Fiber composite materials

Abstract

A fiber composite material includes a composite structure. The composite structure includes stacked prepreg layers and barrier layer units. The prepreg layers have a first fiber component and a first resin component. The barrier layer units have a barrier component. The first fiber component is one of carbon fiber, glass fiber, and basalt fiber; the first resin component is epoxy resin and a curing agent; and the barrier component is one of aluminum foil, copper foil, titanium foil, aluminum-magnesium alloy foil, and nonwoven fabric. Due to the inherent mechanical strength of the barrier component, it is not necessary to continuously monitor and precisely control the heating and curing temperature during the heat curing process of the composite structure to prevent the first resin component from leaking from the prepreg layer, making the processing more convenient. Furthermore, the barrier component ensures that the mechanical strength of the subsequently manufactured product meets the required standards.

Description

[Technical Field]

[0001] This invention relates to a composite material, and more particularly to a fiber composite material. [Previous Technology]

[0002] Referring to Figure 1, a conventional fiber composite material 9 includes a prepreg layer 91, a release layer 92, and a coating layer 93. The release layer 92 is peelably disposed on one surface of the prepreg layer 91 and supports the prepreg layer 91. The coating layer 93 is peelably disposed on the other surface of the prepreg layer 91 and sandwiches the prepreg layer 91 between the release layer 92 and the prepreg layer 91. The prepreg layer 91 includes fiber components and resin components.

[0003] The fiber composite material 9 can be manufactured into a finished product by peeling the release layer 92 and the coating layer 93 from the surface of the prepreg layer 91 and performing a processing procedure including heat curing on the prepreg layer 91. However, the prepreg layer 91 needs to be continuously monitored and precisely controlled during the heat curing process to prevent the resin component from leaking out of the prepreg layer 91, thereby avoiding affecting the mechanical strength of the finished product.

[0004] Therefore, how to improve the prepreg layer 91 so that when the prepreg layer 91 is subjected to the heat curing treatment, it is not necessary to continuously monitor and precisely control the temperature conditions of the heat curing during the heat curing treatment process, so as to improve the convenience of the processing process, and at the same time, the finished product obtained can have good mechanical strength to meet market needs is a problem that the industry urgently wants to solve. [Summary of the Invention]

[0005] Therefore, the object of the present invention is to provide a fiber composite material that can improve the convenience of subsequent processing.

[0006] Thus, the fiber composite material of the present invention comprises a composite structure.

[0007] The composite structure includes a prepreg layer and a barrier layer unit stacked on top of each other. The prepreg layer has a first fiber component and a first resin component. The barrier layer unit has a barrier component. The first fiber component is one of carbon fiber, glass fiber, and basalt fiber. The first resin component has epoxy resin and a curing agent. The barrier component is one of aluminum foil, copper foil, titanium foil, aluminum-magnesium alloy foil, and nonwoven fabric.

[0008] The advantages of the present invention are: through the mechanical strength of the barrier component itself, it is not necessary to continuously monitor and precisely control the temperature conditions of heating and curing during the process of heating and curing the composite structure to prevent the first resin component from being lost from the prepreg layer. Therefore, the processing is more convenient, and the barrier component can also make the finished product have good mechanical strength to meet market requirements.

Implementation Method

[0009] Before the present invention is described in detail, it should be noted that similar elements are represented by the same numbers in the following description.

[0010] The present invention will be further described with reference to the following embodiments, but it should be understood that the embodiments are only illustrative and should not be construed as limiting the implementation of the present invention.

[0011] The fiber composite material of the present invention can be manufactured into a finished product by performing a processing procedure including heat curing. Such finished products include, but are not limited to, sports equipment or rims such as ice hockey sticks, golf clubs, bicycle frames, tennis rackets, peakers, and baseball bats.

[0012] Referring to Figure 2, a first embodiment of the fiber composite material of the present invention is shown, comprising a composite structure 1, a release layer 2, and a coating layer 3. The release layer 2 is peelably disposed on one surface of the composite structure 1 and supports the composite structure 1. The coating layer 3 is peelably disposed on the other surface of the composite structure 1 and sandwiches the composite structure 1 with the release layer 2. In detail, before the fiber composite material is subjected to heat curing treatment, the release layer 2 and the coating layer 3 are first peeled from the surface of the composite structure 1, and then the composite structure 1 is subjected to heat curing treatment, thereby manufacturing the composite structure 1 into a finished product.

[0013] The composite structure 1 includes a prepreg layer 11 and a barrier layer unit 12 stacked on top of each other. In this first embodiment, the release layer 2 is disposed on the surface of the barrier layer unit 12 and sandwiches the barrier layer unit 12 with the prepreg layer 11.

[0014] The prepreg layer 11 has a first fiber component and a first resin component. The function of the prepreg layer 11 is to provide mechanical strength to the finished product. In this first embodiment, the prepreg layer 11 can also be used to bond the coating layer 3 and the barrier layer unit 12.

[0015] The first fiber component comprises one of carbon fiber, glass fiber, and basalt fiber. In this first embodiment, the first fiber component comprises carbon fiber. In some embodiments, the fiber diameter of the first fiber component ranges from 3 micrometers to 20 micrometers.

[0016] The first resin component comprises an epoxy resin and a curing agent. The epoxy resin of the first resin component is selected from at least two of the group consisting of multifunctional epoxy resins, bisphenol A epoxy resins, organosilicone epoxy resins, hyperbranched epoxy resins, bisphenol F epoxy resins, and phenoxy resins. In some embodiments, the first resin component is composed of multifunctional epoxy resins, bisphenol A epoxy resins, organosilicone epoxy resins, and hyperbranched epoxy resins. The multifunctional epoxy resin is, for example, but not limited to, p-aminophenol triglycidyl epoxy resin, 3,3'-diethyl-4,4'-diaminodiphenylmethane tetraglycidyl epoxy resin, and 4,4'-diaminodiphenylmethane tetraglycidyl epoxy resin. The number of epoxy groups in the hyperbranched epoxy resin is, for example, but not limited to, 14 to 32. The number average molecular weight of the hyperbranched epoxy resin is, for example, but not limited to, 4000 to 8000. In some embodiments, when the first resin component contains the phenoxy resin, the first resin component can increase the toughness of the finished product. The type of curing agent is not particularly limited; any reagent capable of curing the epoxy resin is suitable for this invention. The curing agent is, for example, but not limited to, dicyandiamide. In this first embodiment, the first resin component also contains a catalyst. The type of catalyst is not particularly limited; any reagent capable of catalyzing the curing of the epoxy resin is suitable for this invention. The catalyst is, for example, but not limited to, urea derivatives.

[0017] The prepreg layer 11 is prepared as follows: at least two epoxy resins, the curing agent and the catalyst are mixed to obtain the first resin component. The first fiber component is impregnated with the first resin component to obtain the prepreg layer 11.

[0018] The barrier layer unit 12 has a barrier component. This barrier component must have good adhesion to the first resin component. The barrier component not only provides mechanical strength to the finished product, but also, during the heat curing process of the composite structure 1, prevents the first resin component from vertically penetrating the barrier layer unit 12, thereby inhibiting the flow of the first resin component and preventing it from leaking from the prepreg layer 11, thus reducing the resin loss rate of the first resin component. Furthermore, the barrier component allows the first resin component to be evenly distributed between the fibers of the first fiber component, resulting in a clear fiber texture in the finished product and improving the mechanical properties of the finished product's structure. These mechanical properties include, but are not limited to, bending resistance and impact resistance.

[0019] The barrier component comprises one of aluminum foil, copper foil, titanium foil, aluminum-magnesium alloy foil, and nonwoven fabric. The nonwoven fabric is selected from aramid nonwoven fabric, polyester nonwoven fabric, and phenoxy nonwoven fabric. In some embodiments, the barrier component comprises one of aluminum foil, copper foil, titanium foil, and aluminum-magnesium alloy foil. In this first embodiment, the barrier component comprises aluminum foil.

[0020] In this first embodiment, the barrier layer unit 12 further comprises a second resin component, the function of which is to adhere the release layer 2 to the surface of the barrier layer unit 12. The barrier component also needs to have good adhesion to the second resin component. The second resin component comprises an epoxy resin and a curing agent. The epoxy resin of the second resin component is selected from at least two of the group consisting of multifunctional epoxy resins, bisphenol A epoxy resins, organosilicone epoxy resins, hyperbranched epoxy resins, bisphenol F epoxy resins, and phenoxy resins. In some embodiments, the second resin component is composed of multifunctional epoxy resins, bisphenol A epoxy resins, organosilicone epoxy resins, and hyperbranched epoxy resins. The multifunctional epoxy resin is, for example but not limited to, p-aminophenol triglycidyl epoxy resin, 3,3'-diethyl-4,4'-diaminodiphenylmethane tetraglycidyl epoxy resin, and 4,4'-diaminodiphenylmethane tetraglycidyl epoxy resin. The number of epoxy groups in the hyperbranched epoxy resin is, for example but not limited to, 14 to 32. The number-average molecular weight of the hyperbranched epoxy resin is, for example but not limited to, 4000 to 8000. In some embodiments, when the second resin component contains the phenoxy resin, the second resin component can increase the toughness of the finished product. The type of curing agent is not particularly limited; any reagent capable of curing the epoxy resin is suitable for this invention. The curing agent is, for example but not limited to, dicyandiamide. In this first embodiment, the second resin component also contains a catalyst. The type of catalyst is not particularly limited; any reagent capable of catalyzing the curing of the epoxy resin is suitable for this invention. The catalyst is, for example but not limited to, urea derivatives.

[0021] The barrier layer unit 12 is prepared as follows: at least two epoxy resins, the curing agent and the catalyst are mixed to obtain the second resin component. The second resin component is uniformly distributed in the barrier component to obtain the barrier layer unit 12.

[0022] The coating layer 3 is selected from one of a polyolefin film and a polyethylene terephthalate film. The polyolefin film is, for example, but not limited to, a polyethylene film. In this first embodiment, the coating layer 3 is a polyethylene film.

[0023] Referring to Figure 3, a second embodiment of the fiber composite material of the present invention is shown. The difference from the first embodiment is that in the second embodiment, the release layer 2 is disposed on the surface of the prepreg layer 11 and sandwiched between the prepreg layer 11 and the barrier layer unit 12. That is, in the second embodiment, in addition to providing the mechanical strength of the finished product, the prepreg layer 11 can also be used to bond the release layer 2 and the barrier layer unit 12. The function of the second resin component is to bond the coating layer 3 to the surface of the barrier layer unit 12. In the second embodiment, the composition and preparation method of the prepreg layer 11 and the barrier layer unit 12, as well as the composition of the coating layer 3, are the same as in the first embodiment, and will not be described again here.

[0024] Referring to Figure 4, the third embodiment of the fiber composite material of the present invention differs from the first embodiment in that the barrier layer unit 12 of the third embodiment also has a second fiber component, and the barrier layer unit 12 has a barrier layer 121 and an adhesive layer 122.

[0025] In this third embodiment, the adhesive layer 122 is disposed on the surface of the barrier layer 121 and sandwiched between the prepreg layer 11 and the barrier layer 121. The release layer 2 is disposed on the surface of the adhesive layer 122 and sandwiched between the barrier layer 121 and the adhesive layer 122.

[0026] In this third embodiment, in addition to providing the mechanical strength of the finished product, the prepreg layer 11 can also be used to bond the coating layer 3 and the barrier layer 121.

[0027] The composition and preparation method of the prepreg layer 11 and the composition of the coating layer 3 are as described in the first embodiment, and will not be repeated here.

[0028] The barrier layer 121 has the barrier component. The thickness of the barrier layer 121 is not particularly limited. In some embodiments, the thickness of the barrier layer 121 ranges from 1 micrometer to 300 micrometers, thereby preventing damage to the barrier layer 121 and allowing the fiber composite to have ductility. In some embodiments, the barrier layer 121 has a plurality of pores, and the pore diameter of each pore ranges from 0.1 mm to 0.2 mm, but is not limited thereto, and the spacing between any two adjacent pores ranges from 0.5 cm to 5 cm, but is not limited thereto. In some embodiments, the spacing between any two adjacent pores ranges from 0.5 cm to 1 cm. Through these pores in the barrier layer 121, gas present in the composite structure 1 can be discharged outwards during the heat curing process, thereby resulting in a smoother surface of the obtained finished product. The composition and function of the barrier component are the same as those of the barrier component in the first embodiment, and will not be repeated here.

[0029] The adhesive layer 122 has the second fiber component and the second resin component. The composition of the second resin component is as described in the first embodiment and will not be repeated here. The adhesive layer 122 can be used to bond the release layer 2 and the barrier layer 121. In the third embodiment, the adhesive layer 122 can also provide the mechanical strength of the finished product.

[0030] The second fiber component comprises one of carbon fiber, glass fiber, and basalt fiber. In the third embodiment, the second fiber component comprises carbon fiber.

[0031] The barrier layer unit 12 is prepared as follows: at least two epoxy resins, the curing agent and the catalyst are mixed to obtain the second resin component. The second fiber component is impregnated with the second resin component to obtain the adhesive layer 122. Then, the adhesive layer 122 and the barrier layer 121 are stacked to obtain the barrier layer unit 12.

[0032] Referring to Figure 5, a fourth embodiment of the fiber composite material of the present invention is shown. The difference from the third embodiment is that in the fourth embodiment, the release layer 2 is disposed on the surface of the prepreg layer 11 and sandwiched between the prepreg layer 11 and the barrier layer 121. That is, in the fourth embodiment, in addition to providing the mechanical strength of the finished product, the prepreg layer 11 can also be used to bond the release layer 2 and the barrier layer 121, and the adhesive layer 122 can also be used to bond the coating layer 3 and the barrier layer 121.

[0033] The composition and preparation method of the prepreg layer 11 and the barrier layer unit 12, as well as the composition of the coating layer 3, are as described in the third embodiment and will not be repeated here.

[0034] In summary, the fiber composite material of the present invention, through the mechanical strength inherent in the barrier component itself, eliminates the need for continuous monitoring and precise control of the heating and curing temperature during the heat curing process of the composite structure 1, thus enabling the subsequently manufactured product to possess good mechanical strength. Therefore, using this fiber composite material not only makes the heat curing process more convenient but also ensures that the subsequently manufactured product has good mechanical strength to meet market demands, effectively achieving the purpose of the present invention. On the other hand, the barrier component can inhibit the flow of the first resin component, thereby reducing the resin loss rate of the first resin component and enabling the finished product to possess good mechanical strength. Furthermore, the barrier component can also ensure that the first resin component is evenly distributed between the fibers of the first fiber component, thereby making the fiber texture of the finished product made using this fiber composite material clear and giving the finished product structure good mechanical properties.

[0035] However, the above description is only an embodiment of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the contents of the patent specification of the present invention shall still fall within the scope of the patent of the present invention. [Simplified Explanation of the Diagram]

[0036] Other features and effects of the present invention will be clearly presented in the embodiments with reference to the drawings, wherein: FIG1 is a schematic diagram illustrating a conventional fiber composite material; FIG2 is a schematic diagram illustrating a first embodiment of the fiber composite material of the present invention; FIG3 is a schematic diagram illustrating a second embodiment of the fiber composite material of the present invention; FIG4 is a schematic diagram illustrating a third embodiment of the fiber composite material of the present invention; and FIG5 is a schematic diagram illustrating a fourth embodiment of the fiber composite material of the present invention.

Claims

1. A fiber composite material, comprising: a composite structure including a prepreg layer and a barrier layer unit stacked on top of each other, wherein, The prepreg layer has a first fiber component and a first resin component. The barrier layer unit has a barrier component. The first fiber component has one of carbon fiber, glass fiber and basalt fiber. The fiber diameter of the first fiber component ranges from 3 micrometers to 20 micrometers. The first resin component has epoxy resin and a curing agent. The barrier component has one of aluminum foil, copper foil, titanium foil, aluminum-magnesium alloy foil and non-woven fabric.

2. The fiber composite material as claimed in claim 1, wherein, The barrier layer unit also has a second resin component, which has an epoxy resin and a curing agent.

3. The fiber composite material as described in claim 2, wherein, The epoxy resin of the first resin component and the epoxy resin of the second resin component are each selected from at least two of the group consisting of multifunctional epoxy resins, bisphenol A epoxy resins, organosilicone epoxy resins, hyperbranched epoxy resins, bisphenol F epoxy resins and phenoxy resins.

4. The fiber composite material as claimed in claim 2, wherein, The barrier layer unit also has a second fiber component, which is one of carbon fiber, glass fiber and basalt fiber.

5. The fiber composite material as claimed in claim 4, wherein, The barrier layer unit has a barrier layer and an adhesive layer. The adhesive layer is disposed on the surface of the barrier layer and sandwiched between the barrier layer and the prepreg layer. The barrier layer has the barrier component, and the adhesive layer has the second fiber component and the second resin component.

6. The fiber composite material as claimed in claim 5, wherein, The thickness of the barrier layer ranges from 1 micrometer to 300 micrometers.

7. The fiber composite material as claimed in claim 5, wherein, The barrier layer has multiple pores, each with a diameter ranging from 0.1 mm to 0.2 mm, and the spacing between any two adjacent pores ranges from 0.5 cm to 5 cm.

8. The fiber composite material as claimed in claim 1 further comprises a release layer and a coating layer, the release layer being peelably disposed on one surface of the composite structure and supporting the composite structure, and the coating layer being peelably disposed on the other surface of the composite structure and sandwiching the composite structure with the release layer.

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