Hybrid fiber fabric reinforced thermoplastic composite laminate and method of making and use thereof

Abstract

The application relates to the technical field of composite materials, and discloses a mixed-fiber fabric reinforced thermoplastic composite material laminated plate and a preparation method and application thereof. The laminated plate is obtained by die molding a preformed body, wherein the preformed body comprises a plurality of mixed-fiber fabrics and thermoplastic resin films which are sequentially stacked in layers, and the thermoplastic resin film is selected from one or more of a polyamide film, a polyphenylene sulfide film, a polyether ether ketone film, a poly (aryl ether ketone) film, a polycarbonate film and a polysulfone film. The prepared thermoplastic laminated plate is uniform in resin distribution and excellent in comprehensive mechanical properties.

Description

Technical Field

[0001] This invention relates to the field of composite materials technology, specifically to a thermoplastic composite laminate reinforced with mixed-weave fiber fabric, its preparation method, and its application. Background Technology

[0002] Fiber-reinforced resin matrix composites refer to composite materials prepared using thermoplastic or thermosetting resins as the matrix and carbon fibers, E-glass fibers, aramid fibers, etc., as reinforcements through specific molding processes. They possess excellent properties such as high strength, good fatigue resistance, and dimensional stability, making them highly sought after in the automotive, machinery, construction, and transportation industries. Compared to thermosetting composites, thermoplastic composites offer significant advantages such as recyclability, good high-temperature performance, solvent-free preparation processes, and high impact toughness, making them an important direction for cost reduction and high performance in the field of composite materials.

[0003] Vacuum autoclave molding is a commonly used method for preparing fiber-reinforced resin matrix composites, but it suffers from high equipment costs, slow temperature and pressure response, and low control precision. Composite materials are often used in the form of laminates in engineering structures such as large-area wall panels that bear in-plane and out-of-plane loads. Thermoplastic laminates prepared from fiber fabrics and thermoplastic resin films through compression molding offer significant advantages in ensuring product performance stability and handling harsh application environments. In particular, blended woven fabrics can better leverage the advantages of different fiber reinforcements, compensating for their weaknesses and effectively meeting increasingly complex environmental requirements.

[0004] CN106589810A discloses a method for preparing a carbon fiber / glass fiber hybrid stealth composite material. The method includes: using carbon fiber as the core yarn and glass fiber as the braiding yarn, the core yarn and the braiding yarn are braided into a carbon fiber / glass fiber core-spun yarn using a two-dimensional braiding technique; then the carbon fiber / glass fiber core-spun yarn is woven into a fabric, and finally the fabric is composited and cured with epoxy resin using a resin transfer molding process to obtain the carbon fiber / glass fiber hybrid stealth composite material.

[0005] CN105857484A discloses a hybrid composite material for bicycle tubes made of glass fiber and carbon fiber and its preparation method. The internal composite material has different arrangement structures, including high-toughness 0-degree glass fiber, high-toughness + / -45-degree glass fiber, 0-degree carbon fiber and + / -45-degree carbon fiber, to meet the different requirements of tensile strength and stability of different parts of the bicycle tube.

[0006] The molding processes in the above-mentioned existing technologies are not suitable for thermoplastic resins, which can easily cause air holes in the material products, resulting in high porosity and decreased mechanical properties. Furthermore, no research has been conducted on the blending process of different fibers and the preparation process of laminates.

[0007] How to propose a highly designable process for weaving and preparing thermoplastic laminates with efficient and stable product performance from the perspective of process applicability and flexibility is a technical problem that researchers in this field urgently need to solve. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of existing technologies, such as the molding process not being suitable for thermoplastic resins, and the lack of research on the blending process and laminate preparation process for different fibers. This invention provides a thermoplastic composite laminate reinforced with blended fiber fabric, its preparation method, and its application. The prepared thermoplastic laminate has uniform resin distribution and excellent comprehensive mechanical properties.

[0009] To achieve the above objectives, the first aspect of the present invention provides a blended fiber fabric reinforced thermoplastic composite laminate, wherein the laminate is obtained by molding a preform, wherein the preform comprises multiple layers of blended fiber fabric and thermoplastic resin film stacked sequentially, and the thermoplastic resin film is selected from one or more of polyamide film, polyphenylene sulfide film, polyether ether ketone film, polyarylether ketone film, polycarbonate film and polysulfone film.

[0010] A second aspect of the present invention provides a method for preparing the aforementioned hybrid fiber fabric reinforced thermoplastic composite laminate, wherein the preparation method includes:

[0011] (1) The blended fiber fabric and thermoplastic resin film are layered sequentially to obtain a preform;

[0012] (2) The release cloth, the perforated isolation film, the preform, the perforated isolation film and the release cloth are sequentially laid in the mold tooling, and the preform is molded to obtain a laminate.

[0013] A third aspect of the present invention provides an application of the aforementioned hybrid fiber fabric reinforced thermoplastic composite laminate in one or more fields, including wind turbine blades, rail transit, and building reinforcement.

[0014] Through the above technical solution, the present invention has the characteristics of simple operation, strong designability, and high preparation stability. It can give full play to the advantages of different fiber fabric reinforcements. The prepared thermoplastic laminate resin has uniform distribution, excellent comprehensive mechanical properties, and can be repeatedly processed and utilized. It is suitable for different application scenarios and has broad application prospects in the fields of wind turbine blades, rail transit, and building reinforcement. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the compression molding layup in Example 1;

[0016] Figure 2This is a live weaving diagram of the carbon fiber (T800-12K) / aramid fiber (2000D) blended fabric in Example 2;

[0017] Figure 3 The image shows a cross-sectional scanning electron microscope (SEM) image of the laminate prepared in Example 5. Detailed Implementation

[0018] The endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

[0019] As mentioned above, the first aspect of the present invention provides a mixed-fiber fabric reinforced thermoplastic composite laminate, wherein the laminate is obtained by molding a preform, wherein the preform comprises multiple layers of mixed-fiber fabric and thermoplastic resin film stacked sequentially, and the thermoplastic resin film is selected from one or more of polyamide film, polyphenylene sulfide film, polyether ether ketone film, polyarylether ketone film, polycarbonate film and polysulfone film.

[0020] The inventors of this invention have discovered that by blending and coordinating different fibers, allowing each to leverage its performance advantages and compensate for the others' weaknesses, not only can overall performance be improved, but weight and cost can also be reduced, thus increasing economic efficiency. Furthermore, the inventors have prepared a thermoplastic laminate using blended fiber fabric as reinforcement and thermoplastic resin film as matrix through a specific molding process. This laminate possesses advantages such as uniform resin distribution, excellent comprehensive mechanical properties, and reusability, making it suitable for various application scenarios.

[0021] According to the present invention, the thickness of the single-layer hybrid fiber fabric is 200-600μm, preferably 300-500μm; if the thickness of the single-layer hybrid fiber fabric is too thick, it will result in insufficient resin filling of carbon fibers, causing a loose structure and reduced strength; if the thickness of the single-layer hybrid fiber fabric is too thin, it will result in resin filling of the gaps between fibers, hindering the load transfer of fibers, and the strength will also decrease.

[0022] According to the present invention, the thickness of the single-layer thermoplastic resin film is 100-500 μm, preferably 150-400 μm. If the thickness of the single-layer thermoplastic resin film is too thick, the resin content will be too high, preventing it from functioning properly between the fibers and increasing the weight of the material; if the thickness of the single-layer thermoplastic resin film is too thin, the resin content will be too low, resulting in insufficient bonding between the resin and the fibers, thereby reducing mechanical properties.

[0023] In this invention, limiting the thickness ratio of the single-layer hybrid fiber fabric to the single-layer thermoplastic resin film to the above-mentioned range ensures that the resin fully impregnates the carbon fiber and maximizes the bonding strength between the resin and the fiber interface.

[0024] According to the present invention, the thermoplastic resin used to prepare the thermoplastic resin film has a relative molecular mass of 10,000-200,000 and a density of 1.1-1.5 g / cm³. 3 Preferably, the thermoplastic resin has a relative molecular mass of 40,000-180,000 and a density of 1.2-1.4 g / cm³. 3 In this invention, it should be noted that "relative molecular mass" is the same as "relative molecular weight".

[0025] According to the present invention, the fibers in the blended fiber fabric are selected from at least two of carbon fiber, aramid fiber, E-glass fiber, basalt fiber and polytetrafluoroethylene fiber; preferably, the strength grade of the carbon fiber is one or more of T300, T700, T800 and T1000, and the tow grade is one or more of 1K, 3K, 6K, 12K and 24K; preferably, the linear density of the aramid fiber is 200-2000D; preferably, the linear densities of the E-glass fiber, basalt fiber and polytetrafluoroethylene fiber are the same or different, each being 100-1000tex.

[0026] According to the present invention, the structure of the blended fiber fabric is selected from one or more of satin, plain weave and twill weave.

[0027] According to the present invention, the areal density of the blended fiber fabric is 150-400 g / m². 2 .

[0028] According to the present invention, both the upper and lower surfaces of the preform are thermoplastic resin films.

[0029] According to the present invention, the blended fiber fabric satisfies the quasi-isotropic principle.

[0030] A second aspect of the present invention provides a method for preparing the aforementioned hybrid fiber fabric reinforced thermoplastic composite laminate, wherein the preparation method includes:

[0031] (1) The blended fiber fabric and thermoplastic resin film are layered sequentially to obtain a preform;

[0032] (2) The release cloth, the perforated isolation film, the preform, the perforated isolation film and the release cloth are sequentially laid in the mold tooling, and the preform is molded to obtain a laminate.

[0033] According to the present invention, in step (1), the layup method must satisfy the following: the layer is laid up in the manner of one layer of thermoplastic resin film and one layer of mixed fiber fabric, that is, the mixed fiber fabric and thermoplastic resin film are laid up alternately; and the bottom layer and the top layer are thermoplastic resin films to obtain a preform, that is, the upper and lower surfaces of the preform are both thermoplastic resin films; the mixed fiber fabric layup satisfies the quasi-isotropic principle.

[0034] According to the present invention, for the weaving of blended fiber fabrics, two different fibers can be used as weaving raw materials and woven into blended fiber fabrics with a certain weaving structure and areal density by using a rapier loom; wherein, the rapier loom includes a loom, an unwinding machine and a rewinding machine.

[0035] According to the present invention, in step (2), for the preparation of the preform, the blended fiber fabric and thermoplastic resin film can be cut on a cutting bed according to certain size specifications and quantity requirements, and stacked for later use.

[0036] According to the present invention, in step (2), the molding of the preform can be carried out using a mold. First, a release agent is uniformly coated on the surface of the mold. Then, the release cloth, the perforated isolation film, the preform, the perforated isolation film, and the release cloth are laid out sequentially from bottom to top in the mold fixture. Finally, the mold fixture is closed and the template is closed. The preform refers to a preform formed by stacking and laying out the mixed fiber fabric and thermoplastic resin film in a certain layup manner.

[0037] In this invention, the release agent can be one or more of the following: Sakurai MK-0050 high-temperature release agent, Henkel Loctite Frekote 770-NC release agent, and Granudan Zyvax Flex-Z 6.0 release agent.

[0038] In this invention, the release fabric can be airtech Bleeder_Lease_C release fabric and / or Taixing Huayu Company HY-F025Z release fabric.

[0039] In this invention, the perforated separator can be an Airtech THERM260255RCBS separator and / or a Shenzhen Ruihuatai BPF-25 separator.

[0040] According to the present invention, in step (2), the mold fixture carrying the preform is moved to the center of the upper and lower heating plates of the press, and the preform is molded under certain process conditions; wherein, in the present invention, the molding conditions include: hot pressing temperature T of 200-400℃, holding pressure P of 0.5-2MPa, holding time t of 30-60min, and cooling rate Δ of 1℃ / min-8℃ / min; preferably, the molding conditions include: hot pressing temperature T of 240-365℃, holding pressure P of 0.5-2MPa, holding time t of 30-60min, and cooling rate Δ of 1℃ / min-6℃ / min.

[0041] According to the present invention, after the molding is completed, the mold tooling is removed and the mold is opened to obtain a thermoplastic composite laminate reinforced with mixed fiber fabric, which can then be used for subsequent trimming and mechanical property testing.

[0042] According to a preferred embodiment of the present invention, a method for preparing a thermoplastic composite laminate reinforced with blended fiber fabric includes:

[0043] Step 1: Weaving of blended fiber fabrics

[0044] Using two different fibers as woven raw materials, a blended fiber fabric with a certain weaving structure and areal density is woven on a rapier loom; the rapier loom includes a loom, an unwinding machine, and a rewinding machine.

[0045] Step 2: Preparation of the preform

[0046] (1) On the cutting bed, cut the mixed fiber fabric and thermoplastic resin film according to certain size specifications and quantity requirements, and stack them for later use;

[0047] (2) Coat the mold surface evenly with release agent;

[0048] (3) In the mold fixture, the release cloth, the perforated isolation film, the preform, the perforated isolation film, and the release cloth are laid out from bottom to top, and finally the mold fixture is closed and the template is closed; among them, the preform refers to the preform formed by stacking and laying out the mixed fiber fabric and thermoplastic resin film in a certain layering manner.

[0049] Step 3: Preparation of the laminate

[0050] (1) Move the mold tooling containing the preform to the center of the upper and lower heating plates of the press;

[0051] (2) Under certain process conditions, the preform is molded; wherein, the process conditions include: hot pressing temperature T, holding pressure P, holding time t, and cooling rate Δ.

[0052] (3) Remove the mold fixture and open the mold to obtain the mixed fiber fabric reinforced thermoplastic composite laminate, and then carry out subsequent edge trimming and mechanical property testing of the board.

[0053] A third aspect of the present invention provides an application of the aforementioned hybrid fiber fabric reinforced thermoplastic composite laminate in one or more fields, including wind turbine blades, rail transit, and building reinforcement.

[0054] The present invention will be described in detail below through embodiments.

[0055] The sources of each raw material in the following examples and comparative examples are explained:

[0056] The carbon fiber was supplied by Sinopec Shanghai Petrochemical Co., Ltd.

[0057] The aramid fiber was supplied by Sinochem International (Holdings) Co., Ltd.

[0058] E-glass fiber was supplied by China Jushi Co., Ltd.

[0059] The basalt fiber was supplied by Zhejiang Shijin Basalt Fiber Co., Ltd.

[0060] The polytetrafluoroethylene fiber was provided by Shanghai Jinyou Fluorine Materials Co., Ltd.

[0061] The blended fiber fabric was processed and woven by Shanghai Xindiliang Industrial Development Co., Ltd.

[0062] All thermoplastic resin films are commercially available.

[0063] The thickness and mechanical properties of the prepared laminate were tested. The test methods / standards are shown in Table 1.

[0064] Table 1

[0065]

[0066]

[0067] Example 1

[0068] This embodiment illustrates the thermoplastic composite laminate reinforced with blended fiber fabric prepared according to the present invention.

[0069] Step 1: Weaving of blended fiber fabrics

[0070] (1) Using carbon fiber (T300-3K) and E-glass fiber (200tex) as woven raw materials, the fabric is woven on a rapier loom to a surface density of 200g / m². 2 Plain weave fabric made of blended fibers.

[0071] Step 2: Preparation of the preform

[0072] (1) On a cutting bed, eight pieces of mixed-fiber plain weave fabric and nine pieces of polyphenylene sulfide thermoplastic resin film were cut, each with a size of 500mm×500mm, to prepare preforms, which were then stacked for later use; wherein, the relative molecular mass of the polyphenylene sulfide thermoplastic resin in the single-layer polyphenylene sulfide thermoplastic resin film was 80000, and the density was 1.3g / cm³. 3 The thickness is 150μm; the thickness of the single-layer blended fiber plain weave fabric is 300μm; therefore, the thickness of the preform is 3.75mm.

[0073] (2) Coat the mold surface evenly with release agent (Henkel Loctite Frekote 770-NC release agent);

[0074] (3) Figure 1 This is a schematic diagram of the compression molding layup in Example 1, according to... Figure 1 As shown, firstly, in the mold fixture, from bottom to top, the release cloth (airtech Bleeder_Lease_C release cloth), the perforated isolation film (Shenzhen Ruihuatai BPF-25 isolation film), the preform, the perforated isolation film, and the release cloth are laid out sequentially; finally, the mold fixture is closed with the template; where the preform refers to the one prepared in step two (1), wherein the mixed fiber plain weave fabric and the polyphenylene sulfide thermoplastic resin film are laid out alternately, and the upper and lower surfaces are both polyphenylene sulfide thermoplastic resin films.

[0075] Step 3: Preparation of the laminate

[0076] (1) Move the mold tooling containing the preform prepared above to the center of the upper and lower heating plates of the press;

[0077] (2) Under the process conditions of hot pressing temperature T=330℃, holding pressure P=1.5MPa, holding time t=45min, and cooling rate Δ=5℃ / min, the preform is molded.

[0078] (3) Remove the mold fixture and open the mold to obtain the polyphenylene sulfide thermoplastic composite laminate reinforced with mixed fiber plain weave fabric, and carry out subsequent edge trimming and mechanical property testing of the board; wherein, the thickness of the laminate is 2.3mm.

[0079] Example 2

[0080] This embodiment illustrates the thermoplastic composite laminate reinforced with blended fiber fabric prepared according to the present invention.

[0081] Step 1: Weaving of blended fiber fabrics

[0082] (1) Using carbon fiber (T800-12K) and aramid fiber (2000D) as weaving materials, the fabric is woven on a rapier loom to a surface density of 300 g / m². 2 Blended fiber satin fabric; in addition... Figure 2 This is a live weaving diagram of the carbon fiber (T800-12K) / aramid fiber (2000D) blended fabric used in Example 2. Figure 2 In this process, carbon fiber (T800-12K) and aramid fiber (2000D) are used as woven raw materials and woven on a rapier loom to obtain a mixed fiber satin fabric.

[0083] Step 2: Preparation of the preform

[0084] (1) On a cutting bed, 12 pieces of mixed-fiber satin fabric and 13 pieces of polycarbonate thermoplastic resin film were cut, each with a size of 500mm×500mm, to prepare preforms, which were then stacked for later use; wherein, the relative molecular mass of the polycarbonate thermoplastic resin in the single-layer polycarbonate thermoplastic resin film was 60000, and the density was 1.2g / cm³. 3 The thickness is 300μm; the thickness of the single-layer blended fiber satin fabric is 500μm; therefore, the thickness of the preform is 9.9mm.

[0085] (2) Coat the mold surface evenly with release agent (Granudan Zyvax Flex-Z 6.0 release agent);

[0086] (3) First, lay out the release cloth (Taixing Huayu Company HY-F025Z release cloth), the perforated isolation film (airtech THERM260255RCBS isolation film), the preform, the perforated isolation film, and the release cloth in the mold fixture from bottom to top. Finally, close the mold fixture and the template. The preform refers to the one prepared in step two (1), in which the mixed fiber satin fabric and the polycarbonate thermoplastic resin film are laid out alternately, and the upper and lower surfaces are both polycarbonate thermoplastic resin films.

[0087] Step 3: Preparation of the laminate

[0088] (1) Move the mold tooling containing the preform prepared above to the center of the upper and lower heating plates of the press;

[0089] (2) Under the process conditions of hot pressing temperature T=280℃, holding pressure P=1.0MPa, holding time t=30min, and cooling rate Δ=3℃ / min, the preform is molded.

[0090] (3) Remove the mold fixture and open the mold to obtain the polycarbonate thermoplastic composite laminate reinforced with mixed fiber satin fabric, and carry out subsequent edge trimming and mechanical property testing of the board; wherein the thickness of the laminate is 3.5mm.

[0091] Example 3

[0092] This embodiment illustrates the thermoplastic composite laminate reinforced with blended fiber fabric prepared according to the present invention.

[0093] Step 1: Weaving of blended fiber fabrics

[0094] (1) Using aramid fiber (1000D) and basalt fiber (600tex) as weaving raw materials, the fabric is woven on a rapier loom to a surface density of 280 g / m². 2 Blended fiber satin fabric.

[0095] Step 2: Preparation of the preform

[0096] (1) On a cutting bed, 10 pieces of mixed-fiber satin fabric and 11 pieces of polyamide 6 thermoplastic resin film were cut, each with a size of 500mm×500mm, to prepare preforms, which were then stacked for later use; wherein, the relative molecular mass of polyamide 6 thermoplastic resin in the single-layer polyamide 6 thermoplastic resin film was 40000, and the density was 1.2g / cm³. 3 The thickness is 400μm; the thickness of the single-layer blended fiber satin fabric is 500μm; therefore, the thickness of the preform is 9.4mm.

[0097] (2) Coat the mold surface evenly with release agent (Sakurai MK-0050 high temperature release agent);

[0098] (3) First, lay out the release cloth (airtech Bleeder_Lease_C release cloth), the perforated isolation film (airtech THERM260255RCBS isolation film), the preform, the perforated isolation film, and the release cloth in the mold fixture from bottom to top, and finally close the mold fixture and the template; among them, the preform refers to the one prepared in step two (1), wherein the mixed fiber satin fabric and the polyamide 6 thermoplastic resin film are laid out alternately, and the upper and lower surfaces are both polyamide 6 thermoplastic resin films.

[0099] Step 3: Preparation of the laminate

[0100] (1) Move the mold tooling containing the preform prepared above to the center of the upper and lower heating plates of the press;

[0101] (2) Under the process conditions of hot pressing temperature T=240℃, holding pressure P=0.5MPa, holding time t=45min, and cooling rate Δ=1℃ / min, the preform is molded.

[0102] (3) Remove the mold fixture and open the mold to obtain the polyamide 6 thermoplastic composite laminate reinforced with mixed fiber satin fabric, and carry out subsequent edge trimming and mechanical property testing of the board; wherein, the thickness of the laminate is 2.8mm.

[0103] Example 4

[0104] This embodiment illustrates the thermoplastic composite laminate reinforced with blended fiber fabric prepared according to the present invention.

[0105] Step 1: Weaving of blended fiber fabrics

[0106] (1) Using E-glass fiber (800 tex) and polytetrafluoroethylene fiber (400 tex) as woven raw materials, the fabric is woven on a rapier loom to a surface density of 180 g / m². 2 Blended fiber twill fabric.

[0107] Step 2: Preparation of the preform

[0108] (1) On a cutting bed, 12 pieces of mixed-fiber twill fabric and 13 pieces of polyetheretherketone thermoplastic resin film were cut, each with a size of 500mm×500mm, to prepare preforms, which were then stacked for later use; among them, the relative molecular mass of the single-layer polyetheretherketone thermoplastic resin film was 120000, and the density was 1.4g / cm³. 3 The thickness is 270μm; the thickness of the single-layer blended fiber twill fabric is 400μm; therefore, the thickness of the preform is 8.31mm.

[0109] (2) Coat the mold surface evenly with release agent (Henkel Loctite Frekote 770-NC release agent);

[0110] (3) First, lay out the release cloth (airtech Bleeder_Lease_C release cloth), the perforated isolation film (airtech THERM260255RCBS isolation film), the preform, the perforated isolation film, and the release cloth in the mold fixture from bottom to top, and finally close the mold fixture and the template; among them, the preform refers to the one prepared in step two (1), wherein the mixed fiber twill fabric and the polyether ether ketone thermoplastic resin film are laid out alternately, and the upper and lower surfaces are both polyether ether ketone thermoplastic resin films.

[0111] Step 3: Preparation of the laminate

[0112] (1) Move the mold tooling containing the preform prepared above to the center of the upper and lower heating plates of the press;

[0113] (2) Under the process conditions of hot pressing temperature T=365℃, holding pressure P=2.0MPa, holding time t=60min, and cooling rate Δ=6℃ / min, the preform is molded.

[0114] (3) Remove the mold fixture and open the mold to obtain the polyether ether ketone thermoplastic composite laminate reinforced with mixed fiber twill fabric, and carry out subsequent edge trimming and mechanical property testing of the laminate; wherein the thickness of the laminate is 3.4 mm.

[0115] Example 5

[0116] This embodiment illustrates the thermoplastic composite laminate reinforced with blended fiber fabric prepared according to the present invention.

[0117] (1) Step 1: Weaving of blended fiber fabrics

[0118] Using basalt fiber (1000 tex) and polytetrafluoroethylene fiber (800 tex) as woven raw materials, the fabric is woven on a rapier loom to a surface density of 240 g / m². 2 Plain weave fabric made of blended fibers.

[0119] Step 2: Preparation of the preform

[0120] (1) On a cutting bed, eight pieces of mixed-fiber plain weave fabric and nine pieces of polysulfone thermoplastic resin film were cut, each with a size of 500mm×500mm, to prepare preforms, which were then stacked for later use; among them, the relative molecular mass of the single-layer polysulfone thermoplastic resin film was 180,000, and the density was 1.3g / cm³. 3 The thickness is 340μm; the thickness of the single-layer woven plain weave fabric is 300μm; therefore, the thickness of the preform is 5.46mm.

[0121] (2) Coat the mold surface evenly with release agent (Sakurai MK-0050 high temperature release agent);

[0122] (3) First, lay out the release cloth (Taixing Huayu Company HY-F025Z release cloth), the perforated isolation film (airtech THERM260255RCBS isolation film), the preform, the perforated isolation film, and the release cloth in the mold fixture from bottom to top. Finally, close the mold fixture and the template. The preform refers to the one prepared in step two (1), in which the mixed fiber plain weave fabric and the polysulfone thermoplastic resin film are laid out alternately, and the upper and lower surfaces are both polysulfone thermoplastic resin films.

[0123] Step 3: Preparation of the laminate

[0124] (1) Move the mold tooling containing the preform prepared above to the center of the upper and lower heating plates of the press;

[0125] (2) Under the process conditions of hot pressing temperature T=340℃, holding pressure P=1.0MPa, holding time t=30min, and cooling rate Δ=2℃ / min, the preform is molded.

[0126] (3) Remove the mold fixture and open the mold to obtain the polysulfone thermoplastic composite laminate reinforced with mixed fiber plain weave fabric, and carry out subsequent edge trimming and mechanical property testing of the board; wherein, the thickness of the laminate is 2.4mm.

[0127] in addition, Figure 3 A cross-sectional scanning electron microscope image of the laminate prepared in Example 5, from... Figure 3 It can be seen that the resin is evenly distributed and has good bonding with the fiber interface, which is beneficial to improving the mechanical properties of the composite laminate.

[0128] Example 6

[0129] This embodiment illustrates the thermoplastic composite laminate reinforced with blended fiber fabric prepared according to the present invention.

[0130] Step 1: Weaving of blended fiber fabrics

[0131] (1) Using aramid fiber (800D) and E-glass fiber (600tex) as weaving materials, the fabric is woven on a rapier loom to a surface density of 320 g / m². 2 Blended fiber twill fabric.

[0132] Step 2: Preparation of the preform

[0133] (1) On a cutting bed, 10 pieces of mixed-fiber twill fabric and 11 pieces of polyaryletherketone thermoplastic resin film were cut, each with a size of 500mm×500mm, to prepare preforms, which were then stacked for later use; among them, the relative molecular mass of the single-layer polyaryletherketone thermoplastic resin film was 100,000, and the density was 1.4g / cm³. 3 The thickness is 230μm; the thickness of the single-layer blended fiber twill fabric is 400μm; therefore, the thickness of the preform is 6.53mm.

[0134] (2) Coat the mold surface evenly with release agent (Granudan Zyvax Flex-Z 6.0 release agent);

[0135] (3) First, lay out the release cloth (Taixing Huayu Company HY-F025Z release cloth), the perforated isolation film (Shenzhen Ruihuatai BPF-25 isolation film), the preform, the perforated isolation film, and the release cloth in the mold fixture from bottom to top. Finally, close the mold fixture and the template. The preform refers to the one prepared in step two (1), in which the mixed fiber twill fabric and the polyaryletherketone thermoplastic resin film are laid in alternating layers, and the upper and lower surfaces are both polyaryletherketone thermoplastic resin films.

[0136] Step 3: Preparation of the laminate

[0137] (1) Move the mold tooling containing the preform prepared above to the center of the upper and lower heating plates of the press;

[0138] (2) Under the process conditions of hot pressing temperature T=355℃, holding pressure P=1.5MPa, holding time t=60min, and cooling rate Δ=4℃ / min, the preform is molded.

[0139] (3) Remove the mold fixture and open the mold to obtain the polyaryletherketone thermoplastic composite laminate reinforced with mixed fiber twill fabric, and carry out subsequent edge trimming and mechanical property testing of the laminate; wherein the thickness of the laminate is 2.9mm.

[0140] Comparative Example 1

[0141] The laminate was prepared using the same method as in Example 1, except that "a plain weave fabric made of blended fibers using carbon fiber (T300-3K) and E-glass fiber (200tex) as woven raw materials" was replaced with "a plain weave fabric made of fibers using E-glass fiber (200tex) as woven raw materials".

[0142] The thickness and mechanical properties of the prepared laminate were tested.

[0143] Comparative Example 2

[0144] The laminate was prepared using the same method as in Example 1, except that the "polyphenylene sulfide thermoplastic resin film" was replaced with "polyethylene thermoplastic resin film, wherein the polyethylene has a relative molecular mass of 8000 and a density of 0.95 g / cm³". 3 ".

[0145] The thickness and mechanical properties of the prepared laminate were tested.

[0146] Comparative Example 3

[0147] The laminate was prepared using the same method as in Example 1, except that "the thickness of the polyphenylene sulfide thermoplastic resin film is 150 μm" was replaced with "the thickness of the polyphenylene sulfide thermoplastic resin film is 600 μm".

[0148] The thickness and mechanical properties of the prepared laminate were tested.

[0149] Comparative Example 4

[0150] The laminate was prepared using the same method as in Example 1, except that "the thickness of the blended fiber plain weave fabric is 300 μm" was replaced with "the thickness of the blended fiber plain weave fabric is 700 μm".

[0151] The thickness and mechanical properties of the prepared laminate were tested.

[0152] Comparative Example 5

[0153] The laminate was prepared using the same method as in Example 1, except that the phrase "under the process conditions of hot pressing temperature T = 330°C, holding pressure P = 1.5 MPa, holding time t = 45 min, and cooling rate Δ = 5°C / min" was replaced with "under the process conditions of hot pressing temperature T = 360°C, holding pressure P = 2.5 MPa, holding time t = 60 min, and cooling rate Δ = 10°C / min".

[0154] The thickness and mechanical properties of the prepared laminate were tested.

[0155] Test case

[0156] The thickness and mechanical properties of the laminates prepared in Examples 1-6 and Comparative Examples 1-5 were tested, and the test results are shown in Table 2.

[0157] Table 2

[0158]

[0159]

[0160] The preferred embodiments of the present invention have been described in detail above; however, the present invention is not limited thereto. Within the scope of the inventive concept, various simple modifications can be made to the technical solutions of the present invention, including combinations of various technical features in any other suitable manner. These simple modifications and combinations should also be considered as the content disclosed in the present invention and are all within the protection scope of the present invention.

Claims

1. A thermoplastic composite laminate reinforced with mixed-weave fiber fabric, characterized in that, The laminate is obtained by molding a preform, wherein the preform comprises multiple layers of woven fiber fabric and thermoplastic resin film stacked sequentially, and the thermoplastic resin film is selected from one or more of polyamide film, polyphenylene sulfide film, polyether ether ketone film, polyarylether ketone film, polycarbonate film and polysulfone film.

2. The laminate according to claim 1, wherein, The thickness of the single-layer blended fiber fabric is 200-600 μm, preferably 300-500 μm; Preferably, the thickness of a single layer of the thermoplastic resin film is 100-500 μm, and more preferably 150-400 μm.

3. The laminate according to claim 1 or 2, wherein, The thermoplastic resin used to prepare the thermoplastic resin film has a relative molecular mass of 10,000-200,000 and a density of 1.1-1.5 g / cm³. 3 ; Preferably, the thermoplastic resin has a relative molecular mass of 40,000-180,000 and a density of 1.2-1.4 g / cm³. 3 .

4. The laminate according to any one of claims 1-3, wherein, The fibers in the blended fiber fabric are selected from at least two of carbon fiber, aramid fiber, E-glass fiber, basalt fiber and polytetrafluoroethylene fiber.

5. The laminate according to claim 4, wherein, The carbon fiber has a strength grade of one or more of T300, T700, T800 and T1000, and a tow grade of one or more of 1K, 3K, 6K, 12K and 24K. Preferably, the linear density of the aramid fiber is 200-2000D; Preferably, the linear densities of the E-glass fiber, basalt fiber, and polytetrafluoroethylene fiber are the same or different, each ranging from 100 to 1000 tex.

6. The laminate according to any one of claims 1-5, wherein, The structure of the blended fiber fabric is selected from one or more of satin, plain weave, and twill weave; And / or, the areal density of the blended fiber fabric is 150-400 g / m². 2 .

7. The laminate according to any one of claims 1-6, wherein, The upper and lower surfaces of the preform are both thermoplastic resin films; And / or, the blended fiber fabric satisfies the quasi-isotropic principle.

8. A method for preparing a thermoplastic composite laminate reinforced with blended fiber fabric according to any one of claims 1-7, characterized in that, The preparation method includes: (1) The blended fiber fabric and thermoplastic resin film are layered sequentially to obtain a preform; (2) The release cloth, the perforated isolation film, the preform, the perforated isolation film and the release cloth are sequentially laid in the mold tooling, and the preform is molded to obtain a laminate.

9. The preparation method according to claim 8, wherein, In step (2), the molding conditions include: hot pressing temperature T of 200-400℃, holding pressure P of 0.5-2MPa, holding time t of 30-60min, and cooling rate Δ of 1℃ / min-8℃ / min; Preferably, the molding conditions include: hot pressing temperature T of 240-365℃, holding pressure P of 0.5-2MPa, holding time t of 30-60min, and cooling rate Δ of 1℃ / min-6℃ / min.

10. The application of a hybrid fiber fabric reinforced thermoplastic composite laminate according to any one of claims 1-7 in one or more fields of wind turbine blades, rail transit and building reinforcement.

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