Flame-retardant hybrid fiber composite material plate structure and preparation method thereof
By using a composite structure consisting of an internal rigid layer, an intermediate strength layer, and a surface flame-retardant layer, combined with a specific fiber and resin ratio and weaving design, the problem of single-fiber composite materials being unable to meet multiple functional characteristics is solved, achieving comprehensive performance of high stiffness, strength, and flame retardancy.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ZHONGFU SHENYING CARBON FIBER
- Filing Date
- 2026-03-25
- Publication Date
- 2026-05-15
AI Technical Summary
Existing single-fiber composite materials cannot simultaneously meet multiple functional requirements such as high stiffness, strength, excellent wear resistance and flame retardancy.
It adopts a composite structure of an internal rigid layer, an intermediate strength layer and a surface flame-retardant layer. The internal rigid layer provides rigidity and structural stability, the intermediate strength layer transmits and disperses stress, and the surface flame-retardant layer provides flame-retardant properties and abrasion resistance. Through a specific ratio of fibers and resins and a weaving structure design, combined with the use of flame retardants, a dense layer is formed.
This achieves a panel structure that simultaneously possesses high rigidity, strength, excellent wear resistance, and flame retardancy, meeting multiple functional requirements.
Smart Images
Figure CN122034482A_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to the field of composite materials, and in particular to a flame-retardant hybrid fiber composite material sheet structure and its preparation method. Background Technology
[0002] With the rapid development of modern industry, various industries are increasingly demanding higher comprehensive performance from materials. This is especially true in high-end fields such as rail transportation, aerospace, and building decoration, where materials are required not only to have high rigidity and strength, but also excellent wear resistance, flame retardancy, and other multifunctional properties to ensure the stability and safety of equipment operation. Summary of the Invention
[0003] To address the problems existing in related technologies, this disclosure provides a flame-retardant hybrid fiber composite material plate structure and its preparation method.
[0004] According to a first aspect of the present disclosure, a flame-retardant hybrid fiber composite material sheet structure is provided, the sheet structure comprising: Internal rigid layer; An intermediate strength layer surrounds and covers the surface of the inner rigid layer; A surface flame-retardant layer surrounds and covers the surface of the intermediate strength layer. The surface flame-retardant layer comprises a first carbon fiber, a flame-retardant fiber, and a polyester resin, wherein the mass ratio of the first carbon fiber, the flame-retardant fiber, and the polyester resin is 1:(0.5~2.5):(1.5~3.5).
[0005] In some embodiments of this disclosure, the surface flame-retardant layer further includes a flame retardant, wherein the flame retardant accounts for 8% to 35% of the mass of the polyester resin. The flame retardant includes at least one of brominated polystyrene, aluminum hydroxide, and tributyl phosphate.
[0006] In some embodiments of this disclosure, the first carbon fiber includes at least one of M40, M40J, M55, M55J, M60, and M60J; The flame-retardant fiber includes at least one of poly(p-phenylene terephthalamide) fiber, poly(m-phenylene isophthalamide) fiber, and polyphenylene sulfide fiber.
[0007] In some embodiments of this disclosure, the thickness ratio of the inner rigid layer, the intermediate strength layer, and the surface flame-retardant layer is 2:(0.8~1.5):(0.8~1.5).
[0008] In some embodiments of this disclosure, the internal rigid layer comprises a second carbon fiber and an epoxy resin, wherein the mass ratio of the second carbon fiber to the epoxy resin is (0.4~0.7):1; The thickness of the internal rigid layer is 1~10mm.
[0009] In some embodiments of this disclosure, the intermediate strength layer comprises a mixture of fibers and a thermoplastic resin, wherein the mass ratio of the mixture of fibers to the thermoplastic resin is (0.4~1.5):1; The hybrid fiber comprises a third carbon fiber and a toughening fiber, wherein the mass ratio of the third carbon fiber to the toughening fiber is (0.5~7.5):1; The toughening fiber includes at least one of aramid fiber, polyethylene fiber, poly(p-phenylenebenzodioxazole) fiber, and glass fiber.
[0010] In some embodiments of this disclosure, the mixed fibers in the intermediate strength layer are two-dimensional and / or three-dimensional woven structures; The two-dimensional weave structure includes at least one of plain weave, twill weave, and satin weave; The three-dimensional braided structure includes at least one of three-dimensional four-way, three-dimensional five-way, three-dimensional six-way, and three-dimensional seven-way.
[0011] In some embodiments of this disclosure, the sheet structure further includes a thermosetting resin layer that surrounds and covers the surface of the flame-retardant layer, the thickness of which is 1-3 mm.
[0012] According to a second aspect of the present disclosure, a method for preparing a flame-retardant hybrid fiber composite material plate structure is provided. The method is used to prepare the flame-retardant hybrid fiber composite material plate structure as described above. The method includes: Provide an internal rigid layer; An intermediate strength layer is formed around the surface that covers the inner rigid layer; After the first carbon fiber and flame-retardant fiber are circumferentially wound around the surface of the intermediate strength layer, polyester resin is impregnated and cured to obtain a surface flame-retardant layer that surrounds the surface of the intermediate strength layer.
[0013] In some embodiments of this disclosure, providing the internal rigid layer includes: The second carbon fiber and epoxy resin are integrally formed by pultrusion to obtain the internal rigid layer; The intermediate strength layer forming the surface surrounding the inner rigid layer includes: After the mixed fibers are placed on the surface of the inner rigid layer, they are impregnated with thermoplastic resin and cured to obtain the intermediate strength layer that surrounds the surface of the inner rigid layer; the mixed fibers are woven into a two-dimensional woven structure and / or a three-dimensional woven structure.
[0014] The beneficial effects of this disclosure include, but are not limited to: the flame-retardant hybrid fiber composite panel structure provided by this disclosure includes an internal rigid layer, an intermediate strength layer, and a surface flame-retardant layer. The internal rigid layer provides rigidity and structural stability to the panel structure, ensuring that the panel is not easily bent or deformed under stress. The intermediate strength layer surrounds the surface of the internal rigid layer, effectively transferring and dispersing stress generated by external impacts, enhancing the impact resistance of the panel structure. The surface flame-retardant layer surrounds the surface of the intermediate strength layer, providing flame-retardant properties to the panel structure and exhibiting good wear resistance. Thus, the panel structure can simultaneously meet multiple functional requirements such as high rigidity and strength, excellent wear resistance, and flame retardancy.
[0015] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description
[0016] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the principles of these embodiments. In these drawings, similar reference numerals are used to denote similar elements. The drawings described below are some embodiments of the present disclosure, but not all embodiments. Other drawings will be readily available to those skilled in the art based on these drawings without inventive effort.
[0017] Figure 1 This is a schematic diagram of a longitudinal section of a flame-retardant hybrid fiber composite material plate structure, which is an exemplary embodiment of the present disclosure. Figure 2 This is a schematic diagram of a method for preparing a flame-retardant hybrid fiber composite material plate structure according to an exemplary embodiment of the present disclosure; Figure 3 This is a schematic diagram of a flame-retardant hybrid fiber composite material sheet structure, which is an exemplary embodiment of this disclosure. Detailed Implementation
[0018] To make the objectives, technical solutions, and advantages of this disclosure clearer, the technical solutions of this disclosure will be clearly and completely described below in conjunction with the embodiments of this disclosure. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this disclosure can be arbitrarily combined with each other.
[0019] Single-fiber composite materials in related technologies cannot simultaneously meet multi-dimensional performance requirements, such as high stiffness and strength, excellent wear resistance, flame retardancy, and other multiple functional characteristics.
[0020] Based on this, this disclosure provides a flame-retardant hybrid fiber composite panel structure, including an internal rigid layer, an intermediate strength layer, and a surface flame-retardant layer. The internal rigid layer provides rigidity and structural stability to the panel structure, ensuring that the panel is not prone to bending or deformation under stress. The intermediate strength layer surrounds the surface of the internal rigid layer, effectively transferring and dispersing stress generated by external impacts, enhancing the impact resistance of the panel structure. The surface flame-retardant layer surrounds the surface of the intermediate strength layer, providing flame-retardant properties to the panel structure and exhibiting good wear resistance. This allows the panel structure to simultaneously meet multiple functional requirements, including high rigidity and strength, excellent wear resistance, and flame retardancy.
[0021] An exemplary embodiment of this disclosure provides a flame-retardant hybrid fiber composite material plate structure, such as... Figure 1 As shown, the panel structure 100 includes an internal rigid layer 10, an intermediate strength layer 20, and a surface flame-retardant layer 30. The internal rigid layer 10 provides rigidity and structural stability to the panel structure 100, ensuring that the panel is not easily bent or deformed under stress. The intermediate strength layer 20 surrounds the surface of the internal rigid layer 10, effectively transferring and dispersing stress generated by external impacts, enhancing the impact resistance of the panel structure 100. The surface flame-retardant layer 30 surrounds the surface of the intermediate strength layer 20, providing flame-retardant properties to the panel structure 100. The surface flame-retardant layer 30 includes a first carbon fiber, flame-retardant fiber, and polyester resin, with a mass ratio of 1:(0.5~2.5):(1.5~3.5). The first carbon fiber ensures the mechanical strength and modulus of the surface flame-retardant layer 30, the flame-retardant fiber provides flame-retardant properties, and the polyester resin serves as the matrix material, bonding the first carbon fiber and flame-retardant fiber together and providing the surface flame-retardant layer 30 with certain strength and wear resistance. The mass ratio of the first carbon fiber, flame-retardant fiber, and polyester resin is within the range of 1:(0.5~2.5):(1.5~3.5), which can balance the flame-retardant properties, mechanical strength, and wear resistance of the surface flame-retardant layer 30. For example, in the surface flame-retardant layer 30, the mass ratio of the first carbon fiber, flame-retardant fiber, and polyester resin can be 1:0.5:1.5, 1:1:2.5, 1:2:3, or 1:2.5:3.5. The mass ratio of the first carbon fiber, flame-retardant fiber, and polyester resin can also be any value between the exemplary mass ratios, such as any value between 1:(1~2.2):(2~3). Therefore, the plate structure provided in this embodiment can simultaneously satisfy multiple functional characteristics such as high rigidity and strength, excellent wear resistance, and flame retardancy.
[0022] In one exemplary embodiment, the surface flame-retardant layer further includes a flame retardant, the flame retardant being 8% to 35% of the mass of the polyester resin, and the flame retardant including at least one of brominated polystyrene, aluminum hydroxide, and tributyl phosphate.
[0023] In this embodiment, the flame-retardant properties of the surface flame-retardant layer come not only from the flame-retardant fibers but also from the addition of flame-retardant agents to the polyester resin, further enhancing the flame-retardant properties of the surface flame-retardant layer. The flame-retardant mass is 8% to 35% of the polyester resin mass. If the percentage of flame-retardant in the polyester resin mass is less than 8%, the dispersion density of the flame-retardant in the polyester resin is insufficient to form a continuous flame-retardant protective layer in the surface flame-retardant layer. If the percentage of flame-retardant in the polyester resin mass is greater than 35%, although the flame-retardant performance of the surface flame-retardant layer may be further improved, it will have a negative impact on the mechanical properties and molding process of the composite material sheet structure. For example, excessive flame-retardant can easily form stress concentration points at the interface of carbon fiber, flame-retardant fiber, and polyester resin, leading to a significant decrease in the interlaminar shear strength and flexural strength of the composite material sheet structure, making the surface flame-retardant layer prone to brittle cracking or peeling when subjected to external impact. Therefore, in this embodiment, the percentage of flame-retardant in the polyester resin mass is limited to 8% to 35%. For example, the amount of flame retardant can be adjusted according to different application scenarios of the board structure. For instance, in applications requiring high flame retardancy, the amount of flame retardant added to the polyester resin can be increased, while in applications requiring lower flame retardancy, the amount can be reduced to save on the manufacturing cost of the board structure. For example, the flame retardant mass can be 8%, 15%, 20%, 30%, or 35% of the polyester resin mass, and the percentage of flame retardant mass to polyester resin mass can also be any value between the exemplary percentages, such as 10% to 30% of the polyester resin mass.
[0024] Brominated polystyrene flame retardant features high thermal stability and good compatibility with polyester resin. Aluminum hydroxide flame retardant is an environmentally friendly flame retardant, and tributyl phosphate flame retardant can improve the processing flowability of polyester resin. In this embodiment, at least one of brominated polystyrene, aluminum hydroxide, and tributyl phosphate can be selected as the flame retardant; for example, one, two, or all three can be selected simultaneously.
[0025] In one exemplary embodiment, the first carbon fiber includes at least one of M40, M40J, M55, M55J, M60, and M60J.
[0026] M40, M40J, M55, M55J, M60, and M60J are all high-modulus carbon fibers. The first carbon fiber in the surface flame-retardant layer is made of high-modulus carbon fiber, which effectively resists friction and impact on the surface of the flame-retardant layer, improving its wear resistance and thus enhancing the wear resistance of the board structure surface. Furthermore, the aforementioned high-modulus carbon fibers have a low coefficient of thermal expansion, preventing the board structure from expanding when exposed to fire and heat, maintaining dimensional stability, reducing cracking or deformation of the board structure, and thus maintaining the integrity of the surface flame-retardant layer to provide sustained flame-retardant properties.
[0027] In one exemplary embodiment, the flame-retardant fiber includes at least one of poly(p-phenylene terephthalamide) fiber, poly(m-phenylene isophthalamide) fiber, and polyphenylene sulfide fiber.
[0028] Poly(p-phenylene terephthalamide) fiber (PPTA fiber), poly(m-phenylene isophthalamide) fiber (MPTA fiber), and polyphenylene sulfide fiber (PPS fiber) are all high-performance fibers with excellent chemical resistance and thermal stability, and they can quickly self-extinguish after being removed from the flame. In this embodiment, the flame-retardant fiber can be at least one of the following: poly(p-phenylene terephthalamide) fiber, poly(m-phenylene isophthalamide) fiber, and polyphenylene sulfide fiber. For example, one, two, or all three can be used simultaneously.
[0029] In one exemplary embodiment, the thickness ratio of the inner rigid layer, the intermediate strength layer, and the surface flame-retardant layer is 2:(0.8~1.5):(0.8~1.5).
[0030] like Figure 1As shown, the panel structure 100 includes an internal rigid layer 10, an intermediate strength layer 20, and a surface flame-retardant layer 30. The internal rigid layer 10 provides rigidity and structural stability to the panel structure 100, ensuring that the panel is not easily bent or deformed under stress. The intermediate strength layer 20 surrounds the surface of the internal rigid layer 10, effectively transferring and dispersing stress generated by external impacts, enhancing the impact resistance of the panel structure 100. The surface flame-retardant layer 30 surrounds the surface of the intermediate strength layer 20, providing flame-retardant properties to the panel structure 100 and exhibiting good wear resistance. In this embodiment, the thickness ratio of the internal rigid layer 10, the intermediate strength layer 20, and the surface flame-retardant layer 30 is 2:(0.8~1.5):(0.8~1.5). That is, the thickness of the internal rigid layer 10 is relatively large, providing the main rigidity and structural stability for the plate structure 100. The thickness of the intermediate strength layer 20 and the surface flame-retardant layer 30 can be adjusted according to their needs for transmitting and dispersing stress and providing flame-retardant protection. For example, if the intermediate strength layer 20 is too thin, the impact resistance and interlaminar shear strength of the plate structure 100 will be insufficient. If the surface flame-retardant layer 30 is too thin, the fireproof and flame-retardant performance cannot be guaranteed. For example, the thickness ratio of the inner rigid layer 10, the intermediate strength layer 20 and the surface flame retardant layer 30 can be 2:0.8:0.8, 2:1:1.2, 2:1.2:1 or 2:1.5:1.5. The thickness ratio of the inner rigid layer 10, the intermediate strength layer 20 and the surface flame retardant layer 30 can also be any value between the exemplary ratios, such as any value between 2:(1~1.2):(1~1.2).
[0031] In one exemplary embodiment, the inner rigid layer comprises a second carbon fiber and epoxy resin, wherein the mass ratio of the second carbon fiber to the epoxy resin is (0.4~0.7):1, and the thickness of the inner rigid layer is 1~10 mm.
[0032] For example, the second carbon fiber can be at least one of T300, T700, T800, and T1000 high-strength carbon fibers, and the second carbon fiber tow can be at least one of 3K, 6K, 12K, 24K, and 48K. The internal rigid layer comprises high-strength second carbon fibers and epoxy resin, and the mass ratio of the second carbon fiber to epoxy resin is (0.4~0.7):1. Within this mass ratio range, the epoxy resin can fully impregnate and coat the second carbon fiber, and the content of the second carbon fiber can also ensure that the internal rigid layer has sufficiently high strength and modulus to provide rigidity and structural stability for the plate structure. For example, in the internal rigid layer, the mass ratio of the second carbon fiber to epoxy resin can be 0.4:1, 0.5:1, or 0.7:1, and the mass ratio of the second carbon fiber to epoxy resin can also be any value between the exemplary mass ratios, such as any value between (0.5~0.6):1.
[0033] In this embodiment, the thickness of the internal rigid layer is 1-10 mm. Within this thickness range, the internal rigid layer can ensure sufficient rigidity and structural stability for the plate structure, enabling the plate structure to be applied in fields requiring high loads, such as rail transportation, aerospace, and architectural decoration. For example, the thickness of the internal rigid layer can be 1 mm, 3 mm, 8 mm, or 10 mm, or any value between these exemplary thicknesses, such as 3-8 mm. Furthermore, the internal rigid layer can be rectangular column-shaped, and its width can be selected according to the actual usage requirements of the plate structure. For example, the width of the internal rigid layer can be 60-200 mm. Within this width range, excessive width can prevent a decrease in the load-bearing capacity of the plate structure. For example, the width of the internal rigid layer can be 60 mm, 120 mm, or 200 mm, or any value between these exemplary widths, such as 80-150 mm.
[0034] In one exemplary embodiment, the thickness of the surface flame-retardant layer can be 1 to 5 mm. Within this thickness range, the surface flame-retardant layer can provide flame-retardant protection and wear-resistant protection for the board structure without excessively affecting the lightweight design. For example, the thickness of the surface flame-retardant layer can be 1 mm, 3 mm, or 5 mm, or any value between the exemplary thicknesses, such as any value between 2 and 4 mm.
[0035] In one exemplary embodiment, the intermediate strength layer comprises a blend of fibers and a thermoplastic resin, wherein the mass ratio of the blended fibers to the thermoplastic resin is (0.4~1.5):1. The blended fibers comprise a third carbon fiber and a toughening fiber, wherein the mass ratio of the third carbon fiber to the toughening fiber is (0.5~7.5):1, and the toughening fiber comprises at least one selected from aramid fiber, polyethylene fiber, poly(p-phenylenebenzodioxazole) fiber, and glass fiber.
[0036] In this embodiment, an intermediate strength layer surrounds and covers the surface of the inner rigid layer. The intermediate strength layer comprises a blend of fibers and thermoplastic resin. The blended fibers provide high strength to the intermediate strength layer, while the thermoplastic resin, as the matrix, possesses high toughness. The mass ratio of the blended fibers to the thermoplastic resin is in the range of (0.4~1.5):1. The thermoplastic resin can fully impregnate and coat the blended fibers, forming a dense intermediate strength layer that can effectively transfer and disperse stress generated by external impacts, thereby enhancing the impact resistance of the sheet structure.
[0037] In this embodiment, the hybrid fiber includes a third carbon fiber and a toughening fiber. The third carbon fiber provides high strength and high modulus for the intermediate strength layer, while the toughening fiber has high elongation at break and toughness, effectively absorbing impact energy. The mass ratio of the third carbon fiber to the toughening fiber is in the range of (0.5~7.5):1, which allows the intermediate strength layer to maintain high strength while possessing high toughness and impact resistance. For example, when the strength requirement of the intermediate strength layer is high, the mass ratio of the third carbon fiber can be increased; when the impact resistance requirement of the intermediate strength layer is high, the mass ratio of the third carbon fiber can be decreased. For example, the mass ratio of the third carbon fiber to the toughening fiber in the hybrid fiber can be 0.5:1, 2:1, 5:1, or 7.5:1. The mass ratio of the third carbon fiber to the toughening fiber can also be any value between the exemplary mass ratios, such as any value between (2~6):1.
[0038] In this embodiment, the thermoplastic resin may be at least one of polypropylene, polyurethane, polyethylene, polyvinyl chloride, and polystyrene, or other types of thermoplastic resins, which are not limited herein. The third carbon fiber may be at least one of T300, T700, T800, and T1000 high-strength carbon fibers. The toughening fiber may be at least one of aramid fiber (K29, K49, K129), polyethylene fiber, poly(p-phenylenebenzodioxazole) fiber (PBO fiber), and glass fiber. Aramid fiber has high strength, high modulus, and excellent toughness; polyethylene fiber has low density and high specific strength; PBO fiber has extremely high strength and modulus, as well as excellent heat resistance; and glass fiber has low cost and good strength and insulation properties. In actual production, toughening fibers can be selected according to the specific functional requirements of the intermediate strength layer. For example, when the strength and modulus requirements of the intermediate strength layer are high, PBO fiber can be mainly selected as toughening fiber. When it is necessary to control the manufacturing cost of the board structure, glass fiber can be mainly selected as toughening fiber. In addition, two, three or four toughening fibers can be used at the same time.
[0039] In one exemplary embodiment, the thickness of the intermediate strength layer can be 1 to 5 mm. This ensures that the intermediate strength layer can effectively transfer and disperse the stress generated by external impacts without excessively affecting the lightweighting of the board structure, thereby enhancing the impact resistance of the board structure. For example, the thickness of the intermediate strength layer can be 1 mm, 3 mm, or 5 mm, or any value between the exemplary thicknesses, such as any value between 2 and 4 mm.
[0040] In one exemplary embodiment, the mixed fibers in the intermediate strength layer have a two-dimensional or three-dimensional woven structure. The two-dimensional woven structure includes at least one of plain weave, twill weave, and satin weave. The three-dimensional woven structure includes at least one of three-dimensional four-way, three-dimensional five-way, three-dimensional six-way, and three-dimensional seven-way.
[0041] In this embodiment, the mixed fibers in the intermediate strength layer are either a two-dimensional or three-dimensional woven structure, meaning the mixed fibers in the intermediate strength layer are interwoven. This allows the intermediate strength layer to effectively resist delamination, distributing the local impact load throughout the woven network when the sheet structure is subjected to impact, thereby improving the impact resistance of the sheet structure. Two-dimensional woven structures include at least one of plain weave, twill weave, and satin weave, giving the intermediate strength layer high strength and modulus in both the longitudinal and transverse directions. Three-dimensional woven structures include at least one of three-dimensional four-axis, three-dimensional five-axis, three-dimensional six-axis, and three-dimensional seven-axis, which can give the intermediate strength layer high interlaminar shear strength, greatly reducing the possibility of delamination.
[0042] In one exemplary embodiment, the sheet structure further includes a thermosetting resin layer that surrounds the surface of the flame-retardant layer, the thickness of which is 1-3 mm.
[0043] In this embodiment, a thermosetting resin layer is also included on the surface of the flame-retardant layer of the board structure. This thermosetting resin layer serves as a "protective" layer, sealing any micropores or unevenness that may exist on the surface of the flame-retardant layer, thus forming a smooth and dense surface. This prevents moisture or corrosive media from penetrating into the interior of the board structure, improving its weather resistance. Furthermore, when the board is subjected to friction, fire, or heat, the thermosetting resin layer on the surface of the flame-retardant layer provides basic protection, extending the lifespan of the flame-retardant layer. The thickness of the thermosetting resin layer is 1-3 mm, ensuring basic protection for the board structure without excessively increasing its weight or thickness. For example, the thickness of the thermosetting resin layer can be 1 mm, 2 mm, or 3 mm, or any value between these exemplary thicknesses, such as 1.5-2.5 mm. Furthermore, the thermosetting resin in the thermosetting resin layer may be at least one of epoxy resin, phenolic resin, unsaturated polyester resin, and urea-formaldehyde resin, or other types of thermosetting resin may be used, and this disclosure does not limit the choice.
[0044] An exemplary embodiment of this disclosure provides a method for preparing a flame-retardant hybrid fiber composite material plate structure. This method is used to prepare the flame-retardant hybrid fiber composite material plate structure as described above. Figure 2 As shown, the preparation method includes: S100 provides an internal rigid layer.
[0045] S200, forming an intermediate strength layer that surrounds the surface covering the inner rigid layer.
[0046] S300: After circumferentially winding the first carbon fiber and flame-retardant fiber around the surface of the intermediate strength layer, impregnate with polyester resin and cure to obtain a surface flame-retardant layer that surrounds the surface of the intermediate strength layer.
[0047] In the method for preparing the flame-retardant hybrid fiber composite material plate structure provided in this embodiment, following an inside-out sequence, an inner rigid layer is first provided, then an intermediate strength layer is coated on the surface of the inner rigid layer, and finally a surface flame-retardant layer is formed on the surface of the intermediate strength layer. This allows for adjustments to the preparation process of each layer according to the actual application scenario of the plate structure, resulting in plate structures with diverse properties and greatly expanding the application scenarios of the plate structure. Specifically, during the formation of the surface flame-retardant layer on the surface of the intermediate strength layer, the first carbon fiber and flame-retardant fiber are circumferentially wound on the surface of the intermediate strength layer and then impregnated with polyester resin. This facilitates a tight wrapping of the surface flame-retardant layer on the surface of the intermediate strength layer, reducing the risk of delamination between the surface flame-retardant layer and the intermediate strength layer. The circumferential winding angle of the first carbon fiber and flame-retardant fiber on the surface of the intermediate strength layer can be 5°~30°, allowing the first carbon fiber and flame-retardant fiber to share stress when the plate structure is subjected to axial tensile or bending loads. The plate structure prepared by this method has an inner rigid layer that provides rigidity and structural stability, ensuring that the plate is not easily bent or deformed under stress. An intermediate strength layer surrounds the surface of the inner rigid layer, effectively transferring and dispersing stress generated by external impacts, thus enhancing the impact resistance of the panel structure. A surface flame-retardant layer surrounds the surface of the intermediate strength layer, providing flame-retardant properties and good wear resistance to the panel structure. This allows the prepared panel structure to simultaneously meet multiple functional requirements, including high rigidity and strength, excellent wear resistance, and flame retardancy.
[0048] In this embodiment, after impregnation with polyester resin, the polyester resin can be cured and molded using a hot-melt composite method. The processing temperature is controlled within the range of 180~230℃, and the hot-melt time is 10~30min to ensure that the polyester resin is fully cured and to bond the first carbon fiber and the flame-retardant fiber, resulting in a dense surface flame-retardant layer. For example, the processing temperature can be 180℃, 200℃, or 230℃, or any value between these exemplary temperatures, such as any value between 190~220℃. For example, the hot-melt time can be 10min, 20min, or 30min, or any value between these exemplary times, such as any value between 15~25min.
[0049] In one exemplary embodiment, providing the internal rigid layer includes: integrally molding the second carbon fiber and epoxy resin by pultrusion to obtain the internal rigid layer.
[0050] For example, the pultrusion integral molding process can involve impregnating the fiber bundles of the second carbon fiber with epoxy resin and then sequentially feeding them into a preforming mold, a molding mold, and a post-curing oven to cure and obtain an internal rigid layer. The temperature of the preforming mold can be 40~100℃, allowing for preliminary curing of the epoxy resin-impregnated fiber bundles at a lower temperature to avoid defects in the internal rigid layer caused by direct high-temperature curing. For example, the temperature of the preforming mold can be 40℃, 60℃, 80℃, or 100℃, or any value within the exemplary temperature range, such as any value between 50~80℃. The molding mold can include three sections, for example, a first molding mold at 110~170℃, a second molding mold at 130~190℃, and a third molding mold at 140~200℃. The post-curing oven may include four post-curing ovens, for example, a first post-curing molding die at 140~200℃, a second post-curing molding die at 130~190℃, a third post-curing molding die at 110~170℃, and a fourth post-curing molding die at 80~140℃. During the pultrusion molding process, the pultrusion speed can be 20~60 cm / min to ensure that the fiber bundles of the second carbon fiber are fully impregnated with epoxy resin and subsequently uniformly molded and cured. For example, the pultrusion speed can be 20 cm / min, 40 cm / min, or 60 cm / min, or any value between these exemplary speeds, such as any value between 30~50 cm / min.
[0051] In one exemplary embodiment, forming an intermediate strength layer surrounding the surface of an inner rigid layer includes: impregnating a thermoplastic resin after disposing of mixed fibers on the surface of the inner rigid layer, and curing to obtain an intermediate strength layer surrounding the surface of the inner rigid layer, wherein the mixed fibers are woven into a two-dimensional or three-dimensional woven structure.
[0052] In this embodiment, the method of setting the mixed fibers on the surface of the inner rigid layer can be as follows: the mixed fibers are woven into a two-dimensional or three-dimensional woven structure and then wrapped around the surface of the inner rigid layer; or the mixed fibers are woven into a two-dimensional or three-dimensional woven structure on the surface of the inner rigid layer and then wrapped around the surface of the inner rigid layer. After the mixed fibers are wrapped around the surface of the inner rigid layer, they are impregnated with thermoplastic resin and cured to form a dense intermediate strength layer on the surface of the inner rigid layer. This layer can effectively transfer and disperse the stress generated by external impact, thereby enhancing the impact resistance of the board structure. The curing temperature can be 20-50°C higher than the melting temperature of the thermoplastic resin. For example, the curing temperature can be 20°C, 30°C, or 50°C higher than the melting temperature of the thermoplastic resin, and the curing temperature can be any value between 25°C and 45°C higher than the melting temperature of the thermoplastic resin. The curing process can last from 2 to 10 minutes. For example, the curing process can last for 2 minutes, 6 minutes, or 10 minutes. The curing process can also last for any value between the exemplary durations, such as any value between 4 and 8 minutes.
[0053] In an exemplary embodiment, the method for preparing a flame-retardant hybrid fiber composite board structure further includes: applying a thermosetting resin to the surface of the board structure by impregnation or spraying, and curing it at a temperature of 130~150°C for 15~30 minutes to form a thermosetting resin layer surrounding the surface of the flame-retardant layer. This seals any micropores or unevenness that may exist on the surface of the flame-retardant layer, forming a smooth and dense surface. This prevents moisture or corrosive media from penetrating into the interior of the board structure, providing basic protection for the surface of the flame-retardant layer and improving the weather resistance of the board structure. For example, the curing temperature of the thermosetting resin layer forming the surface of the flame-retardant layer can be 120°C, 140°C, or 150°C, or any value between the exemplary temperatures, such as any value between 135~145°C. For example, the curing time of the thermosetting resin layer forming the flame-retardant coating on the surface can be 15 min, 25 min or 30 min, and the curing time can also be any value between the exemplary times, such as any value between 20 and 25 min.
[0054] To more clearly explain the technical solutions provided by the exemplary embodiments of this disclosure, a specific example of the preparation method of the flame-retardant hybrid fiber composite material plate structure provided by this disclosure is given below.
[0055] High-strength T300 second carbon fiber (24K) and epoxy resin were integrally formed by pultrusion at a mass ratio of (0.4~0.7):1. The temperature of the pre-forming die during pultrusion was 40~100℃, and the temperatures of the three forming dies were 110~170℃ for the first die, 130~190℃ for the second die, and 140~200℃ for the third die. The temperatures of the four post-curing ovens were 140~200℃, 130~190℃, 110~170℃, and 80~140℃, respectively. The pultrusion speed was 20~60cm / min. After curing, an internal rigid layer with a thickness of 1~10mm and a width of 60~200mm was obtained, and this internal rigid layer was in the form of a rectangular column.
[0056] After a two-dimensional plain weave structure of mixed fibers is applied to the surface of the inner rigid layer, thermoplastic resin is impregnated at a mass ratio of mixed fibers to thermoplastic resin of (0.4~1.5):1, and then cured to obtain an intermediate strength layer surrounding the surface of the inner rigid layer. The mixed fibers are high-strength T300 third carbon fiber with a tow of 24K and aramid fibers, with a mass ratio of third carbon fiber to aramid fibers of (0.5~7.5):1. The curing temperature can be 20~50℃ higher than the melting temperature of the thermoplastic resin, and the curing time can be 2~10 minutes. After curing, an intermediate strength layer with a thickness of 1~5 mm is obtained.
[0057] The first carbon fiber (M55J), flame-retardant PPTA fiber, and polyester resin are wound in a mass ratio of 1:(0.5~2.5):(1.5~3.5) around the surface of the intermediate strength layer at a 25° circumferential angle, followed by impregnation with polyester resin and curing. 20% polystyrene flame retardant is added to the polyester resin. The curing process utilizes a hot-melt composite method, with the processing temperature controlled within the range of 180~230℃ and the hot-melt time being 10~30 minutes. After curing, a surface flame-retardant layer with a thickness of 1~5 mm is obtained.
[0058] A thermosetting resin is applied to the surface of the board structure by impregnation or spraying, and then cured at 130-150℃ for 15-30 minutes to form a thermosetting resin layer surrounding the flame-retardant coating. The final product is as follows: Figure 3 The rectangular columnar plate structure 100 is shown.
[0059] The panel structure prepared by the method described in the specific examples above has an internal rigid layer that provides rigidity and structural stability, ensuring that the panel is not easily bent or deformed under stress. An intermediate strength layer surrounds the surface of the internal rigid layer, effectively transferring and dispersing stress generated by external impacts, enhancing the impact resistance of the panel structure. A surface flame-retardant layer surrounds the surface of the intermediate strength layer, providing flame-retardant properties and good wear resistance. This allows the prepared panel structure to simultaneously meet multiple functional requirements, including high rigidity and strength, excellent wear resistance, and flame retardancy.
[0060] The above-described contents can be implemented individually or in various combinations, and all such variations are within the scope of this disclosure.
[0061] Finally, it should be noted that in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0062] The above embodiments are only used to illustrate the technical solutions of this disclosure, and are not intended to limit it. Although this disclosure has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this disclosure.
Claims
1. A flame-retardant hybrid fiber composite material plate structure, characterized in that, The plate structure includes: Internal rigid layer; An intermediate strength layer surrounds and covers the surface of the inner rigid layer; A surface flame-retardant layer surrounds and covers the surface of the intermediate strength layer. The surface flame-retardant layer comprises a first carbon fiber, a flame-retardant fiber, and a polyester resin, wherein the mass ratio of the first carbon fiber, the flame-retardant fiber, and the polyester resin is 1:(0.5~2.5):(1.5~3.5).
2. The flame-retardant hybrid fiber composite material plate structure according to claim 1, characterized in that, The surface flame-retardant layer further includes a flame retardant, wherein the flame retardant accounts for 8% to 35% of the mass of the polyester resin; The flame retardant includes at least one of brominated polystyrene, aluminum hydroxide, and tributyl phosphate.
3. The flame-retardant hybrid fiber composite material plate structure according to claim 1, characterized in that, The first carbon fiber includes at least one of M40, M40J, M55, M55J, M60, and M60J; The flame-retardant fiber includes at least one of poly(p-phenylene terephthalamide) fiber, poly(m-phenylene isophthalamide) fiber, and polyphenylene sulfide fiber.
4. The flame-retardant hybrid fiber composite material plate structure according to claim 1, characterized in that, The thickness ratio of the inner rigid layer, the intermediate strength layer, and the surface flame-retardant layer is 2:(0.8~1.5):(0.8~1.5).
5. The flame-retardant hybrid fiber composite material plate structure according to claim 1, characterized in that, The internal rigid layer comprises a second carbon fiber and epoxy resin, wherein the mass ratio of the second carbon fiber to the epoxy resin is (0.4~0.7):1; The thickness of the internal rigid layer is 1~10mm.
6. The flame-retardant hybrid fiber composite material plate structure according to claim 1, characterized in that, The intermediate strength layer comprises a mixture of fibers and a thermoplastic resin, wherein the mass ratio of the mixture of fibers to the thermoplastic resin is (0.4~1.5):1; The hybrid fiber comprises a third carbon fiber and a toughening fiber, wherein the mass ratio of the third carbon fiber to the toughening fiber is (0.5~7.5):1; The toughening fiber includes at least one of aramid fiber, polyethylene fiber, poly(p-phenylenebenzodioxazole) fiber, and glass fiber.
7. The flame-retardant hybrid fiber composite material plate structure according to claim 6, characterized in that, In the intermediate strength layer, the hybrid fibers have a two-dimensional braided structure and / or a three-dimensional braided structure; The two-dimensional weave structure includes at least one of plain weave, twill weave, and satin weave; The three-dimensional braided structure includes at least one of three-dimensional four-way, three-dimensional five-way, three-dimensional six-way, and three-dimensional seven-way.
8. The flame-retardant hybrid fiber composite material plate structure according to any one of claims 1 to 7, characterized in that, The plate structure also includes a thermosetting resin layer, which surrounds and covers the surface of the flame-retardant layer, and the thickness of the thermosetting resin layer is 1~3mm.
9. A method for preparing a flame-retardant hybrid fiber composite material plate structure, characterized in that, The preparation method is used to prepare the flame-retardant hybrid fiber composite material plate structure as described in any one of claims 1 to 8; the preparation method includes: Provide an internal rigid layer; An intermediate strength layer is formed around the surface that covers the inner rigid layer; After the first carbon fiber and flame-retardant fiber are circumferentially wound around the surface of the intermediate strength layer, polyester resin is impregnated and cured to obtain a surface flame-retardant layer that surrounds the surface of the intermediate strength layer.
10. The method for preparing the flame-retardant hybrid fiber composite material plate structure according to claim 9, characterized in that, The provision of the internal rigid layer includes: The second carbon fiber and epoxy resin are integrally formed by pultrusion to obtain the internal rigid layer; The intermediate strength layer forming the surface surrounding the inner rigid layer includes: After the mixed fibers are placed on the surface of the inner rigid layer, they are impregnated with thermoplastic resin and cured to obtain the intermediate strength layer that surrounds the surface of the inner rigid layer; the mixed fibers are woven into a two-dimensional woven structure and / or a three-dimensional woven structure.