Glass fiber mat reinforced thermoplastic composite board

Abstract

The utility model relates to the technical field of composite boards, in particular to a glass fiber mat reinforced thermoplastic composite board which comprises an uppermost recycled material and new material mixing layer and a lowermost recycled material and new material mixing layer, and a pure new material layer group is arranged between the two recycled material and new material mixing layers. The pure new material layer group comprises a plurality of mixed plate layers and high-elasticity reinforced glass fiber needled felt layers, the mixed plate layers and the high-elasticity reinforced glass fiber needled felt layers are adjacently arranged and laminated one by one, and the number of the mixed plate layers is one more than that of the high-elasticity reinforced glass fiber needled felt layers; the recycled material and new material mixed layer is formed by crushing leftover materials cut from the mixed plate layer and the high-elasticity reinforced glass fiber needled felt layer, mixing the crushed leftover materials with a polypropylene new material and adding the mixture to the upper surface and the lower surface of the pure and new material layer group, and both the recycled material and new material mixed layer and the pure and new material layer group contain glass fiber filaments; the monofilament average length of the glass fiber filaments in the returned material and new material mixing layer is smaller than that of the pure new material layer group; according to the utility model, the consumption of new materials is saved, the structure is strengthened, PP materials can be completely melted into the glass fiber monofilaments, and the connection is tight.

Description

Technical Field

[0001] This utility model relates to the field of composite board technology, and in particular to a glass fiber mat reinforced thermoplastic composite board with high impregnation and high mechanical properties. Background Technology

[0002] Lightweighting has become a global trend in automotive development. Currently, automotive dashboards, bumpers, battery covers, seat frames, coat racks, protective panels, and electrical brackets are typically made of GMT composite sheets. However, there is still room for improvement in the performance and cost control of existing GMT composite sheets.

[0003] Therefore, it is necessary to provide a new type of glass fiber mat reinforced thermoplastic composite sheet TML, where T stands for thermoplastics, M stands for glass fiber mat, and L stands for laminated plate, to better meet the needs of automotive manufacturing process development. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and address the problems of the GMT sheets commonly used in the market, by providing a self-developed special structure high-impregnation, high-mechanical-strength glass fiber mat-reinforced thermoplastic composite board.

[0005] To achieve the above objectives, the solution adopted by this utility model is as follows:

[0006] A glass fiber mat reinforced thermoplastic composite board includes an uppermost and a lowermost layer of recycled and virgin material mixed layers. Between the two recycled and virgin material mixed layers, a pure virgin material layer group is provided. The pure virgin material layer group includes several mixed board layers and several high-elasticity reinforced glass fiber needle-punched felt layers. The mixed board layers and high-elasticity reinforced glass fiber needle-punched felt layers are stacked and pressed one after another adjacently, and the number of mixed board layers is one more than the number of high-elasticity reinforced glass fiber needle-punched felt layers.

[0007] The recycled material and virgin material mixed layer is made by crushing the scraps cut from the mixed board layer and the high-elasticity reinforced glass fiber needle-punched felt layer and mixing them with polypropylene virgin material, which is then added to the upper and lower surfaces of the pure virgin material layer group. Both the recycled material and virgin material mixed layer and the pure virgin material layer group contain glass fiber filaments. The average length of a single glass fiber filament in the recycled material and virgin material mixed layer is shorter than that in the pure virgin material layer group.

[0008] Furthermore, the high-elasticity reinforced glass fiber needled felt layer consists of two layers, with a hybrid board layer on both the upper and lower surfaces of each high-elasticity reinforced glass fiber needled felt layer.

[0009] Furthermore, the mixed plate layer comprises a mixture of polypropylene and reinforcing carbon black particles, and contains flame retardants, antioxidants, and hollow glass microspheres, wherein the volume percentage of the polypropylene is at least 1.6 times the volume percentage of the reinforcing carbon black particles.

[0010] Furthermore, the volume ratio of recycled material to virgin material in the recycled material-virgin material mixture layer is 70:30.

[0011] Furthermore, the board dimensions are as follows: net width: 600–1250 mm, thickness: 1–10 mm, density: 1.0–1.7 g / cm³. 3 Weight fluctuation range: ±0.15%.

[0012] Furthermore, the high-elasticity reinforced glass fiber needle-punched felt layer produces fluffy felt loops through needle punching.

[0013] Furthermore, a multi-axial fabric plus chopped filament needle-punched felt composite layer is provided between the recycled material mixing layer and the mixing board layer; the multi-axial fabric plus chopped filament needle-punched felt composite layer is composed of an upper glass fiber raw filament felt layer, a lower reinforcing glass fiber multi-axial fabric and a chopped filament layer needle-punched composite layer, and the upper glass fiber raw filament felt layer and the chopped filament layer, and the lower reinforcing glass fiber multi-axial fabric and the chopped filament layer are respectively combined into one by a lower needle-punching process and an upper needle-punching process.

[0014] Furthermore, a chopped glass fiber needle-punched felt layer or a continuous glass fiber needle-punched felt layer is provided between the recycled material mixing layer and the mixing board layer; both the chopped glass fiber needle-punched felt layer and the continuous glass fiber needle-punched felt layer are composed of an upper glass fiber filament felt layer, a lower glass fiber filament felt layer and an intermediate layer, and the upper glass fiber filament felt layer and the intermediate layer, and the lower glass fiber filament felt layer and the intermediate layer are respectively bonded together by a lower needle-punching process and an upper needle-punching process.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0016] 1. Saves on virgin material usage and reduces costs. By recycling and reusing waste PP sheets, the amount of virgin raw material used is reduced, and performance and quality similar to virgin PP sheets can be obtained. This has the advantages of saving resources, being environmentally friendly and sustainable, and reducing costs.

[0017] 2. Structural reinforcement: PP board composite glass fiber mat with good modulus can significantly improve the strength, heat resistance and rigidity of the material. By laminating glass fiber mat into PP sheets, the tensile strength, flexural strength, and modulus can be significantly improved, while also enhancing its heat resistance. Specifically, the advantages of glass fiber reinforced PP materials include: improved heat resistance: the heat resistance temperature of glass fiber reinforced PP materials can reach 120℃ to 165℃, exceeding that of ordinary PP materials; increased strength: tensile strength can reach 57.17MPa to 68.17MPa, tensile modulus can reach 4712MPa to 5169MPa, flexural strength can reach 74.19MPa to 105.22MPa, and flexural modulus can reach 3361MPa to 4019MPa, these indicators far exceed those of ordinary PP materials; enhanced rigidity: the addition of glass fiber mat greatly improves the rigidity of the material, reducing the possibility of deformation and bending; chemical resistance: it can withstand corrosion from acids, alkalis, salt solutions, and various organic solvents, making it suitable for harsh environments and for manufacturing high-strength, anti-aging, flame-retardant, and high-heat-resistant parts and structural components.

[0018] 3. Complete impregnation ensures that the PP material is fully melted into the glass fiber monofilaments, resulting in a tight bond. The needle-punched felt rings provide high elasticity, allowing the molten glass fiber needle-punched felt on the PP board to be completely impregnated with the original filaments both between and within the bundles. This results in better fluffing of the finished product after heating in the oven during secondary processing. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of Embodiment 1 of the present utility model;

[0020] Figure 2 This is a three-dimensional structural diagram of Embodiment 2 of the present invention;

[0021] Figure 3 This is a three-dimensional structural diagram of Embodiment 3 of the present invention;

[0022] Figure 4 This is a three-dimensional structural diagram of Embodiment 4 of the present invention;

[0023] Figure 5 This is a schematic diagram illustrating the fluffing and swelling changes of this utility model under heating.

[0024] In the diagram: 1. Mixed layer of recycled and virgin materials; 2. Pure virgin material layer group; 2a. Mixed board layer; 2b. High-elasticity reinforced glass fiber chopped needle-punched felt layer; 3. Multiaxial cloth plus chopped needle-punched felt composite layer; 4. Glass fiber chopped needle-punched felt layer; 5. Glass fiber continuous needle-punched felt layer. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.

[0026] like Figure 1 As shown in Embodiment 1, a glass fiber mat reinforced thermoplastic composite board includes two layers of recycled and virgin material mixed layer 1 at the top and bottom, and a pure virgin material layer group 2 is provided between the two layers of recycled and virgin material mixed layer 1. The pure virgin material layer group 2 includes several layers of mixed board layer 2a and several layers of high elasticity reinforced glass fiber needle-punched felt layer 2b. The mixed board layer 2a and the high elasticity reinforced glass fiber needle-punched felt layer 2b are stacked and pressed one next to each other, and the number of mixed board layer 2a is one more than the number of high elasticity reinforced glass fiber needle-punched felt layer 2b.

[0027] The recycled material-new material mixture layer 1 consists of scraps cut from the mixed board layer 2a and the high-elasticity reinforced glass fiber needle-punched felt layer 2b. These scraps are crushed and mixed with virgin polypropylene material, then added to the top and bottom surfaces of the pure virgin material layer group 2. The addition of some virgin material after crushing the board edges enhances the tensile and flexural moduli of the board, and also improves the material flow performance within the mold during the production of structural components. Both the recycled material-new material mixture layer 1 and the pure virgin material layer group 2 contain glass fiber filaments with a diameter of 12–23 μm. The glass fiber filaments in the recycled material-new material mixture layer 1 have a higher degree of fragmentation, and the average length of a single filament is shorter than that in the pure virgin material layer group 2. The volume ratio of recycled material to virgin material in the recycled material-new material mixture layer 1 is 70:30, a reasonable ratio that strikes a balance between performance and cost.

[0028] The high-elasticity reinforced glass fiber needle-punched felt layer 2b is formed into a fluffy felt ring through needle punching. Two layers of the high-elasticity reinforced glass fiber needle-punched felt layer 2b are provided, with a mixed board layer 2a on both the upper and lower surfaces of each layer. Heating completely melts the polypropylene sheet, achieving complete impregnation of the molten polypropylene between and within the glass fiber needle-punched felt bundles, ultimately resulting in a smooth sheet surface. Thermoplastic composites can be remolded and recycled, exhibiting both environmental friendliness and economic efficiency, characteristics not found in thermosetting composites, which cannot be recycled. Furthermore, the recyclability of thermoplastic composites effectively meets the environmental requirements of the materials industry. The completed composite sheet has high strength, particularly high modulus, allowing the polypropylene material to be completely melted into the single filaments of the reinforcing thermoplastic glass fiber needle-punched felt layer.

[0029] The mixed plate layer 2a comprises a mixture of polypropylene and reinforcing carbon black particles, and contains flame retardants, antioxidants, and hollow glass microspheres. The volume percentage of polypropylene is at least 1.6 times the volume percentage of reinforcing carbon black particles.

[0030] Specifically, adding PP to glass fiber reinforced polypropylene significantly improves the tensile strength and flexural properties of the material, enhances adhesion, improves the interaction between glass fiber and polypropylene, and reduces surface defects. The effect of reinforcing carbon black on polypropylene is mainly reflected in increased strength and stiffness, as well as improved mechanical properties. Reinforcing carbon black increases the crystallization temperature of the polypropylene matrix by forming heterogeneous nucleation with it, thereby significantly improving the toughness and strength of polypropylene. This reinforcing effect is not only reflected in the physical properties of polypropylene but also in its chemical stability and weather resistance. The addition of reinforcing carbon black allows the polypropylene material to absorb the impact of external forces through molecular chain slippage and significant physical adsorption, buffering friction or hysteretic deformation caused by external forces and ensuring uniform stress distribution. Furthermore, reinforcing carbon black effectively promotes the crystallization process of polypropylene, increasing its crystallization rate. This promoting effect helps improve the overall performance of polypropylene materials, including increased hardness, dimensional stability, and rigidity. Adding hollow glass microspheres with a particle size of 15–30 μm can improve the lightweight nature of materials while maintaining high strength, stiffness, toughness, and fatigue resistance.

[0031] For the specific component proportion range of hybrid layer 2, please refer to the table below.

[0032] polypropylene 40％-68.5％ Reinforcing carbon black granules 13％-25％ Hollow glass microspheres 3.5％-9％ Flame retardant 8％-13％ Calcium stearate 3％-5％ antioxidants 3％-5％ stabilizer 1％-3％

[0033] Calcium stearate is commonly used as a lubricant and release agent in industrial production, especially in the production of styrene resin, polypropylene, phenolic resin, and amino resin, where it can increase the gelation speed of rigid products. Flame retardants form a glassy or stable foam covering layer at high temperatures, isolating oxygen and providing heat and oxygen insulation, preventing the escape of flammable gases, thereby achieving flame retardancy. Stabilizers in polypropylene improve its stability, heat resistance, and anti-aging properties, thereby extending its service life and improving processing performance. Antioxidants mainly delay and inhibit the degradation process of polymer materials, extending the service life of polymer products.

[0034] This utility model discloses a glass fiber mat-reinforced thermoplastic composite board, which has the advantages of being lightweight, corrosion-resistant, rust-free, and having good heat insulation, sound insulation, and electrical insulation properties. The board dimensions are as follows: net width: 600-1250mm, thickness: 1-10mm, density: 1.0-1.7g / cm³. 3 Weight fluctuation range: ±0.15%. It can mold complex shapes in one piece and has excellent performance. The performance test data with a glass fiber content of 30% is as follows:

[0035] Glass fiber content (by mass) 30％ <![CDATA[Density / g / cm 3 > 1.13±0.1 Tensile strength / MPa 57.17～68.17 Bending strength / MPa 74.19～105.22 Tensile modulus / MPa 4712～5169 Flexural modulus / MPa 3361～4019 Heat distortion temperature / ℃ 120℃～165℃

[0036] This utility model discloses a glass fiber felt-reinforced thermoplastic composite board. During manufacturing, it is unwound by a multi-layer unwinding device, consisting of multiple layers of molten polypropylene matrix material and multiple layers of glass fiber needle-punched felt reinforcement material stacked into a "sandwich" structure (with three, five, seven, and nine layers in total). It is then continuously produced through a double-strip continuous press involving heating, melting, impregnation, cooling, shaping, edge trimming, slitting, length cutting, and fully automated stacking. In the secondary processing of this glass fiber felt-reinforced thermoplastic composite board, the product becomes more fluffy after heating in an oven. Figure 5 As shown, its thickness can be increased to 7 times the original.

[0037] Example 2, reference Figure 2 Unlike Embodiment 1, a multiaxial fabric plus chopped filament needle-punched felt composite layer 3 is provided between the recycled material mixing layer 1 and the mixing plate layer 2a. The multiaxial fabric plus chopped filament needle-punched felt composite layer 3 is composed of an upper glass fiber raw filament felt layer, a lower reinforcing glass fiber multiaxial fabric and a chopped filament layer needle-punched composite. The upper glass fiber raw filament felt layer and the chopped filament layer, and the lower reinforcing glass fiber multiaxial fabric and the chopped filament layer are respectively bonded together by a lower needle-punching process and an upper needle-punching process.

[0038] Example 3, reference Figure 3 Unlike Example 1, a glass fiber chopped needle-punched felt layer 4 is provided between the recycled material mixing layer 1 and the mixing plate layer 2a.

[0039] Example 4, Reference Figure 4 Unlike Example 1, a continuous glass fiber needle-punched felt layer 5 is provided between the recycled material mixing layer 1 and the mixing board layer 2a. The fibers of the continuous felt are continuous, therefore its mechanical strength is better than that of chopped strand mat. The needle-punched felt has a high porosity, which is beneficial for the diffusion, flow, and impregnation of polypropylene, and the surface of the continuous glass fiber felt layer can improve the surface decoration effect of the composite board material.

[0040] Both the glass fiber chopped needle-punched mat layer 4 and the glass fiber continuous needle-punched mat layer 5 are composed of an upper glass fiber filament mat layer, a lower glass fiber filament mat layer and an intermediate layer. The upper glass fiber filament mat layer and the intermediate layer, and the lower glass fiber filament mat layer and the intermediate layer are respectively bonded together by the lower needle-punching process and the upper needle-punching process.

[0041] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. It should be noted that for those skilled in the art, any changes, modifications or additions without departing from the concept of the present utility model should fall within the protection scope of the present utility model.

Claims

1. A glass fiber mat reinforced thermoplastic composite board, characterized in that: The material includes two layers of recycled and new material mixed layer (1) at the top and bottom, and a pure new material layer group (2) is provided between the two layers of recycled and new material mixed layer (1). The pure new material layer group (2) includes several layers of mixed board layer (2a) and several layers of high elastic reinforced glass fiber needle-punched felt layer (2b). The mixed board layer (2a) and the high elastic reinforced glass fiber needle-punched felt layer (2b) are stacked and pressed one next to each other, and the number of mixed board layer (2a) is one more than the number of high elastic reinforced glass fiber needle-punched felt layer (2b). The recycled material mixed layer (1) is made by crushing the scraps cut from the mixed board layer (2a) and the high-elasticity reinforced glass fiber needle-punched felt layer (2b) and mixing them with polypropylene virgin material, which is then added to the upper and lower surfaces of the pure virgin material layer group (2). Both the recycled material mixed layer (1) and the pure virgin material layer group (2) contain glass fiber filaments. The average length of a single glass fiber filament in the recycled material mixed layer (1) is less than that in the pure virgin material layer group (2).

2. The glass fiber mat reinforced thermoplastic composite board according to claim 1, characterized in that: The high-elasticity reinforced glass fiber needled felt layer (2b) is provided in two layers, and each high-elasticity reinforced glass fiber needled felt layer (2b) is provided with a hybrid board layer (2a) on both the upper and lower surfaces.

3. The glass fiber mat reinforced thermoplastic composite board according to claim 1, characterized in that: Board dimensions: net width: 600~1250mm, thickness: 1~10mm, density: 1.0~1.7g / cm³, weight fluctuation range: ±0.15%.

4. The glass fiber mat reinforced thermoplastic composite board according to claim 1, characterized in that: The high-elasticity reinforced glass fiber needle-punched felt layer (2b) produces a fluffy felt ring through needle punching.

5. A glass fiber mat reinforced thermoplastic composite board according to any one of claims 1 to 4, characterized in that: A multiaxial fabric plus short-cut filament needle-punched felt composite layer (3) is provided between the recycled material and new material mixing layer (1) and the mixing plate layer (2a).

6. A glass fiber mat reinforced thermoplastic composite board according to any one of claims 1 to 4, characterized in that: A glass fiber chopped needle-punched felt layer (4) or a glass fiber continuous needle-punched felt layer (5) is provided between the recycled material mixing layer (1) and the mixing plate layer (2a).

7. The glass fiber mat reinforced thermoplastic composite board according to claim 5, characterized in that: The multiaxial fabric plus chopped filament needle-punched felt composite layer (3) is composed of an upper glass fiber filament felt layer, a lower reinforcing glass fiber multiaxial fabric and a chopped filament layer needle-punched composite. The upper glass fiber filament felt layer and the chopped filament layer, and the lower reinforcing glass fiber multiaxial fabric and the chopped filament layer are respectively combined into one by the lower needle-punching process and the upper needle-punching process.

8. The glass fiber mat reinforced thermoplastic composite board according to claim 6, characterized in that: Both the glass fiber chopped needle-punched felt layer (4) and the glass fiber continuous needle-punched felt layer (5) are composed of an upper glass fiber filament felt layer, a lower glass fiber filament felt layer and an intermediate layer. The upper glass fiber filament felt layer and the intermediate layer, and the lower glass fiber filament felt layer and the intermediate layer are respectively combined into one by the lower needle-punching process and the upper needle-punching process.

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