Prepreg material

Abstract

A prepreg material comprises a plurality of prepreg structures, each prepreg structure is a multi-layer structure and comprises a fiber resin layer, a first resin layer, a metal layer and a second resin layer, and the multi-layer structure has different materials, an expansion coefficient, a viscosity coefficient and a thickness. The prepreg structure is pre-cured and then stacked in a layered mode to form the prepreg material, the fiber resin layer and the second resin layer are combined to form an interface, displacement of the prepreg structure stacked in the layered mode is reduced through the interface, and the overall strength of the prepreg material is further improved.

Description

Technical Field

[0001] A prepreg material. Background Technology

[0002] Prepregs are widely used in many high-performance applications. Traditional prepreg structures consist of fiber layers and resin layers. While they provide basic strength and rigidity, they deteriorate rapidly in applications requiring long-term high loads, high strength, high temperatures, or corrosive environments. This results in insufficient durability or protection, affecting their lifespan and performance.

[0003] Furthermore, when processing traditional impregnated structures, such as when drilling or cutting, radial forces often cause problems such as delamination or fiber breakage because the resin layer cannot support the fiber layer. This makes it difficult to maintain precise shape and size, increasing processing difficulty and risk.

[0004] Therefore, it can be seen that developing a prepreg structure with high strength and reduced fiber layer damage during processing is the goal of related fields. Summary of the Invention

[0005] To address the issue of maintaining high strength in prepreg structures while minimizing fiber layer damage during processing, this invention provides a prepreg material with a multi-layer structure comprising at least two prepreg structures, wherein each prepreg structure includes:

[0006] A fiber-resin layer, wherein the fiber layer is impregnated with a first resin, the first resin permeating the fiber layer.

[0007] And each fiber that covers the fiber layer;

[0008] A first resin layer is formed by the fiber resin layer being laid on the first surface of a metal layer, and the first resin permeating to the first surface of the metal layer.

[0009] The metal layer is a sheet or a mesh, including the first surface and a second surface; and a second resin layer is laid on the second surface of the metal layer, wherein the thickness of the second resin layer is greater than the thickness of the first resin layer;

[0010] The various prepreg structures are stacked in layers, wherein the fiber resin layer is bonded to the second resin layer, wherein the first resin and the second resin layer form an interface through their resin adhesion to each other, and wherein the first resin and the second resin layer are different resins.

[0011] The thickness of the first resin layer is less than 0.01 micrometers.

[0012] The fiber layer contains either a unidirectional fiber or a non-unidirectional fiber.

[0013] The pre-curing methods include temperature-controlled pre-curing, time-controlled pre-curing, pressure-controlled pre-curing, light-curing, and chemical pre-curing.

[0014] The unidirectional fiber includes carbon fiber, glass fiber, aramid fiber (Kevlar), polyethylene fiber, steel fiber, or flax fiber.

[0015] The non-unidirectional fiber includes nylon fiber, silicon fiber, bamboo fiber, copper fiber, or tin fiber.

[0016] The metal layer comprises a single metal or an alloy.

[0017] The single metal may include aluminum (Al), titanium (Ti), stainless steel, copper (Cu), steel, nickel (Ni), magnesium (Mg), lead (Pb), platinum (Pt), chromium (Cr), or silver (Ag).

[0018] The first resin comprises a thermosetting resin or a thermoplastic resin. The thermosetting resin comprises one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), and maleic anhydride resin (BMI). The thermoplastic resin comprises, but is not limited to, one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), and styrene resin (SAN).

[0019] The second resin layer comprises either the thermosetting resin or the thermoplastic resin. The thermosetting resin comprises one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), and maleic anhydride resin (BMI). The thermoplastic resin comprises, but is not limited to, one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), and styrene resin (SAN).

[0020] Based on the above, the present invention has the following advantages:

[0021] 1. The metal layer in the prepreg material significantly increases the strength and rigidity of the prepreg material, wherein the metal layer is stronger than the fiber layer, which helps to strengthen the structure of the prepreg material and improve the ability of the prepreg material to withstand external loads, thereby enhancing the overall performance of the prepreg material.

[0022] 2. The metal layer provides excellent fire resistance, thermal stability and corrosion resistance, and can protect the prepreg material in high-wear or special environments (such as high-temperature or corrosive environments), extending the service life of the prepreg material. In addition, the presence of the metal layer also improves the wear resistance of the prepreg material.

[0023] 3. During processing, such as cutting and drilling, the second resin layer makes the prepreg material easier to handle. The second resin layer provides good processing performance, helps the prepreg material maintain its shape and size during manufacturing, and reduces the difficulties and risk of damage during processing.

[0024] 4. The bonding between the first resin layer and the second resin layer strengthens the bonding between the multilayer structures of the prepreg structure. The interface between the first resin layer and the second resin layer is formed during the final curing, and the adhesion between the layers in the multilayer structure is improved, thereby preventing interlayer separation or delamination, and greatly enhancing the overall strength and stability of the prepreg material. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of a preferred embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of a preferred embodiment of the present invention.

[0027] Symbol explanation:

[0028] 10 Prepreg Structure

[0029] 11 fiber resin layers

[0030] 111 fiber layer

[0031] 112 First Resin

[0032] 12 First resin layer

[0033] 13 metal layers

[0034] 14 Second resin layer Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] The present invention will now be described in further detail with reference to the accompanying drawings:

[0037] Please refer to Figure 1 The present invention provides a prepreg material comprising a plurality of the prepreg structures 10 stacked together.

[0038] The prepreg structure 10 is a multilayer structure, which includes a fiber resin layer 11, a first resin layer 12, a metal layer 13 and a second resin layer 14. Because the multilayer structure has different materials, expansion coefficients, viscosity coefficients or thicknesses, the multilayer structure in the prepreg structure 10 can be combined with each other and the displacement of the multilayer structure can be reduced, thereby further improving the overall strength of the prepreg structure 10.

[0039] Furthermore, after the prepreg structure 10 forms the multilayer structure, it undergoes a pre-curing process, which allows the prepreg structure 10 to protect the multilayer structure and enhance the strength between the multilayer structures.

[0040] The fiber resin layer 11 is formed by impregnating a fiber layer 111 with a first resin 112, so that the first resin 112 evenly penetrates into the fiber layer 111 and covers each fiber of the fiber layer 111.

[0041] The pre-curing methods include temperature-controlled pre-curing, time-controlled pre-curing, pressure-controlled pre-curing, light-curing, and chemical pre-curing.

[0042] The fiber layer 111 comprises either a unidirectional fiber or a non-unidirectional fiber. A unidirectional fiber is defined as fibers arranged in the same direction with minimal gaps between them, resulting in a tight bond between the fibers. This unidirectional fiber provides the prepreg structure 10 with high strength and rigidity in one fiber direction, while also reducing the weight of the prepreg structure 10. This allows the prepreg structure 10 to withstand high tensile loads and exhibits strong rigidity and tensile strength.

[0043] The non-unidirectional fiber refers to the fiber arranged in multiple directions, with gaps formed between the fibers, which gives the fiber layer 111 strong toughness and flexibility, and can provide certain strength and rigidity in different directions. The non-unidirectional fiber can provide the prepreg structure 10 with excellent impact resistance and durability.

[0044] Preferably, in this invention, the fiber layer 111 is made of unidirectional fiber, which gives the fiber layer 111 a unidirectional property. The unidirectional fiber includes carbon fiber, glass fiber, aramid fiber (Kevlar), polyethylene fiber, steel fiber or flax fiber. The non-unidirectional fiber includes nylon fiber, silicon fiber, bamboo fiber, copper fiber or tin fiber.

[0045] The first resin 112 fully penetrates the fibers of the fiber layer 111, coats each fiber, and fills the gaps between the fibers, so that the fibers maintain a stable arrangement and distribution. The first resin 112 also provides sufficient fluidity and viscosity, so that the first resin 112 can be fully fused and contact an interface, and improve the adhesion between the fiber resin layer 11 and the interface. This helps to form a good bond between the multilayer structure during the subsequent curing process of the prepreg material, thereby improving the overall strength and stability of the prepreg material.

[0046] Preferably, the first resin 112 may be a thermosetting resin or a thermoplastic resin, wherein the thermosetting resin includes, but is not limited to, one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), and maleic anhydride resin (BMI), wherein the thermoplastic resin includes, but is not limited to, one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), and styrene resin (SAN).

[0047] The first resin layer 12 is a portion of the first resin 112. When the fiber resin layer 11 is laid on the first surface of the metal layer 13, a portion of the first resin 112 permeates from the fiber resin layer 11 to the first surface of the metal layer 13 and forms the first resin layer 12.

[0048] Preferably, in this embodiment of the invention, the first resin layer 12 is formed on the first surface of the metal layer 13 with a thickness of less than 0.01 micrometers.

[0049] The metal layer 13 can be formed by a single metal or an alloy mixture. The metal layer 13 can be a sheet or a mesh. Furthermore, the metal layer 13 is pre-treated by cutting or stamping the metal and then treating its surface by deoxidation or degreasing to form the metal layer 13, which further improves the adhesion between the metal layer 13 and the first resin layer 12.

[0050] The metal layer 13 provides strength and rigidity to the prepreg structure 10. Since the rigidity of the metal layer 13 is greater than that of the fiber layer 111, the metal layer 13 can strengthen the overall structure of the prepreg structure 10 and increase the ability of the prepreg structure 10 to withstand external loads.

[0051] In addition, the metal layer 13 can also improve the durability of the prepreg structure 10 and enhance its wear resistance. When the prepreg structure 10 is in a high-wear environment or requires additional protection, such as a high-temperature or corrosive environment, the metal layer 13 provides excellent fire resistance, thermal stability and corrosion resistance.

[0052] In the fields of electronic devices and communications, the conductivity and electromagnetic shielding effect of the metal layer 13 can effectively prevent electromagnetic interference, protect electronic components, and improve the electrical performance of the prepreg structure 10. The metal layer 13 enhances the functionality of the prepreg structure 10 and also provides better thermal conductivity, which helps to dissipate heat or maintain the thermal stability of the material.

[0053] The resin fiber layer 11 is laid on the first surface of the metal layer 13 by methods including manual lamination, vacuum extrusion, and injection.

[0054] The material of the metal layer 13 includes one or a combination of metals such as aluminum (Al), titanium (Ti), stainless steel, copper (Cu), steel, nickel (Ni), magnesium (Mg), lead (Pb), platinum (Pt), chromium (Cr), or silver (Ag).

[0055] The second resin layer 14 can be a thermosetting resin or a thermoplastic resin. The second resin layer 14 prevents the second surface of the metal layer 13 from being damaged by environmental erosion, reduces defects on the second surface of the metal layer 13, and extends the service life of the metal layer 13. The second resin layer 12 is laid on the second surface of the metal layer 13. The second resin layer 14, together with the metal layer 13, the first resin layer 12, and the fiber resin layer 11, form the multilayer structure. The coefficient of thermal expansion, the coefficient of viscosity, and the thickness of the second resin layer 14 and the first resin layer 12 can be the same or different.

[0056] Preferably, in this embodiment of the invention, the second resin layer 14 is thicker than the first resin layer 12, in order to further prevent the second surface of the metal layer 13 from being damaged by an external force or an external environment.

[0057] Furthermore, the second resin layer 14 provides the prepreg structure 10 with improved processability, making it easier to operate during processing, such as cutting or drilling, and contributing to the shape and size of the final product.

[0058] In a preferred embodiment of the present invention, the resin of the second resin layer 12 is not limited, and the resin of the second resin layer 12 may refer to the resin of the first resin 112 described above.

[0059] Furthermore, after the prepreg structure 10 forms the multilayer structure, pre-curing is performed. This pre-curing causes partial curing of the first resin 112 and the second resin layer 14. At this time, the first resin 112 and the second resin layer 14 have high viscosity and low fluidity. This pre-curing helps to provide bonding strength between the layers of the multilayer structure and can remove air bubbles between the first resin 112 and the second resin layer 12, improving the density and uniformity between the layers of the multilayer structure. At the same time, after this pre-curing, the fiber layer 111 and the metal layer 13 can be prevented from contacting the outside world, thereby increasing the material preservation life of the fiber layer 111 and the metal layer 13.

[0060] Please refer to Figure 2 The prepreg material is composed of at least two prepreg structures 10 stacked in a layered manner, wherein the prepreg structure 10 has been pre-cured, wherein each prepreg structure 10 is bonded to the second resin layer 14 through the fiber resin layer 11, wherein the first resin 112 and the second resin layer 14 form an interface through their resin adhesion to each other.

[0061] Furthermore, the prepreg material can undergo a final curing process, wherein the first resin 112 and the second resin layer 14 still contain unreacted resin. During the final curing process, a temperature is used to allow the unreacted resin in the first resin 112 and the second resin layer 14 to continue to react, while simultaneously creating a cross-linked structure between the resins in the first resin 112 and the second resin layer 14. This makes the interface more robust and enhances the interlayer adhesion between the prepreg structures 10, preventing the interlayer separation or delamination of the prepreg structures 11.

[0062] Furthermore, when the prepreg material is processed, such as by drilling, cutting, grinding, or screwing, the interface can reduce the radial force that directly damages the prepreg structure 10. Due to the different properties of the first resin 112 and the second resin layer 14, such as the coefficient of expansion, the hardness of the resin, or the environmental resistance of the resin, the direct fracture or brittleness of the multilayer structure in the prepreg material can be reduced.

[0063] Based on the above, the present invention has the following advantages:

[0064] 1. The metal layer 13 in the prepreg material significantly increases the strength and rigidity of the prepreg material. The metal layer 13 is stronger than the fiber layer 111, which helps to strengthen the structure of the prepreg material and improve the ability of the prepreg material to withstand external loads, thereby enhancing the overall performance of the prepreg material.

[0065] 2. The metal layer 13 provides excellent fire resistance, thermal stability and corrosion resistance, and can protect the prepreg material in high-wear environments or special environments (such as high-temperature or corrosive environments), extending the service life of the prepreg material. In addition, the presence of the metal layer 13 also improves the wear resistance of the prepreg material.

[0066] 3. During processing, such as cutting and drilling, the second resin layer 14 makes the prepreg material easier to handle. The second resin layer 14 provides good processing performance, helps the prepreg material maintain its shape and size during manufacturing, and reduces the difficulties and risk of damage during processing.

[0067] 4. The bonding between the first resin 112 and the second resin layer 14 strengthens the bonding between the multilayer structures of the prepreg structure 10. The interface between the first resin 112 and the second resin layer 14 is formed during the final curing, and the adhesion between the layers in the multilayer structure is improved, thereby preventing interlayer separation or delamination, and greatly enhancing the overall strength and stability of the prepreg material.

[0068] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A prepreg material, characterized in that, The prepreg material has a multilayer structure, comprising at least two prepreg structures, wherein each prepreg structure includes: A fiber resin layer, wherein a fiber layer is impregnated with a first resin, the first resin permeates the fiber layer and coats each fiber of the fiber layer; A first resin layer is formed by the fiber resin layer being laid on the first surface of a metal layer, and the first resin permeating to the first surface of the metal layer. The metal layer is a thin sheet or a mesh, and includes the first surface and a second surface; and A second resin layer is laid on the second surface of the metal layer, wherein the thickness of the second resin layer is greater than the thickness of the first resin layer; The various prepreg structures are stacked in layers, wherein the fiber resin layer is bonded to the second resin layer, wherein the first resin and the second resin layer form an interface through their resin adhesion to each other, and wherein the first resin and the second resin layer are different resins.

2. The prepreg structure as described in claim 1, characterized in that, The thickness of the first resin layer is less than 0.01 micrometers.

3. The prepreg structure as described in claim 2, characterized in that, The fiber layer contains either a unidirectional fiber or a non-unidirectional fiber.

4. The prepreg structure as described in claim 3, characterized in that, The pre-curing methods include temperature-controlled pre-curing, time-controlled pre-curing, pressure-controlled pre-curing, light-curing, and chemical pre-curing.

5. The prepreg structure as described in claim 4, characterized in that, The unidirectional fiber contains carbon fiber, glass fiber, aramid fiber (Kevlar), polyethylene fiber, steel fiber, or flax fiber.

6. The prepreg structure as described in claim 4, characterized in that, The non-unidirectional fiber includes nylon fiber, silicon fiber, bamboo fiber, copper fiber, or tin fiber.

7. The prepreg structure according to any one of claims 1 to 6, characterized in that, The metal layer contains a single metal or alloy.

8. The prepreg structure as described in claim 7, characterized in that, The single metal may include aluminum (Al), titanium (Ti), stainless steel, copper (Cu), steel, nickel (Ni), magnesium (Mg), lead (Pb), platinum (Pt), chromium (Cr), or silver (Ag).

9. The prepreg structure as described in claim 8, characterized in that, The first resin comprises a thermosetting resin or a thermoplastic resin, wherein the thermosetting resin comprises one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), and maleic anhydride resin (BMI), and the thermoplastic resin comprises one or a combination of polyether ether ketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), and styrene resin (SAN).

10. The prepreg structure as described in claim 9, characterized in that, The second resin layer comprises either the thermosetting resin or the thermoplastic resin, wherein the thermosetting resin comprises one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), and maleic anhydride resin (BMI), and the thermoplastic resin comprises one or a combination of polyether ether ketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), and styrene resin (SAN).

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