Filament nonwoven reinforced carbon fiber

Abstract

The utility model provides a kind of filament nonwoven fabric reinforced carbon fiber, it is related to composite manufacturing technical field, including filament nonwoven fabric reinforced carbon fiber body, the filament nonwoven fabric reinforced carbon fiber body includes filament nonwoven fabric layer, resin matrix layer, carbon fiber layer.The utility model is formed by adopting needle punching or spun-bond process three-dimensional staggered arrangement structure, improves the overall strength and toughness of material, while the bonding force between fiber is strengthened, effectively prevent the rupture or delamination phenomenon during use, and using epoxy resin material is infiltrated and solidified by hot-pressing forming process, so that each layer is tightly combined, the interface bonding performance and mechanical stability of composite material are improved, to significantly enhance the overall structural strength, and carbon fiber layer uses plain weave or twill weave carbon fiber fabric, the advantages of high strength and high modulus of carbon fiber are fully exerted, which provides excellent load-carrying capacity and deformation resistance for composite material.

Description

Technical Field

[0001] This utility model relates to the field of composite material manufacturing technology, and in particular to a long-filament nonwoven fabric reinforced with carbon fiber. Background Technology

[0002] In the continuous development of materials science, high-performance composite materials have been widely used in many fields due to their excellent comprehensive properties. Long-filament nonwoven reinforced carbon fiber materials, as a new type of high-performance composite material, are gradually becoming the focus of research and application. Carbon fiber, with its superior properties such as high strength, high modulus, low density, high temperature resistance, and corrosion resistance, shows great application potential in aerospace, automotive industry, sporting goods, and other fields.

[0003] In the existing technology, carbon fiber composite materials still have some shortcomings. On the one hand, carbon fiber itself is a brittle material with poor toughness. Under the influence of external force or long-term environmental effects, it is prone to defects such as delamination and cracking, which greatly limits its application range and service life. On the other hand, the surface and edge crack resistance of traditional carbon fiber composite materials is weak. During long-term use, under the influence of environmental factors, cracks are prone to form on the surface and edges and gradually propagate, eventually leading to a decline in material performance or even failure, thus requiring improvement. Utility Model Content

[0004] The purpose of this invention is to solve the problems of poor toughness, weak impact resistance, and easy cracking of the surface and edges of carbon fiber composite materials in the prior art, and to propose a long filament nonwoven fabric to reinforce carbon fiber.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a filament nonwoven fabric reinforced carbon fiber, comprising a filament nonwoven fabric reinforced carbon fiber body, wherein the filament nonwoven fabric reinforced carbon fiber body comprises a filament nonwoven fabric layer, a resin matrix layer, a carbon fiber layer, a first anti-cracking protective layer and a second anti-cracking protective layer, wherein the filament nonwoven fabric layer, the resin matrix layer and the carbon fiber layer are sequentially composited from bottom to top, and the filament nonwoven fabric layer and the carbon fiber layer are bonded and fixed together by the resin matrix layer, wherein the first anti-cracking protective layer is disposed on the side of the filament nonwoven fabric layer away from the resin matrix layer, and the second anti-cracking protective layer is disposed on the side of the carbon fiber layer away from the resin matrix layer.

[0006] Preferably, the filament nonwoven fabric layer is made of continuous filaments by needle punching or spunbonding, and the fibers are arranged in a three-dimensional interlaced structure.

[0007] Preferably, the carbon fiber layer is composed of carbon fiber fabric, and the carbon fiber fabric is woven in a plain weave or a twill weave.

[0008] Preferably, the resin material of the resin matrix layer is epoxy resin, and the resin matrix layer is impregnated and cured by a hot pressing molding process for the filament nonwoven fabric layer and the carbon fiber layer.

[0009] Preferably, both the first and second anti-cracking protective layers are thermoplastic elastomer films, and the first and second anti-cracking protective layers are fixedly connected to the filament nonwoven fabric layer and the carbon fiber layer respectively by a hot-press bonding process.

[0010] Compared with the prior art, the advantages and positive effects of this utility model are as follows:

[0011] 1. In this utility model, a three-dimensional interlaced structure is formed by needle punching or spunbonding, which improves the overall strength and toughness of the material and enhances the bonding force between fibers, effectively preventing breakage or delamination during use. Epoxy resin is impregnated and cured through hot pressing, which ensures a tight bond between the layers, improving the interfacial bonding performance and mechanical stability of the composite material, thereby significantly enhancing the overall structural strength. The carbon fiber layer is made of carbon fiber fabric with plain or twill weave, which fully utilizes the advantages of high strength and high modulus of carbon fiber, providing the composite material with excellent load-bearing capacity and resistance to deformation.

[0012] 2. In this utility model, by setting a first anti-cracking protective layer and a second anti-cracking protective layer on the upper and lower surfaces of the composite material respectively, and using a thermoplastic elastomer film to fix and connect them through a hot-pressing bonding process, the anti-cracking performance of the material edges and surfaces is enhanced, and the durability and service life of the product in complex environments are improved. Attached Figure Description

[0013] Figure 1 A three-dimensional structural diagram of a long-filament nonwoven fabric reinforced with carbon fiber is provided for this utility model;

[0014] Figure 2 A cross-sectional view of a long-filament nonwoven fabric reinforced with carbon fiber is provided for this utility model.

[0015] Legend: 1. Long filament nonwoven fabric reinforced carbon fiber body; 101. Long filament nonwoven fabric layer; 102. Resin matrix layer; 103. Carbon fiber layer; 104. First anti-cracking protective layer; 105. Second anti-cracking protective layer. Detailed Implementation

[0016] To better understand the above-mentioned objectives, features, and advantages of this utility model, the present utility model will be further described below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0017] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the present invention is not limited to the specific embodiments disclosed in the following specification.

[0018] Example 1: As Figures 1-2 As shown, this utility model provides a technical solution: a filament nonwoven fabric reinforced carbon fiber, comprising a filament nonwoven fabric reinforced carbon fiber body 1, the filament nonwoven fabric reinforced carbon fiber body 1 comprising a filament nonwoven fabric layer 101, a resin matrix layer 102, a carbon fiber layer 103, a first anti-cracking protective layer 104, and a second anti-cracking protective layer 105, the filament nonwoven fabric layer 101, the resin matrix layer 102, and the carbon fiber layer 103 are sequentially composited from bottom to top, the filament nonwoven fabric layer 101 and the carbon fiber layer 103 are bonded and fixed together by the resin matrix layer 102, the first anti-cracking protective layer 104 is disposed on the side of the filament nonwoven fabric layer 101 away from the resin matrix layer 102, and the second anti-cracking protective layer 105 is disposed on the side of the carbon fiber layer 103 away from the resin matrix layer 102. On one side of the resin matrix layer 102, the filament nonwoven fabric layer 101 is made of continuous filaments by needle punching or spunbonding, and the fibers are arranged in a three-dimensional interlaced structure. The carbon fiber layer 103 is composed of carbon fiber fabric, which is woven in plain weave or twill weave. The resin material of the resin matrix layer 102 is epoxy resin. The resin matrix layer 102 is impregnated and cured with the filament nonwoven fabric layer 101 and the carbon fiber layer 103 by hot pressing molding process. The first anti-cracking protective layer 104 and the second anti-cracking protective layer 105 are both thermoplastic elastomer films. The first anti-cracking protective layer 104 and the second anti-cracking protective layer 105 are fixedly connected to the filament nonwoven fabric layer 101 and the carbon fiber layer 103 by hot pressing bonding process, respectively.

[0019] In this embodiment, a three-dimensional interlaced structure is formed by needle punching or spunbonding, which improves the overall strength and toughness of the material and enhances the bonding force between fibers, effectively preventing breakage or delamination during use. Epoxy resin is used for impregnation and curing through a hot-pressing process, ensuring a tight bond between the layers and improving the interfacial bonding performance and mechanical stability of the composite material, thereby significantly enhancing the overall structural strength. The carbon fiber layer 103, made of carbon fiber fabric with a plain or twill weave, fully utilizes the advantages of high strength and high modulus of carbon fiber, providing excellent load-bearing capacity and deformation resistance for the composite material. By setting a first anti-cracking protective layer 104 and a second anti-cracking protective layer 105 on the upper and lower surfaces of the composite material, and fixing them together using a thermoplastic elastomer film through a hot-pressing process, the crack resistance of the material edges and surfaces is enhanced, improving the durability and service life of the product in complex environments.

[0020] The working principle of this embodiment is as follows: First, continuous filaments are used to create a nonwoven fabric layer 101 through needle punching or spunbonding processes, forming a three-dimensional interlaced structure to construct a basic framework with good mechanical distribution. Then, carbon fiber fabric made using plain or twill weave is laid on the nonwoven fabric layer 101 to form a carbon fiber layer 103. Next, epoxy resin is used as the resin matrix material, and the nonwoven fabric layer 101 and carbon fiber layer 103 are fully impregnated through a hot-press molding process. The curing process is completed under certain temperature and pressure conditions, allowing the two to be firmly bonded into a single structure through the resin matrix layer 102. Finally, the nonwoven fabric layer 101 is moved away from the... The first anti-cracking protective layer 104 and the second anti-cracking protective layer 105 are fixedly connected on one side of the resin matrix layer 102 and the side of the carbon fiber layer 103 away from the resin matrix layer 102 by hot pressing bonding process, respectively. Both layers are made of thermoplastic elastomer film material, which further improves the overall surface integrity and edge stability of the composite material. In actual use, the three-dimensional interlaced structure of the filament nonwoven fabric layer 101 and the woven structure of the carbon fiber layer 103 work together to withstand external forces. The resin matrix layer 102 ensures the effective transmission of forces between layers, while the anti-cracking protective layers on the upper and lower surfaces resist the damage to the material surface and edges caused by external impacts and environmental factors, ensuring the stability of material performance.

[0021] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present utility model without departing from the technical solution of the present utility model shall still fall within the protection scope of the technical solution of the present utility model.

Claims

1. A filament nonwoven fabric reinforced carbon fiber, comprising a filament nonwoven fabric reinforced carbon fiber body (1), characterized in that: The filament nonwoven fabric reinforced carbon fiber body (1) includes a filament nonwoven fabric layer (101), a resin matrix layer (102), a carbon fiber layer (103), a first anti-cracking protective layer (104), and a second anti-cracking protective layer (105). The filament nonwoven fabric layer (101), the resin matrix layer (102), and the carbon fiber layer (103) are sequentially composited from bottom to top. The filament nonwoven fabric layer (101) and the carbon fiber layer (103) are bonded and fixed together by the resin matrix layer (102). The first anti-cracking protective layer (104) is located on the side of the filament nonwoven fabric layer (101) away from the resin matrix layer (102), and the second anti-cracking protective layer (105) is located on the side of the carbon fiber layer (103) away from the resin matrix layer (102).

2. The carbon fiber reinforced filament nonwoven fabric according to claim 1, characterized in that: The nonwoven fabric layer (101) is made of continuous filaments by needle punching or spunbonding, and the fibers are arranged in a three-dimensional interlaced structure.

3. The carbon fiber reinforced filament nonwoven fabric according to claim 1, characterized in that: The carbon fiber layer (103) is composed of carbon fiber fabric, which is woven in a plain weave or a twill weave.

4. The carbon fiber reinforced filament nonwoven fabric according to claim 1, characterized in that: The resin material of the resin matrix layer (102) is epoxy resin. The resin matrix layer (102) is formed by hot pressing to impregnate and cure the filament nonwoven fabric layer (101) and the carbon fiber layer (103).

5. The carbon fiber reinforced filament nonwoven fabric according to claim 1, characterized in that: The first anti-cracking protective layer (104) and the second anti-cracking protective layer (105) are both thermoplastic elastomer films. The first anti-cracking protective layer (104) and the second anti-cracking protective layer (105) are fixedly connected to the filament nonwoven fabric layer (101) and the carbon fiber layer (103) respectively by hot pressing bonding process.

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