slowly draw the glass fiber. The resin is sheared, conveyed by the screw, passes through the melt pump and the runner, and finally enters the mold cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet. The sheet is formed by a shaping roller and a cooling roller (the temperature of the cooling roller is 40 °C) to obtain the final prepreg tape product. The mass of the continuous glass fiber is 60% of the total mass of the product.

[0062] Comparative Example 2

[0063] Pour 12.5 Kg of ABS resin, 25 Kg of SAN resin, and 1.5 Kg of maleic anhydride - styrene random copolymer into a mixer and mix evenly for 25 minutes; put the mixed material into the hopper of an extruder. The temperatures of each section of the extruder are as follows: Zone 1: 230 °C; Zone 2: 240 °C; Zone 3: 250 °C; Zone 4: 260 °C; Zone 5: 270 °C; the connection area between the barrel and the mold: 270 °C; the hanger die area: 270 °C; the impregnation mold area: 270 °C. Place the glass fiber yarn roll on the yarn rack. The continuous glass fiber passes through the reed and the yarn spreading roller and enters the impregnation mold cavity, and exits from the die head on the other side of the mold cavity. Start the extruder (rotation speed 55 r / min), and at the same time, slowly draw the glass fiber; the resin is sheared, conveyed by the screw, passes through the melt pump and the runner, and finally enters the mold cavity to complete the impregnation of the glass fiber and the resin, obtaining a sheet; the sheet is formed by a sizing roller and a cooling roller (the temperature of the cooling roller is 40 °C) to obtain the final prepreg product. The mass of the continuous glass fiber is 60% of the total mass of the product.

[0064] In this application, the mechanical properties of the prepreg are detected by measuring the tensile strength and tensile modulus. The test standard is GB / T 1447 - 2005, and the test method is the tensile property test method. Specimen preparation: Use a utility knife to cut the prepreg product into specimens 20 mm wide and 1 m long. This application also measures the thickness, glass fiber content, and impact strength of the prepreg product.

[0065] The specific formulation ratio design and test data are shown in Table 1.

[0066] Table 1

[0067]

[0068]

[0069] According to the data in Table 1, from the comparison of Example 1, Comparative Example 1, and Comparative Example 2, it can be seen that by adopting the scheme of combining a toughening agent and a compatibilizer, the thickness of the product can be significantly reduced, the fiber content can be increased, and the mechanical properties of the product can be improved.

[0070] From the comparison of Example 1 and Example 2, it can be seen that increasing the addition amount of the compatibilizer can improve the mechanical properties of the product. However, considering the material cost, the maximum addition amount of the compatibilizer is preferably 1.5% of the addition amount of the thermoplastic resin.

[0071] From the comparison of Example 2 and Example 3, it can be seen that increasing the addition amount of the toughening agent does not significantly improve the mechanical properties of the product, and the compatibility of the prepreg product becomes poor and it is easy to crack.

[0072] In summary, through the combination of toughening agent and compatibilizer in a certain proportion, the mechanical properties, thickness, and fiber content of the continuous fiber reinforced thermoplastic prepreg tape are significantly optimized and improved, which enables the material to adapt to more severe working conditions and broadens the application scenarios of the material.

[0073] Unless otherwise defined, the technical and scientific terms used herein have the same meanings as commonly understood by those skilled in the technical field of this application. The terms used herein are only for the purpose of describing specific implementation purposes and are not intended to limit this application. The features described in one implementation herein can be applied to another implementation alone or in combination with other features, unless the feature is not applicable or otherwise stated in that other implementation.

[0074] This application has been described through the above implementations. However, it should be understood that the above implementations are only for illustrative and explanatory purposes. This application is not limited to the above implementations. 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 a styrene-acrylonitrile copolymer.

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

4. The continuous fiber reinforced thermoplastic prepreg tape according to claim 3, characterized in that The diameter of the glass fiber is 15 - 20 μm, and / or The linear density of the glass fiber is 1100 - 1300 Tex.

5. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, characterized in that, The toughening agent is a maleic anhydride grafted hydrogenated styrene-butadiene block copolymer.

6. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, characterized in that, The compatibilizer is a maleic anhydride, styrene random copolymer.

7. The continuous fiber reinforced thermoplastic prepreg tape according to claim 1, characterized in that, The addition amount of the compatibilizer is less than or equal to 1.5% of the addition amount of the thermoplastic resin.

8. A method for preparing a continuous fiber reinforced thermoplastic prepreg tape according to any one of claims 1-7 above, characterized in that, Comprising the following steps: S10: Mix the following raw materials by weight percentage: Thermoplastic resin 38 - 47%; Toughening agent 1.5 - 1.9%; Compatibilizer 0.4 - 0.6%; S20: Draw out 50 - 60% of the continuous fiber by weight percentage from the creel; S30: Melt the mixture in step S10 and compound it with the continuous fiber to obtain the continuous fiber reinforced thermoplastic prepreg tape.

9. The preparation method according to claim 8, characterized in that, The mixing time in step S10 is 20 - 30 min.

10. The preparation method according to claim 8, wherein, The melting temperature of the material in step S30 is 210 - 290 °C.

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