Carbon fiber thermoplastic composite material structure

Abstract

The utility model belongs to the field of materials, and provides a carbon fiber thermoplastic composite material structure, which is characterized in that an upper surface layer, a lower surface layer and a middle layer are laminated and combined through a concave structure, and then a reinforcing layer is connected at a certain temperature and pressure to form a secondary infiltration connection integral part. According to the carbon fiber thermoplastic composite material structure, the splicing type design of three layers of layers is adopted, and the carbon fiber three-dimensional weaving structure is adopted at the interface bonding part, so that the interface bonding strength of the carbon fiber thermoplastic composite material plate or profile is effectively improved. In addition, the connecting part adopts a carbon fiber three-dimensional woven structure, so that the structural rigidity, strength and stability are greatly improved.

Description

Technical Field

[0001] The utility model belongs to the field of materials and relates to a thermoplastic composite material plate or profile. Background Art

[0002] The information disclosed in this background technology section is only intended to increase the understanding of the overall background of the utility model, and shall not necessarily be regarded as an admission or any form of suggestion that the information constitutes the prior art already known to ordinary technicians in this field.

[0003] Carbon fiber thermoplastic composite material is a composite material reinforced by multi-dimensional carbon fiber fabric using thermoplastic resin as the matrix. It can be processed and formed many times by using the thermal characteristics of repeated plasticization and molding of thermoplastic resin. It can be used for rapid processing and molding of plates, various special-shaped plates or multi-curved profiles. For larger composite plates or profiles, it is inevitable to connect materials. The traditional connection method is to use mechanical connection (bolts, nuts, etc.) or adhesive connection. For carbon fiber composite materials, if mechanical connection is used, it is inevitable to open holes in the plates or profiles. This will cause stress concentration damage to the subsequent use of structural parts. For adhesive connection, since most thermoplastic resins are non-polar materials, they have very strict requirements on adhesives, and their bonding strength is often low, which is prone to interface debonding problems at the connection.

[0004] Therefore, there is an urgent need for a carbon fiber thermoplastic composite structure with higher interface bonding strength. Utility Model Content

[0005] In order to solve the above problems, the utility model provides a carbon fiber thermoplastic composite material structure. The utility model adopts a three-layer stacking design and a carbon fiber three-dimensional woven structure (reinforcement layer) at the interface bonding part, which effectively improves the interface bonding strength of the carbon fiber thermoplastic composite material plate or profile.

[0006] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0007] The first aspect of the utility model provides a carbon fiber thermoplastic composite material structure, which adopts a three-layer stacking combination design, including: an upper surface layer, an intermediate layer, a lower surface layer, and a reinforcement layer; the upper surface layer is provided with a first convex joint, the lower surface layer is provided with a second convex joint, the upper surface of the intermediate layer is provided with a first concave interface, and the lower surface of the intermediate layer is provided with a second concave interface, the upper surface layer, the intermediate layer, and the lower surface layer are arranged in sequence from top to bottom, the first convex joint is embedded in the first concave interface, a reinforcement layer is arranged between the first convex joint and the first concave interface, the second convex joint is embedded in the second concave interface, and a reinforcement layer is arranged between the second convex joint and the second concave interface.

[0008] The utility model adopts upper and lower surface layers and an intermediate layer for lamination combination, and then forms a secondary infiltration connection integral component through a connection strengthening layer under a certain temperature and pressure.

[0009] In some embodiments, the upper and lower surface layers adopt a three-dimensional woven fabric structure.

[0010] In some embodiments, the three-dimensional woven fabric structure of the upper and lower surfaces adopts any one of three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional, and three-dimensional seven-directional fabric structures, and the three-dimensional fabric structures of the upper and lower surface layers can be designed in any combination and matching.

[0011] In some embodiments, the middle layer adopts a planar fabric structure.

[0012] In some embodiments, the middle layer is any one of a plain weave, a twill weave or a satin weave structure of carbon fiber.

[0013] The thickness of the upper surface layer, the middle layer and the lower surface layer can be flexibly adjusted according to design requirements.

[0014] Furthermore, the carbon fiber in the molding structure of the composite material plate or profile can be selected from any type such as T300, T700, T800, T1000 and is not limited to the above types. A mixed fiber structure of carbon fiber, glass fiber, and aramid fiber can also be adopted, and the mixing ratio can be flexibly adjusted according to design requirements.

[0015] The composite material sheet or profile can be formed by melt infiltration composite molding of the above-mentioned laminated fabric using a thermoplastic resin matrix, wherein the resin matrix can be any type of polyethylene, polypropylene, polyurethane, polyphenylene sulfide, polyamide, polyoxymethylene, polyethylene terephthalate, polyether ketone, polyetheretherketone, etc. and is not limited to the above types, and the final resin content is controlled in the range of 40-60%.

[0016] The interface connection part of the composite material plate or profile adopts a concave reserved interface design, and the length of the upper and lower surface layers on both sides is greater than the middle layer to form a concave structure along the thickness section of the plate, and its depth is flexibly designed according to the connection design requirements.

[0017] Furthermore, the lengths of the upper and lower surface layers exceed those of the middle layer by 50 mm to 100 mm.

[0018] Furthermore, the lengths of the upper and lower surface layers exceed those of the middle layer by 60 mm to 80 mm.

[0019] The composite material sheet or profile can be formed by hot pressing. First, each single layer of the three-layer structure is subjected to hot pressing and infiltration. Then, the three layers are stacked and subjected to a secondary infiltration combination treatment. The heating temperature range of the single-layer infiltration and secondary infiltration temperatures is flexibly designed according to the type of thermoplastic resin. The pressure control during the heating process is flexibly adjusted within the range of 1-15MPa, and the single-layer and secondary infiltration times are flexibly adjusted within the range of 30-90min.

[0020] In some embodiments, the reinforcement layer is made of hybrid carbon fiber multi-dimensional structural fabric.

[0021] In some embodiments, the hybrid carbon fiber multi-dimensional structural fabric of the reinforcement layer is formed by high modulus carbon fiber hybrid high strength carbon fiber, and adopts any one of the fabric structure types such as three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional, and three-dimensional seven-directional.

[0022] Furthermore, the high modulus carbon fiber can be any one of M40, M40J, M55, M55J, M60, M60J, etc., and the high strength carbon fiber can be any one of T300, T700, T800, T1000, etc. and is not limited to the above types. The mixing ratio of the two fibers can be adjusted according to design requirements.

[0023] The thickness of the multi-dimensional structural fabric connection reinforcement layer fiber preform and the thickness of the final connection reinforcement layer can be flexibly designed according to the depth and thickness of the connection concave shape.

[0024] In the utility model, the carbon fiber thermoplastic composite material structure can be manufactured by a physical and chemical co-solidification molding method, including:

[0025] A multi-dimensional stacking design is carried out in the molding structure of the composite material plate, and a concave interface is reserved at the connection part;

[0026] A hybrid carbon fiber multi-dimensional structural fabric is used to form a fiber preform for connecting reinforcement layers;

[0027] During the connection and molding process, the concave structure of the carbon fiber thermoplastic composite material sheet to be connected is preassembled by connecting the reinforcement layer fiber preform, and then it is placed in an injection mold to inject high-flow modified thermoplastic resin into the reinforcement layer fiber preform under high pressure. At the same time, the interface position of the connecting profile or sheet is subjected to secondary infiltration, high-temperature heating and pressurization treatment. After a certain connection processing time, an integral composite material product is finally formed.

[0028] In some embodiments, during the connection molding process, the concave structure of the carbon fiber thermoplastic composite material plate to be connected is preassembled by connecting the reinforcing layer fiber preform, the plate concave structure is docked, and the cavity formed by the concave structure is embedded in the connecting reinforcing layer fiber preform to form a preassembled structure, and then the assembled structure is placed in a connecting hot press heater for secondary melt infiltration molding, and the molding temperature is flexibly adjusted according to the type of thermoplastic resin matrix. The hot press pressure is controlled within the range of 1-10MPa.

[0029] In some embodiments, in the secondary melt infiltration connection molding process, a high-flow modified thermoplastic resin is simultaneously injected under high pressure using a high-pressure injection tool to impregnate the reinforcement layer fiber preform inside the connection cavity. The type of the high-flow modified thermoplastic resin matrix used is consistent with the type of the connection plate resin, the injection temperature used is consistent with the connection molding heating temperature range, the injection pressure is controlled within the range of 10-20 MPa, and the injection time is controlled within the range of 10-30 min.

[0030] In some embodiments, the processing time of the secondary infiltration connection molding is controlled within the range of 30-90 minutes and can be flexibly designed according to the connection molding and co-curing processing requirements.

[0031] Beneficial effects of the utility model

[0032] (1) The utility model adopts a three-layer stacking design, which is matched with a carbon fiber three-dimensional woven structure at the interface bonding part, effectively improving the interface bonding strength of the carbon fiber thermoplastic composite material plate or profile.

[0033] (2) The utility model avoids the use of mechanical hole-opening methods, thereby avoiding the stress concentration problem of the composite material caused by the hole-opening.

[0034] (3) The utility model adopts a carbon fiber three-dimensional woven structure at the interface bonding part, which effectively improves the rigidity of the connection interface and improves the interface bonding strength.

[0035] (4) The utility model has a simple structure, strong practicability and is easy to promote. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation on the present invention.

[0037] Figure 1 The invention relates to a plate or profile forming method of a carbon fiber thermoplastic composite material by physical and chemical co-solidification connection, comprising 1 an upper surface layer, 2 an intermediate layer, 3 a lower surface layer and 4 a reinforcement layer. DETAILED DESCRIPTION

[0038] It should be noted that the following detailed descriptions are exemplary and are intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.

[0039] Terminology explanation:

[0040] "M40, M40J, M55, M55J, M60, M60J" are all product models of high modulus carbon fiber.

[0041] "T300, T700, T800, T1000" and others are all product models of high-strength carbon fiber.

[0042] The present invention will be further described in detail below in conjunction with specific embodiments. It should be noted that the specific embodiments are intended to explain the present invention rather than to limit it.

[0043] Example 1

[0044] A sheet or profile of carbon fiber thermoplastic composite material with physical and chemical co-solidification connection, a three-layer stacking combination design of a multi-dimensional structure is carried out in the molding structure of the composite material sheet, and a concave interface is reserved for the connection part. The upper and lower surface layers adopt a three-dimensional four-directional fabric structure of T300 carbon fiber, and the middle layer adopts a plain weave fabric structure of T300 carbon fiber. The length of the surface layers on both sides exceeds the middle layer by 50mm.

[0045] Molding methods include:

[0046] In the first step, each single layer of the three-layer structure is subjected to hot pressing and melt infiltration (ie, primary melt infiltration) to form corresponding carbon fiber thermoplastic composite material structural parts.

[0047] In the second step, a three-dimensional four-way structural fabric of a 1:1 mixed M40 high modulus carbon fiber and T300 high strength carbon fiber is used to form a connection reinforcement layer fiber preform to strengthen the connection part, and the number of layers is 4.

[0048] In the third step, during the connection and molding process, the concave structure of the carbon fiber thermoplastic composite material sheet to be connected is pre-laminated and assembled through the connection reinforcement layer fiber preform, and then it is placed in an injection mold to high-flow modified thermoplastic resin for high-pressure injection impregnation of the connection reinforcement layer fiber preform. At the same time, the interface position of the connecting profile or sheet is subjected to a secondary melt infiltration treatment at a pressure of 1MPa and a temperature of 210°C. After 30 minutes, an integral composite material product is finally formed.

[0049] Example 2

[0050] A sheet or profile of carbon fiber thermoplastic composite material with physical and chemical co-solidification connection, a three-layer stacking combination design of a multi-dimensional structure is carried out in the molding structure of the composite material sheet, and a concave interface is reserved for the connection part. The upper and lower surface layers adopt a three-dimensional five-directional fabric structure of T700 carbon fiber, and the middle layer adopts a plain weave structure of T700 carbon fiber. The length of the surface layers on both sides exceeds the middle layer by 100mm.

[0051] Molding methods include:

[0052] In the first step, each single layer of the three-layer structure is subjected to hot pressing and melt infiltration (ie, primary melt infiltration) to form corresponding carbon fiber thermoplastic composite material structural parts.

[0053] In the second step, a three-dimensional seven-way multi-dimensional structural fabric of M55 high modulus carbon fiber mixed with T700 high strength carbon fiber in a ratio of 2:1 is used to form a connection reinforcement layer fiber preform to strengthen the connection part, and the number of layers is 5.

[0054] In the third step, during the connection and molding process, the concave structure of the carbon fiber thermoplastic composite material sheet to be connected is pre-laminated and assembled through the connection reinforcement layer fiber preform, and then it is placed in an injection mold to high-flow modified thermoplastic resin for high-pressure injection impregnation of the connection reinforcement layer fiber preform. At the same time, the interface position of the connecting profile or sheet is subjected to a secondary melt infiltration treatment at a pressure of 2MPa and a temperature of 220°C. After 40 minutes, an integral composite material product is finally formed.

[0055] Example 3

[0056] A sheet or profile of carbon fiber thermoplastic composite material with physical and chemical co-solidification connection, a three-layer stacking combination design of a multi-dimensional structure is carried out in the molding structure of the composite material sheet, and a concave interface is reserved for the connection part. The upper and lower surface layers adopt a three-dimensional six-directional fabric structure of T800 carbon fiber, and the middle layer adopts a satin flat fabric structure of T800 carbon fiber. The length of the surface layers on both sides exceeds the middle layer by 60mm.

[0057] Molding methods include:

[0058] In the first step, each single layer of the three-layer structure is subjected to hot pressing and melt infiltration (ie, primary melt infiltration) to form corresponding carbon fiber thermoplastic composite material structural parts.

[0059] In the second step, a three-dimensional six-directional multi-dimensional structural fabric of a 3:1 mixed M60 high modulus carbon fiber and T800 high strength carbon fiber is used to form a connection reinforcement layer fiber preform to strengthen the connection part, and the number of layers is 5.

[0060] In the third step, during the connection and molding process, the concave structure of the carbon fiber thermoplastic composite material sheet to be connected is pre-laminated and assembled through the connection reinforcement layer fiber preform, and then it is placed in an injection mold to high-flow modified thermoplastic resin for high-pressure injection impregnation of the connection reinforcement layer fiber preform. At the same time, the interface position of the connecting profile or sheet is subjected to secondary infiltration treatment at a pressure of 4MPa and a temperature of 230°C. After 30-90 minutes, an integral composite material product is finally formed.

[0061] Example 4

[0062] A sheet or profile of carbon fiber thermoplastic composite material with physical and chemical co-solidification connection, a three-layer stacking combination design of a multi-dimensional structure is carried out in the molding structure of the composite material sheet, and a concave interface is reserved for the connection part. The upper and lower surface layers adopt a three-dimensional seven-way fabric structure of T1000 carbon fiber, and the middle layer adopts a satin flat fabric structure of T800 carbon fiber. The length of the surface layers on both sides exceeds the middle layer by 80mm.

[0063] Molding methods include:

[0064] In the first step, each single layer of the three-layer structure is subjected to hot pressing and melt infiltration (ie, primary melt infiltration) to form corresponding carbon fiber thermoplastic composite material structural parts.

[0065] In the second step, a three-dimensional six-directional multi-dimensional structural fabric of M60J high modulus carbon fiber mixed with T1000 high strength carbon fiber in a ratio of 3.5:1 is used to form a connection reinforcement layer fiber preform to strengthen the connection part, and the number of layers is 6.

[0066] In the third step, during the connection and molding process, the concave structure of the carbon fiber thermoplastic composite material sheet to be connected is pre-laminated and assembled through the connection reinforcement layer fiber preform, and then it is placed in an injection mold to high-flow modified thermoplastic resin for high-pressure injection impregnation of the connection reinforcement layer fiber preform. At the same time, the interface position of the connecting profile or sheet is subjected to a secondary melt infiltration treatment at a pressure of 8MPa and a temperature of 200°C. After 90 minutes, an integral composite material product is finally formed.

[0067] The above description is only the preferred embodiment of the utility model, and is not intended to limit the utility model. For those skilled in the art, the utility model can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the utility model shall be included in the protection scope of the utility model.

Claims

1. A carbon fiber thermoplastic composite material structure, characterized in that: include: An upper surface layer, an intermediate layer, a lower surface layer, and a strengthening layer; the upper surface layer is provided with a first convex joint, the lower surface layer is provided with a second convex joint, the upper surface of the intermediate layer is provided with a first concave interface, and the lower surface of the intermediate layer is provided with a second concave interface. The upper surface layer, the intermediate layer, and the lower surface layer are arranged in sequence from top to bottom, the first convex joint is embedded in the first concave interface, a strengthening layer is arranged between the first convex joint and the first concave interface, the second convex joint is embedded in the second concave interface, and a strengthening layer is arranged between the second convex joint and the second concave interface.

2. The carbon fiber thermoplastic composite material structure according to claim 1, characterized in that: The upper and lower surface layers adopt a three-dimensional woven fabric structure.

3. The carbon fiber thermoplastic composite material structure according to claim 2, characterized in that: The three-dimensional woven fabric structure adopts any one of three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional and three-dimensional seven-directional fabric structures.

4. The carbon fiber thermoplastic composite material structure according to claim 1, characterized in that: The middle layer adopts a planar fabric structure.

5. The carbon fiber thermoplastic composite material structure according to claim 4, characterized in that: The middle layer is any one of a carbon fiber flat plain weave, twill weave or satin weave structure.

6. The carbon fiber thermoplastic composite material structure according to claim 1, characterized in that: The reinforcement layer adopts a hybrid carbon fiber multi-dimensional structural fabric.

7. The carbon fiber thermoplastic composite material structure according to claim 6, characterized in that: The hybrid carbon fiber multi-dimensional structural fabric adopts any one of the fabric structure types among three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional and three-dimensional seven-directional.

8. The carbon fiber thermoplastic composite material structure according to claim 1, characterized in that: The lengths of the upper and lower surface layers are greater than the middle layer.

9. The carbon fiber thermoplastic composite material structure according to claim 1, characterized in that: The lengths of the upper and lower surface layers exceed those of the middle layer by 50 mm to 100 mm.

10. The carbon fiber thermoplastic composite material structure according to claim 1, characterized in that: The lengths of the upper and lower surface layers exceed the middle layer by 60 mm to 80 mm.

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