A carbon fiber layered trim part and a method of manufacturing the same
By integrating flame retardants and UV absorbers into epoxy resin through a chemical reaction, modifying the carbon fiber surface to introduce mercapto groups, and using a functionally complementary curing agent, the flame retardancy and mechanical properties of epoxy resin-based carbon fiber decorative parts were solved, resulting in decorative parts with self-healing capabilities.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- JIANGYIN JIESHENG ZHIZAO TECH CO LTD
- Filing Date
- 2025-07-18
- Publication Date
- 2026-07-31
AI Technical Summary
Epoxy resin-based carbon fiber decorative parts are prone to spreading when burning, failing to meet fire safety regulations, and the addition of large amounts of flame retardants affects their mechanical properties.
By pre-chemically integrating flame retardants and UV absorbers in epoxy resin, thiol groups are introduced onto the surface of modified carbon fibers, and curing is performed using a curing agent with complementary functions, forming stable chemical bonds and dynamic exchange reactions.
This technology improves the flame retardant and mechanical properties of carbon fiber decorative parts, while also enabling them to self-heal, meet fire safety requirements, and maintain material integrity.
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Abstract
Description
Technical Field
[0001] This invention belongs to the field of composite material technology, specifically relating to a carbon fiber layered decorative part and its preparation method. Background Technology
[0002] Carbon fiber layered decorative parts, with their superior specific strength, specific stiffness, excellent fatigue resistance, ability to form complex curved surfaces, and modern appearance, have been widely used in high-end consumer electronics, luxury car interiors, and luxury goods. The fabrication of carbon fiber layered decorative parts requires high-performance carbon fiber networks as reinforcements, embedded in a thermosetting polymer matrix to transfer loads and provide overall shape and protection. Among the many available matrix resins, epoxy resin is widely used due to its excellent wettability and adhesion, good rigidity and strength, and excellent corrosion resistance. However, epoxy resin is a flammable material. Lacking flame-retardant properties and potentially causing flame spread during combustion, epoxy resin-based decorative parts fail to meet fire safety regulations in the transportation and electronics sectors. To achieve flame-retardant properties in epoxy resin-based decorative parts, a large amount of flame retardant needs to be added to the base resin. While small-molecule flame retardants offer superior flame-retardant properties and are liquid at room temperature, thus not increasing the viscosity of epoxy resin, adding large amounts of flame retardant will severely affect the curing reaction network structure and crosslinking density within the epoxy resin, significantly impacting its mechanical properties. To address these technical deficiencies, this invention provides a carbon fiber layered decorative part and its preparation method. Summary of the Invention
[0003] The purpose of this invention is to provide a carbon fiber layered decorative part and its preparation method, so as to solve the problems mentioned in the background art.
[0004] The objective of this invention can be achieved through the following technical solutions: A method for preparing a carbon fiber layered decorative component includes the following steps: Step 1: Mix benzoquinone, phosphite, and tetrahydrofuran in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, react at a temperature of 40-60℃ for 6-10 hours. After the reaction is completed, remove the solvent by rotary evaporation. Wash the remaining solid with hot water and dry it to obtain the flame retardant. The second step involves mixing the flame retardant, ultraviolet absorber, cystamine, and N,N-dimethylformamide in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the temperature is raised to 55-65°C. Then, paraformaldehyde is added to the three-necked flask in batches. After the addition is complete, the reaction is carried out at 80-90°C for 2-4 hours. After the reaction is completed, the solvent is removed by rotary evaporation to obtain the first curing agent. Step 3: Extract carbon fiber in acetone solution at 65-75℃ for 24 hours to remove the sizing agent on the surface and obtain desized carbon fiber. Then, mix the desized carbon fiber, silver nitrate, potassium persulfate, and deionized water in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, stir at 70-80℃ for 3-4 hours. After the reaction is completed, filter out the solid, wash with anhydrous ethanol, and dry to obtain oxidized carbon fiber. Step 4: Mix carbon oxide, silane coupling agent, and ethanol solution in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, react at 50-80℃ for 2-8 hours. After the reaction is complete, filter out the solid, wash with anhydrous ethanol, and dry to obtain modified carbon fiber. Step 5: Weave the modified carbon fiber into a carbon fiber mesh according to the predetermined pattern. Mix the bisphenol F epoxy resin, the first curing agent, and the second curing agent evenly to obtain the matrix resin. Apply a release agent to the surface of the mold in advance. Step 6: Apply the base resin to the mold surface as the base layer. Then, lay the woven carbon fiber mesh on the epoxy resin base layer and apply the base resin from the center outwards. After the resin has fully impregnated the carbon fiber mesh, roll it to remove air bubbles. Repeat the process of applying epoxy resin and laying carbon fiber mesh and rolling to remove air bubbles until all layers are laid. Then, lay the release cloth, flow guide net, and breathable felt in sequence and cover with a vacuum bag. After sealing, vacuum and compact, then heat cure. After cooling to room temperature and demolding, trim, grind, and polish to obtain the carbon fiber layered decorative part.
[0005] Furthermore, the benzoquinone is one of 1,4-benzoquinone and 1,2-benzoquinone.
[0006] Furthermore, the phosphite is one of dimethyl phosphite and diethyl phosphite.
[0007] Furthermore, the ultraviolet absorber contains at least one phenolic hydroxyl group, including at least one of UV-0 (2,4-dihydroxybenzophenone), UV-24 (2,2'-dihydroxy-4-methoxybenzophenone), and BP-2 (2,2',4,4'-tetrahydroxybenzophenone).
[0008] Furthermore, the acetone solution is an ethanol solution of acetone.
[0009] Preferably, the acetone solution is an ethanol solution of acetone with a volume fraction of 50%.
[0010] Furthermore, the silane coupling agent is one of KH-580 and KH-590.
[0011] Preferably, the ethanol solution is an aqueous solution of ethanol with a volume fraction of 40-60%.
[0012] Preferably, the release agent is one of Neno W-201, Diva 7300, and Diva 7355.
[0013] Furthermore, the second curing agent is 1-(3-aminopropyl)-2-methylimidazole.
[0014] Furthermore, the mass ratio of benzoquinone, phosphite, and tetrahydrofuran is 10:12-22:40-60.
[0015] Furthermore, the mass ratio of the flame retardant, ultraviolet absorber, cystamine, N,N-dimethylformamide, and paraformaldehyde is 17-19:0.2-0.4:15-18:60-80:3-3.4.
[0016] Furthermore, the mass ratio of the carbon fiber to the acetone solution is 50-66:780-1030.
[0017] Furthermore, the mass ratio of the desized carbon fiber, silver nitrate, potassium persulfate, and deionized water is 48–64:3–4:48–64:1800–2400.
[0018] Furthermore, the mass ratio of the oxidized carbon fiber, silane coupling agent, and ethanol solution is 45-60:9-18:700-940.
[0019] Furthermore, the mass ratio of the modified carbon fiber, bisphenol F epoxy resin, first curing agent, and second curing agent is 50-70:27-40:20-25:3-5.
[0020] Furthermore, in step five, the conditions for achieving uniform mixing are as follows: stir at 800–1000 rpm for 120–150 s, then reduce the speed to 300–400 rpm and continue stirring for 40–60 s.
[0021] Furthermore, in step six, the conditions for heat curing are: curing at 75–85°C for 100–140 min, followed by curing at 135–145°C for another 100–140 min.
[0022] A carbon fiber layered decorative part is prepared by any of the above preparation steps.
[0023] The beneficial effects of this invention are: 1) This invention uses benzoquinone and phosphite as raw materials, and utilizes the nucleophilic addition reaction between phosphite and benzoquinone to obtain a flame retardant. Then, using this flame retardant with phenolic hydroxyl groups and the ultraviolet absorber with phenolic hydroxyl groups as active aromatic hydrogen donors, a Mannich condensation reaction is carried out with cystamine and paraformaldehyde to obtain a curing agent. This invention effectively solves the problems of dispersion and migration of additives in high-viscosity epoxy resins, as well as the influence of excessive flame retardant addition on the mechanical properties of epoxy resins, by pre-integrating small molecule flame retardants and ultraviolet absorbers into the curing agent through a chemical reaction.
[0024] 2) This invention introduces a large number of thiol groups on the surface of carbon fibers by sequentially desizing, oxidizing, and grafting them. The hydroxyl groups on the surface of the modified carbon fibers can undergo a reversible thiol-disulfide bond exchange reaction with the disulfide bonds in the curing agent. This not only forms new covalent bonds in the early stage of curing and establishes a stable chemical bond between the modified carbon fibers and the epoxy resin, but also spontaneously repairs the microcracks caused by damage after the decorative parts are subjected to external impact, effectively maintaining the appearance integrity of the decorative parts and reducing the impact of mechanical damage on the appearance.
[0025] 3) This invention uses two complementary curing agents to cure epoxy resin. The first curing agent possesses both a flexible methylene segment and disulfide bond structure and a rigid aromatic ring structure. The flexible methylene segment and disulfide bond effectively enhance the mobility of molecular chain segments, thereby significantly improving the toughness of epoxy resin. Furthermore, the enhanced chain segment mobility promotes dynamic thiol-disulfide bond exchange reactions in the system. This makes it easier for the corresponding groups to contact and recombine after microcracks appear in the decorative part, effectively improving the self-healing efficiency of epoxy resin. Simultaneously, the synergistic effect of the rigid aromatic ring structure and the flexible disulfide bond achieves a balance between rigidity and flexibility in the molecular chain segments, which is beneficial for enhancing the overall mechanical strength of the material while improving toughness. The second curing agent contains an imidazole structure. The imidazole ring itself is rigid, which helps improve the rigidity and heat resistance of the epoxy resin curing network. In addition, imidazole, as an organic base, can effectively catalyze the dynamic exchange reaction between thiol-disulfide bonds, thus further synergistically improving the self-healing efficiency and rate of epoxy resin for microcracks, building upon the improved repair potential of the first curing agent. Detailed Implementation
[0026] The technical solutions of the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments in this application specification, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection claimed in this application.
[0027] The raw materials used in this invention are not particularly restricted in terms of their source; they can be purchased from the market or prepared using conventional methods known to those skilled in the art. Example 1
[0028] A method for preparing a carbon fiber layered decorative component includes the following steps: Step 1: According to the mass fraction, 10 parts of 1,4-benzoquinone, 12 parts of dimethyl phosphite, and 40 parts of tetrahydrofuran are mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture is reacted at 40°C for 10 hours. After the reaction is completed, the solvent is removed by rotary evaporation, and the remaining solid is washed with hot water and dried to obtain the flame retardant. Step 2: According to the mass percentage, mix 17 parts flame retardant, 0.2 parts UV-0, 15 parts cystamine, and 60 parts N,N-dimethylformamide in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, raise the temperature to 55°C. Then, add 3 parts of paraformaldehyde in 3 batches, with each batch containing 1 part. After the addition is complete, react at 80°C for 4 hours. After the reaction is complete, remove the solvent by rotary evaporation to obtain the first curing agent. Step 3: According to the mass fraction, 50 parts of carbon fiber were extracted in an ethanol solution of 780 parts of 50% acetone at 65°C for 24 hours to remove the sizing agent on the surface and obtain desized carbon fiber. Then, 48 parts of desized carbon fiber, 3 parts of silver nitrate, 48 parts of potassium persulfate, and 1800 parts of deionized water were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was stirred at 70°C for 4 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain oxidized carbon fiber. Step 4: By mass fraction, 45 parts of oxidized carbon fiber, 9 parts of silane coupling agent KH-590, and 700 parts of 60% ethanol aqueous solution were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was reacted at 50°C for 8 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain modified carbon fiber. Step 5: Weave 50 parts of modified carbon fiber into carbon fiber mesh according to the predetermined pattern. Stir 27 parts of bisphenol F epoxy resin, 20 parts of first curing agent, and 3 parts of 1-(3-aminopropyl)-2-methylimidazolium at 800 rpm for 150 s, then reduce the speed to 300 rpm and continue stirring for 60 s to obtain the matrix resin. Apply release agent Nenno W-201 to the surface of the mold in advance. Step 6: Apply the base resin to the mold surface as the underlayer. Then, lay the woven carbon fiber mesh on the epoxy resin underlayer and apply the base resin from the center outwards. After the resin fully impregnates the carbon fiber mesh, roll it to remove air bubbles. Repeat the process of applying epoxy resin and laying carbon fiber mesh and rolling to remove air bubbles until all layers are laid. Then, lay the release cloth, flow guide net, and breathable felt in sequence and cover with a vacuum bag. After sealing, vacuum and compact it. Cure at 75℃ for 140 minutes, then continue curing at 135℃ for 140 minutes. After cooling to room temperature and demolding, trim, grind, and polish to obtain the carbon fiber layered decorative part.
[0029] A carbon fiber layered decorative part is prepared by the above-described preparation steps. Example 2
[0030] A method for preparing a carbon fiber layered decorative component includes the following steps: Step 1: According to the mass fraction, 10 parts of 1,2-benzoquinone, 17 parts of diethyl phosphite, and 50 parts of tetrahydrofuran are mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture is reacted at 50°C for 8 hours. After the reaction is completed, the solvent is removed by rotary evaporation, and the remaining solid is washed with hot water and dried to obtain the flame retardant. Step 2: According to the mass percentage, mix 18 parts flame retardant, 0.3 parts UV-24, 16.5 parts cystamine, and 70 parts N,N-dimethylformamide in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, raise the temperature to 60°C. Then, add 3.2 parts paraformaldehyde in two batches, with each batch containing 1.6 parts. After the addition is complete, react at 85°C for 3 hours. After the reaction is complete, remove the solvent by rotary evaporation to obtain the first curing agent. Step 3: By mass fraction, 58 parts of carbon fiber were extracted in 905 parts of 50% acetone ethanol solution at 70℃ for 24 hours to remove the surface sizing agent and obtain desized carbon fiber. Then, 56 parts of desized carbon fiber, 3.5 parts of silver nitrate, 56 parts of potassium persulfate, and 2100 parts of deionized water were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was stirred at 75℃ for 3.5 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain oxidized carbon fiber. Step 4: By mass, 52.5 parts of oxidized carbon fiber, 13.5 parts of silane coupling agent KH-590, and 820 parts of 50% ethanol aqueous solution were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was reacted at 65°C for 5 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain modified carbon fiber. Step 5: 60 parts of modified carbon fiber are woven into carbon fiber mesh according to the predetermined pattern. 33.5 parts of bisphenol F epoxy resin, 22.5 parts of first curing agent, and 4 parts of 1-(3-aminopropyl)-2-methylimidazole are stirred at 900 rpm for 135 s, then the speed is reduced to 350 rpm and stirred for another 50 s to obtain the matrix resin. The mold release agent Diva 7300 is pre-applied to the surface of the mold. Step 6: Apply the base resin to the mold surface as the underlayer. Then, lay the woven carbon fiber mesh on the epoxy resin underlayer and apply the base resin from the center outwards. After the resin fully impregnates the carbon fiber mesh, roll it to remove air bubbles. Repeat the process of applying epoxy resin and laying carbon fiber mesh and rolling to remove air bubbles until all layers are laid. Then, lay the release cloth, flow guide net, and breathable felt in sequence and cover with a vacuum bag. After sealing, vacuum and compact it. Cure at 80℃ for 120 minutes, and then continue to cure at 140℃ for 120 minutes. After cooling to room temperature and demolding, trim, grind, and polish to obtain the carbon fiber layered decorative part.
[0031] A carbon fiber layered decorative part is prepared by the above-described preparation steps. Example 3
[0032] A method for preparing a carbon fiber layered decorative component includes the following steps: Step 1: According to the mass fraction, 10 parts of 1,4-benzoquinone, 22 parts of diethyl phosphite, and 60 parts of tetrahydrofuran are mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture is reacted at 60°C for 6 hours. After the reaction is completed, the solvent is removed by rotary evaporation, and the remaining solid is washed with hot water and dried to obtain the flame retardant. Step 2: According to the mass percentage, mix 19 parts flame retardant, 0.4 parts BP-2, 18 parts cystamine, and 80 parts N,N-dimethylformamide in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, raise the temperature to 65°C. Then, add 3.4 parts paraformaldehyde in two batches, with each batch containing 1.7 parts. After the addition is complete, react at 90°C for 2 hours. After the reaction is complete, remove the solvent by rotary evaporation to obtain the first curing agent. Step 3: By mass fraction, 66 parts of carbon fiber were extracted in an ethanol solution of 1030 parts by volume of 50% acetone at 75°C for 24 hours to remove the surface sizing agent and obtain desized carbon fiber. Then, 64 parts of desized carbon fiber, 4 parts of silver nitrate, 64 parts of potassium persulfate, and 2400 parts of deionized water were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was stirred at 80°C for 3 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain oxidized carbon fiber. Step 4: By mass fraction, 60 parts of oxidized carbon fiber, 18 parts of silane coupling agent KH-580, and 940 parts of 40% ethanol aqueous solution are mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture is reacted at 80°C for 2 hours. After the reaction is completed, the solid is filtered out, washed with anhydrous ethanol, and dried to obtain modified carbon fiber. Step 5: 70 parts of modified carbon fiber are woven into carbon fiber mesh according to the predetermined pattern. 40 parts of bisphenol F epoxy resin, 25 parts of the first curing agent, and 5 parts of 1-(3-aminopropyl)-2-methylimidazole are stirred at 1000 rpm for 120 seconds, then the speed is reduced to 400 rpm and stirred for another 40 seconds to obtain the matrix resin. The mold release agent Diva 7355 is pre-applied to the surface of the mold. Step 6: Apply the base resin to the mold surface as the underlayer. Then, lay the woven carbon fiber mesh on the epoxy resin underlayer and apply the base resin from the center outwards. After the resin fully impregnates the carbon fiber mesh, roll it to remove air bubbles. Repeat the process of applying epoxy resin and laying carbon fiber mesh and rolling to remove air bubbles until all layers are laid. Then, lay the release cloth, flow guide net, and breathable felt in sequence and cover with a vacuum bag. After sealing, vacuum and compact it. Cure at 85℃ for 100 minutes, and then continue to cure at 145℃ for 100 minutes. After cooling to room temperature and demolding, trim, grind, and polish to obtain the carbon fiber layered decorative part.
[0033] A carbon fiber layered decorative part is prepared by the above-described preparation steps.
[0034] Comparative Example 1 The difference between this comparative example and Example 1 is that, instead of preparing a first curing agent, a commercially available curing agent T-31 is used to directly prepare carbon fiber layered decorative parts, and the method of adding flame retardants and ultraviolet absorbers is changed to direct addition.
[0035] Step 1: According to the mass fraction, 50 parts of carbon fiber were extracted in 780 parts of 50% acetone ethanol solution at 65℃ for 24 hours to remove the surface sizing agent and obtain desized carbon fiber. Then, 48 parts of desized carbon fiber, 3 parts of silver nitrate, 48 parts of potassium persulfate, and 1800 parts of deionized water were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was stirred at 70℃ for 4 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain oxidized carbon fiber. Step 2: By mass fraction, 45 parts of oxidized carbon fiber, 9 parts of silane coupling agent KH-590, and 700 parts of 60% ethanol aqueous solution were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was reacted at 50°C for 8 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain modified carbon fiber. Step 3: 50 parts of modified carbon fiber are woven into carbon fiber mesh according to the predetermined pattern. 27 parts of bisphenol F epoxy resin, 12 parts of dimethyl phosphite, 0.2 parts of UV-0, 7.8 parts of curing agent T-31, and 3 parts of 1-(3-aminopropyl)-2-methylimidazole are stirred at 800 rpm for 150 s, then the speed is reduced to 300 rpm and stirred for another 60 s to obtain the matrix resin. The mold release agent Neno W-201 is pre-applied to the surface of the mold. Step 4: Apply the base resin to the mold surface as the underlayer. Then, lay the woven carbon fiber mesh on the epoxy resin underlayer and apply the base resin from the center outwards. After the resin fully impregnates the carbon fiber mesh, roll it to remove air bubbles. Repeat the process of applying epoxy resin and laying carbon fiber mesh and rolling to remove air bubbles until all layers are laid. Then, lay the release cloth, flow guide net, and breathable felt in sequence and cover with a vacuum bag. After sealing, vacuum and compact it. Cure at 75℃ for 140 minutes, then continue curing at 135℃ for 140 minutes. After cooling to room temperature and demolding, trim, grind, and polish to obtain the carbon fiber layered decorative part.
[0036] A carbon fiber layered decorative part is prepared by the above-described preparation steps.
[0037] Comparative Example 2 The difference between this comparative example and Comparative Example 1 is that no flame retardant was added when preparing the decorative parts.
[0038] Step 1: According to the mass fraction, 50 parts of carbon fiber were extracted in 780 parts of 50% acetone ethanol solution at 65℃ for 24 hours to remove the surface sizing agent and obtain desized carbon fiber. Then, 48 parts of desized carbon fiber, 3 parts of silver nitrate, 48 parts of potassium persulfate, and 1800 parts of deionized water were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was stirred at 70℃ for 4 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain oxidized carbon fiber. Step 2: By mass fraction, 45 parts of oxidized carbon fiber, 9 parts of silane coupling agent KH-590, and 700 parts of 60% ethanol aqueous solution were mixed in a three-necked flask equipped with a condenser, thermometer, and magnetic stirrer. After turning on the magnetic stirrer, the mixture was reacted at 50°C for 8 hours. After the reaction was completed, the solid was filtered out, washed with anhydrous ethanol, and dried to obtain modified carbon fiber. Step 3: 50 parts of modified carbon fiber are woven into carbon fiber mesh according to the predetermined pattern. 27 parts of bisphenol F epoxy resin, 0.2 parts of UV-0, 7.8 parts of curing agent T-31, and 3 parts of 1-(3-aminopropyl)-2-methylimidazole are stirred at 800 rpm for 150 s, then the speed is reduced to 300 rpm and stirred for another 60 s to obtain the matrix resin. The mold release agent Nenno W-201 is pre-applied to the surface of the mold. Step 4: Apply the base resin to the mold surface as the underlayer. Then, lay the woven carbon fiber mesh on the epoxy resin underlayer and apply the base resin from the center outwards. After the resin fully impregnates the carbon fiber mesh, roll it to remove air bubbles. Repeat the process of applying epoxy resin and laying carbon fiber mesh and rolling to remove air bubbles until all layers are laid. Then, lay the release cloth, flow guide net, and breathable felt in sequence and cover with a vacuum bag. After sealing, vacuum and compact it. Cure at 75℃ for 140 minutes, then continue curing at 135℃ for 140 minutes. After cooling to room temperature and demolding, trim, grind, and polish to obtain the carbon fiber layered decorative part.
[0039] A carbon fiber layered decorative part is prepared by the above-described preparation steps.
[0040] Experimental Example 1 The carbon fiber layered decorative parts prepared in Examples 1-3 and Comparative Example 1 were subjected to flame retardant performance tests, flexural strength tests, impact resistance tests, and self-healing performance tests, respectively. The test results are shown in Tables 1 and 2.
[0041] Flame retardant performance test: Tested in accordance with standard UL 94.
[0042] Bending strength test: The test shall be conducted in accordance with the standard GB / T9341-2008.
[0043] Impact resistance test: The test was conducted in accordance with the standard GB / T 1843-2008.
[0044] Self-healing performance test: Micro-cracks were created by repeatedly bending the decorative parts inside them. The decorative parts with micro-cracks were then transferred to a heating table and continuously heated at 60°C. The self-healing time of each component of the decorative parts was recorded. The faster the self-healing speed, the better the self-healing performance.
[0045] Table 1
[0046] Table 2
[0047] As can be seen from Tables 1 and 2, the decorative parts of the present invention in Examples 1 to 3 have good mechanical properties and flame retardant properties, and can achieve self-repair by heating after being subjected to external mechanical damage. However, although a large amount of flame retardant was added to the decorative parts in Comparative Example 1, the dispersion of the flame retardant in the epoxy resin was poor, and there was still a problem of insufficient flame retardant performance in local areas where the flame retardant was less distributed. Moreover, the large amount of flame retardant added had a serious impact on the mechanical properties of the material.
[0048] The descriptions of the above embodiments are merely illustrative of the methods and core ideas of the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A method for producing a carbon fiber layered trim part, characterized by, Includes the following steps: A flame retardant is obtained by nucleophilic addition reaction of benzoquinone and phosphite. Then, a first curing agent is obtained by Mannich condensation reaction of the flame retardant, ultraviolet absorber, cystamine, and paraformaldehyde. The carbon fiber is desizing, oxidizing, and grafting silane coupling agent to obtain modified carbon fiber. The modified carbon fiber is woven to obtain carbon fiber mesh. Bisphenol F epoxy resin, the first curing agent, and the second curing agent are stirred and mixed evenly to obtain a matrix resin. The matrix resin is then brushed onto a mold pre-coated with a release agent as the base layer. The carbon fiber mesh is then laid on the base layer. After rolling to remove air bubbles, the epoxy resin is brushed and the carbon fiber mesh is laid and rolled to remove air bubbles is repeated until all layers are laid. After vacuum compaction, heat curing is performed. After cooling to room temperature and demolding, the carbon fiber layered decorative parts are obtained by trimming, grinding, and polishing. The ultraviolet absorber is at least one of UV-0, UV-24, and BP-2, and the second curing agent is 1-(3-aminopropyl)-2-methylimidazole; The mass ratio of benzoquinone to phosphite is 10:12-22; the mass ratio of flame retardant, ultraviolet absorber, cystamine, and paraformaldehyde is 17-19:0.2-0.4:15-18:3-3.
4. The mass ratio of modified carbon fiber, bisphenol F epoxy resin, first curing agent, and second curing agent is 50-70:27-40:20-25:3-5.
2. The method for preparing a carbon fiber layered decorative component according to claim 1, characterized in that, Benzoquinone is one of 1,4-benzoquinone and 1,2-benzoquinone; phosphite is one of dimethyl phosphite and diethyl phosphite; silane coupling agent is one of KH-580 and KH-590; and mold release agent is one of Neno W-201, Diva 7300, and Diva 7355.
3. The method for preparing a carbon fiber layered decorative component according to claim 1, characterized in that, The conditions for nucleophilic addition reactions to occur are: The benzoquinone, phosphite, and tetrahydrofuran were mixed and reacted at a controlled temperature of 40–60 °C.
4. The method for preparing a carbon fiber layered decorative component according to claim 1, characterized in that, The conditions for the Mannich condensation reaction to occur are: Flame retardant, ultraviolet absorber, cystamine, and N,N-dimethylformamide are mixed and the system temperature is raised to 55-65°C. Then, paraformaldehyde is added to the system, and the temperature is controlled at 80-90°C for reaction after the addition is complete.
5. The method for preparing a carbon fiber layered decorative component according to claim 1, characterized in that, The desizing conditions for carbon fiber are extraction in acetone solution at 65-75℃ for 24 hours, and oxidation conditions are mixing the desizing carbon fiber, silver nitrate, potassium persulfate, and deionized water and reacting at 70-80℃ for 3-4 hours. The mass ratio of carbon fiber to silane coupling agent is 45-60:9-18.
6. The method for preparing a carbon fiber layered decorative component according to claim 1, characterized in that, The conditions for uniform mixing are to stir at 800-1000 rpm for 120-150 seconds, then reduce the speed to 300-400 rpm and continue stirring for 40-60 seconds.
7. The method for preparing a carbon fiber layered decorative component according to claim 1, characterized in that, The heat curing conditions are: cure at 75-85℃ for 100-140 min, then continue curing at 135-145℃ for another 100-140 min.
8. A carbon fiber layered trim piece, characterized by, A carbon fiber layered decorative part is prepared by the preparation method described in any one of claims 1 to 7.