Flame-retardant carbon fiber-glass fiber composite plate
By employing a multi-layer structure and fiber hybrid filling technology, the contradictions between lightweight, mechanical strength, and flame retardancy in electric vehicle safety protection panel materials have been resolved, achieving a balance between high mechanical strength and flame retardancy, thereby improving the safety and range of electric vehicles.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SICHUAN HONGGUAN CARBON FIBER TECHNOLOGY CO LTD
- Filing Date
- 2025-07-15
- Publication Date
- 2026-07-14
AI Technical Summary
Existing electric vehicle safety protection plate materials present a dilemma in balancing lightweight, mechanical strength, and flame retardancy. Insufficient flame retardant content affects mechanical strength, while excessive content weakens the performance of composite materials.
It adopts a multi-layer structure design, including a top plate, shock-absorbing pads and stiffening plates. It uses carbon fiber and glass fiber blended fabric to reinforce flame-retardant polypropylene hot-rolled plates, combined with long-cut carbon fiber and short glass fiber mixed filler, adding modifiers to improve toughness and impact resistance, and using bromine-antimony or phosphorus-nitrogen intumescent flame retardants to form a continuous network structure to improve tensile strength and crack resistance.
It achieves lightweighting, improved mechanical strength and flame retardancy, enhanced impact and puncture resistance, reduced porosity and delamination, and ensures the uniformity and safety of the composite board.
Smart Images
Figure CN224490325U_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the technical field of fiber-filled composite panels, specifically relating to flame-retardant carbon fiber and glass fiber composite panels. Background Technology
[0002] Carbon fiber and glass fiber composite panels utilize a mixture of carbon fiber and glass fiber fillers to balance the advantages and disadvantages of both. Carbon fiber can improve the strength and stiffness of the material, while glass fiber can increase the toughness and impact resistance. The mixture of carbon fiber and glass fiber fillers can be adjusted according to specific application requirements to obtain different properties. Composite panels reinforced with a mixture of both have good mechanical strength and are very suitable for use in automotive safety components.
[0003] The fiber filling methods for carbon fiber and glass fiber composite boards are mainly divided into blended fabric filling and loose fiber filling. Blended fabric filling can better improve the mechanical strength of the board, but during the filling process, the layers of blended fabric are stacked, which can easily trap air bubbles, resulting in poor degassing and high porosity, high interlayer ratio, and high segregation. Loose fiber filling allows air bubbles to be released through the gaps between fibers, resulting in good degassing, but the mechanical strength is not as good as the blended fabric filling structure. How to balance the mechanical strength and degassing of composite boards has become a contradiction to be solved.
[0004] Currently, most safety guard plate components for electric vehicles are made of aluminum alloy, manganese steel, or PVC. Electric vehicles have lower engine power and range compared to traditional gasoline vehicles. Manganese steel is too heavy, which reduces the vehicle's range and hill-climbing ability. Aluminum alloy and PVC are lightweight but lack strength, making them susceptible to impact deformation and even puncture, thus offering limited protection. To balance lightweight design and safety, the use of fiber-filled composite panels to replace PVC and metal panels for electric vehicle safety guard plates has become a current trend. Since fires involving electric vehicles are far more frequent than those involving traditional gasoline vehicles, and electric vehicle safety guard plates protect vital components, ignition can lead to more severe consequences. Therefore, electric vehicle safety guard plates must also possess good flame retardancy. If the amount of flame retardant in the composite panel is too small, it will not be effective; if the amount is too large, it will affect the grain structure of the composite material and weaken its mechanical strength. Balancing the mechanical strength and flame retardancy of the composite panel has become a pressing contradiction. Utility Model Content
[0005] In view of the above-mentioned shortcomings of the existing technology, the present invention provides a flame-retardant carbon fiber and glass fiber composite board that takes into account both lightweight and safety, as well as mechanical strength and flame retardancy.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: a flame-retardant carbon fiber and glass fiber composite board, comprising: a top plate, shock-absorbing pads, stiffening ribs, and a bottom plate; the stiffening ribs are arranged in a 90° staggered pattern on the upper and lower layers to form longitudinal and transverse reinforcing ribs; the top plate is located at the top of the upper stiffening ribs; the bottom plate is located at the bottom of the lower stiffening ribs; the shock-absorbing pads are embedded in the grooves of the stiffening ribs and are respectively connected to the top plate, stiffening ribs, and bottom plate.
[0007] Both the top and bottom plates are made of carbon fiber and glass fiber blended fabric reinforced flame-retardant polypropylene hot-rolled plates. The carbon fiber and glass fiber blended fabric acts as reinforcing ribs, improving the tensile strength and crack resistance of the plate, and can also act as connecting bonds between polypropylene crystal lattices, preventing the generation and propagation of microcracks, further improving crack resistance and impact resistance. The carbon fiber and glass fiber blended fabric has pre-distributed degassing pores, which can better degas during hot rolling, reduce porosity and delamination rate, improve the uniformity of the plate texture, compensate for the weakening of the mechanical strength of the composite plate by the flame retardant filling, ensure the filling dosage of the flame retardant, and take into account both the mechanical strength and flame retardancy of the plate. The flame retardant is a bromine-antimony system or a phosphorus-nitrogen intumescent flame retardant.
[0008] The stiffening plate is a double-layered circular arc corrugated plate, with the upper and lower corrugated plates arranged at 90° intervals. The grooves of the upper and lower corrugated plates are perpendicular to each other, forming longitudinal and transverse reinforcing ribs, which can effectively improve support, reduce thickness, and improve the lightweight effect. The stiffening plate is a hot-rolled polypropylene plate filled with a mixture of carbon fiber and glass fiber. The filling fibers are long-cut carbon fibers and short glass fibers. The long-cut carbon fibers form a continuous network structure in the stiffening plate to act as reinforcing ribs, improving tensile strength and crack resistance. The short glass fibers are more evenly dispersed in the stiffening plate, which can promote the uniform crystallization of polypropylene and act as inter-lattice bonds to prevent the formation of microcracks. The addition of carbon fiber and glass fiber fillers further enhances crack resistance and impact resistance. Both carbon fiber and glass fiber are loose fiber fillers, resulting in better degassing. During hot rolling, they exhibit good flowability and filling properties, ensuring uniform board texture and smooth fiber structure while reducing porosity and delamination, thus further improving the mechanical strength of the reinforcing ribs. Polypropylene is modified with polyethylene and polybutadiene. The addition of polyethylene enhances the toughness and impact resistance of the modified polypropylene board, while polybutadiene serves as an elastomer component, combining rigidity and flexibility to improve the elongation and fatigue resistance of the modified polypropylene board.
[0009] The arc of the shock-absorbing pad is consistent with the arc of the stiffening plate. The material is glass fiber filled flame-retardant polyurethane, and the glass fiber filling method is a mixture of long and short glass fibers. The long glass fibers form a continuous network structure in the shock-absorbing pad to act as reinforcing ribs, improving tensile strength and crack resistance. The short glass fibers are more evenly dispersed in the shock-absorbing pad, which can promote the uniform crystallization of polyurethane and act as inter-lattice bonds to prevent the generation and propagation of microcracks, further improving crack resistance and impact resistance. This compensates for the weakening of the mechanical strength of the shock-absorbing pad by the flame-retardant filling component, ensures the filling dosage of flame retardant, and takes into account both the mechanical strength and flame retardancy of the plate shock-absorbing pad. The flame-retardant components are aluminum hydroxide and phosphate ester.
[0010] The impact resistance, crack resistance, and puncture resistance testing of this utility model can be directly applied to the safety guard plate steel cone impact test, taking into account both mechanical strength and gas dissipation.
[0011] When the steel cone strikes, the shock-absorbing pads act as a buffer. After the stiffening plate is impacted, it squeezes the shock-absorbing pads through elastic deformation, further transferring the impact load to the shock-absorbing pads and improving the buffering and shock absorption effect.
[0012] When the steel cone pierces the base plate, the carbon fiber and glass fiber blend fabric acts as a reinforcing rib, improving the tensile strength and crack resistance of the plate. It also acts as a connecting bond between the polypropylene crystal lattices, preventing the generation and propagation of microcracks, further enhancing crack resistance and impact resistance. The carbon fiber and glass fiber blend fabric also acts as a connecting thread within the base plate, preventing fragmentation and securing the steel cone, limiting its further penetration. When the steel cone penetrates the damping pad, the long glass fibers form a continuous mesh structure within the pad, acting as a reinforcing rib, improving tensile strength and crack resistance. The short glass fibers, evenly dispersed, act as connecting bonds between grains, preventing the generation and propagation of microcracks, further enhancing crack resistance and impact resistance, preventing crack propagation, securing the steel cone, and limiting its further penetration. When the steel cone penetrates the reinforcing plate, the crisscrossing arc-shaped structure of the upper and lower layers of the reinforcing plate, as well as the elastic deformation of the reinforcing plate upon impact, cause the penetrating steel cone to deflect, changing straight-line penetration into arc-shaped penetration, increasing its penetration thickness, dispersing its impact stress, and reducing its penetration. Long-cut carbon fibers form a continuous mesh structure in the reinforcing plate, acting as reinforcing ribs, improving tensile strength and crack resistance. The short glass fibers filling the plate act as intergranular bonds, preventing the generation and propagation of microcracks, further improving crack resistance and impact resistance. This also prevents crack propagation, jams the steel cone, and limits its further penetration. Even if the steel cone penetrates the bottom plate, shock-absorbing pads, and reinforcing plate, the top plate, like the bottom plate, can further jam the steel cone, preventing it from penetrating the plate material.
[0013] Compared with the existing technology, the present invention has the following advantages:
[0014] This invention has a good lightweight effect: it uses plastic instead of steel, which effectively reduces weight; the upper and lower layers of the stiffening plate are arranged in a 90° crisscross pattern to form longitudinal and transverse reinforcing ribs, which can effectively improve support, reduce thickness, and further improve the lightweight effect.
[0015] This utility model offers excellent safety protection: it features a multi-layered composite protective structure that replaces a single-material board structure. The combination of rigid and flexible boards, along with shock-absorbing pads embedded within them, effectively balances the board's impact resistance, crack resistance, and puncture resistance.
[0016] The present invention has a good shock absorption and buffering effect: when the present invention is subjected to impact, the shock-absorbing rubber pad plays a buffering role. After the stiffening plate is impacted, it squeezes the shock-absorbing rubber pad through elastic deformation, further transferring the impact load to the shock-absorbing rubber pad and improving the buffering and shock absorption effect.
[0017] This invention features a low porosity, low interlayer ratio, and minimal segregation in its sheet material. The carbon fiber and glass fiber blended fabric filling the top and bottom plates has pre-distributed degassing pores, which effectively eliminates air, reduces porosity and interlayer ratio, improves the uniformity of the sheet material, and balances mechanical strength and degassing performance. The reinforcing ribs are filled with a mixture of long-cut carbon fiber and short glass fiber, which has good degassing performance and good flowability and filling properties during hot rolling of the arc, ensuring better uniformity of the composite sheet material and smooth fiber structure, while reducing porosity and interlayer ratio.
[0018] This invention balances flame retardancy and mechanical strength: The top and bottom plates are filled with carbon fiber and glass fiber blended fabric to enhance mechanical strength, compensating for the weakening effect of flame retardant on the composite board's mechanical strength, ensuring the appropriate amount of flame retardant, and balancing both flame retardancy and mechanical strength. The shock-absorbing pads are filled with a mixture of long and short glass fibers to enhance mechanical strength, compensating for the weakening effect of flame retardant on the pads' mechanical strength, ensuring the appropriate amount of flame retardant, and balancing both flame retardancy and mechanical strength. Ribs are wrapped between the top, bottom, and shock-absorbing pads, preventing direct contact with open flames in case of fire. After the top, bottom, and shock-absorbing pads melt, they cover the ribs, effectively preventing them from igniting, thus eliminating the need for flame retardants to reduce mechanical strength.
[0019] This utility model has good versatility. It is not only suitable for electric vehicle safety guard plates, but also for other safety protection components with fire protection requirements. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of the structure of this utility model. Detailed Implementation
[0021] like Figure 1 As shown, this utility model is a flame-retardant carbon fiber and glass fiber composite board, which adopts a multi-layer structure, including: a top plate 1, a shock-absorbing pad 2, a stiffener 3, and a bottom plate 4; the stiffener 3 is arranged in a 90° staggered pattern on the upper and lower layers to form longitudinal and transverse reinforcing ribs; the top plate 1 is located at the top of the stiffener 3; the bottom plate 4 is located at the bottom of the stiffener 3; the shock-absorbing pad 2 is embedded in the groove of the stiffener 3 and connects the top plate 1, the stiffener 3, and the bottom plate 4 respectively.
[0022] Both the top plate 1 and the bottom plate 4 are hot-rolled polypropylene plates reinforced with carbon fiber and glass fiber blended fabric and flame retardant. The carbon fiber and glass fiber blended fabric has pre-distributed air-eliminating holes. The flame retardant is a bromine-antimony system or a phosphorus-nitrogen intumescent flame retardant.
[0023] The stiffening plate 3 is a double-layer circular arc corrugated plate, with the upper and lower corrugated plates arranged at 90° intervals and the grooves of the upper and lower corrugated plates perpendicular to each other, forming longitudinal and transverse reinforcing ribs; the stiffening plate 3 is a hot-rolled polypropylene plate filled with a mixture of carbon fiber and glass fiber, with the filling fibers being long-cut carbon fibers and short glass fibers; the polypropylene is modified with polyethylene and polybutadiene.
[0024] The arc of the shock-absorbing pad 2 is consistent with the arc of the stiffener 3. The material is fiberglass-filled flame-retardant polyurethane, and the fiberglass filling method is a mixture of long and short fiberglass. The flame-retardant components are aluminum hydroxide and phosphate ester.
Claims
1. A flame-retardant carbon fiber and glass fiber composite board, comprising: Top plate, shock-absorbing pads, stiffening ribs, bottom plate; the top plate is located on top of the upper stiffening ribs; The base plate is located at the bottom of the lower layer of stiffening slabs; its characteristic is that the stiffening slabs are arranged in a 90° staggered pattern between the upper and lower layers. The shock-absorbing pads are embedded in the grooves of the stiffening slab and are connected to the top plate, stiffening slab, and bottom plate respectively.
2. The flame-retardant carbon fiber and glass fiber composite board according to claim 1, characterized in that: The carbon fiber and glass fiber blended fabrics of the top and bottom plates have pre-distributed air-removing holes.
3. A flame-retardant carbon fiber and glass fiber composite board according to claim 1 or 2, characterized in that: The stiffener is a double-layered circular arc corrugated plate, with the upper and lower corrugated plates arranged at 90° intervals, and the grooves of the upper and lower corrugated plates perpendicular to each other.
4. The flame-retardant carbon fiber and glass fiber composite board according to claim 3, characterized in that: The arc of the shock-absorbing rubber pad is consistent with the arc of the stiffening plate.