Composite material component and manufacturing method therefor

Abstract

A composite material component of the present invention, comprising: a substrate, comprising a bonding material and a fiber material layer, a plurality of fibers in the fiber material layer being bonded to the bonding material; and a thermal insulation layer, which is bonded to one surface of the substrate and comprises an adhesive material and a plurality of hollow microspheres, the plurality of hollow microspheres being distributed in the adhesive material and linked by means of the adhesive material. The manufacturing method for the composite material component comprises the following steps: coating the surface of the substrate with a thermal insulation coating, the thermal insulation coating comprising the adhesive material and the plurality of hollow microspheres, and the substrate comprising the bonding material and the fiber material layer; and heating and curing the thermal insulation coating to form the thermal insulation layer bonded to the surface of the substrate. The present invention can provide effective thermal insulation and protection, and can prevent the composite material component from exceeding a heat deflection temperature or a glass transition temperature, so as to maintain the structural strength and the compression strength, and meanwhile, to achieve corrosion resistance.

Description

Composite material component and manufacturing method thereof Technical Field

[0001] The present invention relates to a composite material component and a manufacturing method thereof. Background Art

[0002] Composite components are commonly used in many fields, such as composite automotive parts like rims, housings, and other components. For example, rims are often subject to high temperatures during operation. For example, during braking, composite rims are exposed to high-temperature heat conduction, radiation, or convection from adjacent brake calipers and rotor components. These high temperatures can easily cause the polymers in the composite rim to exceed their heat deflection temperature (HDT) or glass transition temperature (Tg), resulting in reduced mechanical properties, degradation, or even damage to the composite rim.

[0003] Some conventional technologies incorporate a thermal insulation layer on the surface of composite components. However, the thermal conductivity of conventional thermal insulation layers is insufficient, and the adhesion strength needs to be improved. Furthermore, the structural strength, compressive strength, and corrosion resistance of conventional thermal insulation layers do not meet practical requirements, especially for automotive components with high performance requirements, and they cannot meet the required physical or mechanical properties.

[0004] Therefore, it is necessary to provide a novel and progressive composite material component and a manufacturing method thereof to solve the above problems.

[0005] Summary of the Invention

[0006] The main purpose of the present invention is to provide a composite material component and its manufacturing method, which can provide effective thermal insulation and protection, avoid exceeding the thermal deformation temperature or glass transition temperature of the composite material component, maintain structural strength and compressive strength, and at the same time have corrosion resistance.

[0007] To achieve the above objectives, the present invention provides a composite member comprising: a substrate comprising a bonding material and a fiber material layer, wherein a plurality of fibers of the fiber material layer are bonded to the bonding material; and a heat-insulating layer bonded to a surface of the substrate, comprising an adhesive material and a plurality of hollow particles, wherein the plurality of hollow particles are distributed in the adhesive material and connected by the adhesive material.

[0008] Preferably, the substrate is a rim.

[0009] Preferably, the fiber material layer is a carbon fiber material layer, and the adhesive material includes adhesive and resin material.

[0010] Preferably, the resin material includes at least one of epoxy resin, phenol epoxy resin, acrylic resin, polyurethane acrylic resin and acrylic resin.

[0011] Preferably, the mixing ratio of the plurality of hollow particles and the adhesive material is A:B, wherein A is 10-100, and B is 10-100.

[0012] Preferably, A:B is 40:60, 50:50, or 60:50.

[0013] Preferably, the substrate further includes a roughened surface, and the adhesive material is bonded to the roughened surface.

[0014] Preferably, the adhesive material includes a middle layer and two side layers located on both sides of the middle layer, the plurality of hollow particles are distributed at least in the middle layer, one of the two side layers is bonded to the roughened surface, and the two side layers are resin materials, and the resin material includes at least one of epoxy resin, phenol epoxy resin, acrylic resin, polyurethane acrylic resin and acrylic resin.

[0015] Preferably, the hollow particles are ceramic hollow closed-pore microspheres or hollow glass microspheres, and the adhesive material combines the bonding material and the fiber material layer.

[0016] Preferably, the hollow particles include silicon dioxide and metal oxides. The hollow particles further include iron oxide, titanium dioxide, calcium oxide, magnesium oxide and sodium oxide. The metal oxide includes aluminum oxide or zirconium oxide.

[0017] Preferably, the content of silicon dioxide is 50% to 70%, the content of aluminum oxide or zirconium oxide is 20% to 50%, the content of iron oxide is 1.5% to 2.5%, the content of titanium dioxide is 1.4% to 1.6%, the content of calcium oxide is 1% to 10%, the content of magnesium oxide is 0.5% to 1%, and the content of sodium oxide is 0.5% to 1%.

[0018] Preferably, the particle size of the hollow particles is 10 microns to 500 microns.

[0019] Preferably, the density of the hollow particles is 0.5 g / cm 3 to 0.8g / cm 3 .

[0020] Preferably, the bulk density of the plurality of hollow particles is 0.3 g / cm 3 to 0.4g / cm 3 .

[0021] Preferably, the compressive strength of the hollow particles is greater than or equal to 350 MPa.

[0022] Preferably, the thermal conductivity of the hollow particles is 0.000903m 2 / h to 0.0015m 2 / h.

[0023] Preferably, the thermal conductivity of the hollow particles is 0.054 W / m·K to 0.095 W / m·K.

[0024] Preferably, the oil absorption rate of the hollow particles is 0.68 g (oil) / g to 0.69 g (oil) / g.

[0025] To achieve the above-mentioned objectives, the present invention further provides a method for manufacturing a composite component, comprising the following steps: coating a heat-resistant coating on the surface of a substrate, the heat-resistant coating comprising an adhesive material and a plurality of hollow particles, the substrate comprising a bonding material and a fiber material layer; and heating and curing the heat-resistant coating to form a heat-resistant layer bonded to the surface of the substrate.

[0026] Preferably, the heat-resistant coating is sprayed onto the surface of the substrate.

[0027] Preferably, the mixing ratio of the plurality of hollow particles in the heat-resistant coating and the adhesive material is A:B, wherein A is 10-100, and B is 10-100.

[0028] Preferably, the adhesive material includes an adhesive and a resin material, and the resin material includes at least one of epoxy resin powder resin, phenol powder epoxy resin, acrylic powder resin, polyurethane acrylic powder resin and acrylic powder resin. During the heating process of the heat-resistant coating, the resin material melts and bonds to the surface of the substrate and the plurality of hollow particles.

[0029] Preferably, before coating the heat-resistant coating, a step of roughening the surface of the substrate is further included.

[0030] Preferably, the surface of the substrate is roughened by sandblasting.

[0031] Preferably, before coating the heat-resistant coating, a step of imparting static charge to the heat-resistant coating is further included, so that the heat-resistant coating with static charge can be adsorbed on the surface of the substrate.

[0032] Preferably, the step of roughening the surface of the substrate comprises the following steps:

[0033] preheating the substrate;

[0034] Electrostatically spraying a powder resin base layer on the roughened surface of the substrate;

[0035] Electrostatically spraying the heat-resistant coating onto the powder resin base layer;

[0036] pre-curing the heat-resistant coating;

[0037] Electrostatically spraying a powder resin protective layer on the pre-cured heat-resistant coating; and

[0038] The powder resin bottom layer, the heat-resistant coating and the powder resin protective layer are cured.

[0039] The advantages of the present invention are:

[0040] The composite material component and the manufacturing method thereof provided by the present invention can provide effective heat insulation and protection, prevent the composite material component from exceeding the thermal deformation temperature or glass transition temperature, thereby maintaining structural strength and compressive strength, and at the same time being corrosion-resistant. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG1 is a schematic diagram of a composite member according to an embodiment of the present invention.

[0042] 2 to 7 are schematic diagrams of a method for manufacturing a composite member according to an embodiment of the present invention.

[0043] FIG8 is a schematic diagram of a wheel rim with a heat-resistant layer according to an embodiment of the present invention.

[0044] FIG9 is a graph showing test data of a wheel rim with a heat-resistant layer according to an embodiment of the present invention. DETAILED DESCRIPTION

[0045] The following examples are merely used to illustrate possible implementations of the present invention, but are not intended to limit the scope of the present invention.

[0046] Please refer to FIG. 1 , which shows an embodiment of the present invention. The composite member 1 of the present invention includes a substrate 10 and a heat-resistant layer 20 .

[0047] The substrate 10 includes a bonding material 11 and a fiber material layer 12. The fibers of the fiber material layer 12 are bonded to the bonding material 11. The heat-resistant layer 20 is bonded to a surface of the substrate 10. The heat-resistant layer 20 includes an adhesive material 21 and a plurality of hollow particles 22. The hollow particles 22 are distributed within and connected by the adhesive material 21. As a result, the heat-resistant layer 20 has an extremely low density and low thermal conductivity, effectively insulating and protecting the substrate 10 from exceeding the thermal deformation temperature or glass transition temperature of the composite component 1, thereby maintaining structural and compressive strength while also being corrosion-resistant.

[0048] In one embodiment, the substrate 10 may be a wheel rim 100, and the heat-resistant layer 20 is, for example, disposed on the rim 101 and spokes 102 of the wheel rim 100 (FIG. 8). It is understood that the substrate 10 may also be any portion of the wheel rim, other components or portions of the vehicle, or components or portions of other devices. In this embodiment, the bonding material 11 is epoxy resin, the fiber material layer 12 is a carbon fiber material layer 12, and the adhesive material 21 includes an adhesive and a resin material. The adhesive may be made of the same material as the resin material. The resin material 212 includes at least one of epoxy resin, phenol epoxy resin, acrylic resin, polyurethane acrylic resin, and acrylic resin. The mixing ratio of the plurality of hollow particles 22 to the adhesive material 21 is A:B, where A is 10-100 and B is 10-100. A:B is preferably 40:60, 50:50, or 60:50. This allows the adhesive material 21 to be reliably bonded to the surface of the substrate 10. Preferably, the substrate 10 further includes a roughened surface 13. The adhesive material 21 bonds to the roughened surface 13, thereby enhancing the bonding between the adhesive material 21 and the substrate 10. The fiber material layer 12 may be exposed through roughening or may be initially exposed. The adhesive material 21 may bond to the bonding material 11 and simultaneously to the fiber material layer 12, further enhancing the bonding between the adhesive material 21 and the substrate 10. However, the fiber material layer 12 may not be exposed. The adhesive material 21 includes a middle layer 213 and two side layers 214 located on either side of the middle layer 213. The plurality of hollow particles 22 are distributed at least within the middle layer 213. One of the two side layers 214 is bonded to the roughened surface 13. The two side layers 214 are made of a resin material, including at least one of epoxy resin, phenol epoxy resin, acrylic resin, polyurethane acrylic resin, and acrylic resin. The middle layer 213 and the two side layers 214 are preferably integrally connected.

[0049] Specifically, the hollow particles 22 are hollow closed-cell ceramic microspheres or hollow glass microspheres, which impart extremely high structural strength, compressive strength, and corrosion resistance to the composite component 1. For example, the hollow particles 22 include silicon dioxide (SiO2) and metal oxides. The hollow particles 22 further include iron oxide (Fe2O3), titanium dioxide (TiO2), calcium oxide (CaO), magnesium oxide (MgO), and sodium oxide (Na2O). The metal oxides include aluminum oxide (Al2O3) or zirconium oxide (ZrO2). The silicon dioxide content is 50% to 70%, the aluminum oxide or zirconium oxide content is 20% to 50%, the iron oxide content is 1.5% to 2.5%, the titanium dioxide content is 1% to 1.5%, the calcium oxide content is 1% to 10%, the magnesium oxide content is 0.5% to 1%, and the sodium oxide content is 0.5% to 1%.

[0050] More specifically, the particle size of the hollow particles 22 is 10 μm to 500 μm; the density of the hollow particles 22 is 0.5 g / cm 3 to 0.8g / cm 3 The bulk density of the plurality of hollow particles 22 is 0.3g / cm 3 to 0.4g / cm 3 The compressive strength of the hollow particles 22 is greater than or equal to 350 MPa; the thermal diffusivity of the hollow particles 22 is 0.000903 m 2 / h to 0.0015m 2 / h; the heat transfer coefficient of the hollow particles 22 is 0.054W / m·K to 0.095W / m·K; and the oil absorption rate of the hollow particles 22 is 0.68g(oil) / g to 0.69g(oil) / g. It should be noted that the above factors and values ​​can be appropriately adjusted and coordinated based on different requirements, such as the thickness, weight, thermal conductivity, structural strength, compressive strength, and corrosion resistance of the heat-resistant layer. Some factors may even be omitted.

[0051] Referring to Figures 2 to 7, the present invention further provides a method for manufacturing a composite component, comprising the following steps: coating a heat-resistant coating 20a on the surface of a substrate 10, the heat-resistant coating 20a comprising an adhesive material 21 and a plurality of hollow particles 22, the substrate 10 comprising a bonding material 11 and a fiber material layer 12; and heating and curing the heat-resistant coating 20a to form a heat-resistant layer 20 bonded to the surface of the substrate 10.

[0052] In this embodiment, the heat-resistant coating 20a is sprayed onto the surface of the substrate 10. Preferably, before applying the heat-resistant coating 20a, a step of roughening the surface of the substrate 10 is further included, such as but not limited to sandblasting, grinding, scraping, engraving, etc. to roughen the surface of the substrate 10, thereby exposing the fiber material layer 12 and maintaining the roughness. After roughening the surface of the substrate 10, it is preferably further cleaned the roughened surface 13, thereby increasing the adhesion between the heat-resistant coating 20a layer and the surface of the substrate 10. Preferably, before applying the heat-resistant coating 20a, a step of electrostatically charging the heat-resistant coating 20a is further included, such as using an electrostatic spraying device to spray the heat-resistant coating 20a onto the surface of the substrate 10, so that the heat-resistant coating 20a with an electrostatic charge can be more stably adsorbed on the surface of the substrate 10, and better thickness uniformity and surface flatness can also be obtained. The heating and curing step can be performed in an oven, or in other heating environments or methods. During the heating of the heat-resistant coating 20 a , the resin material 212 is melted and bonded to the surface of the substrate 10 and the plurality of hollow particles 22 .

[0053] More specifically, after roughening the surface of the substrate 10, the following steps are included: preheating the substrate 10 to improve bonding with the adhesive material 21; electrostatically spraying a powder resin base layer 214a on the roughened surface of the substrate 10 to increase interlayer adhesion; electrostatically spraying the heat-resistant coating 20a on the powder resin base layer 214a; pre-curing the heat-resistant coating 20a to increase interlayer stability; electrostatically spraying a powder resin protective layer 214b on the pre-cured heat-resistant coating 20a to improve protection for the plurality of hollow particles 22; and curing the powder resin base layer 214a, the heat-resistant coating 20a, and the powder resin protective layer 214b to form the composite member 1. The materials of the powder resin base layer 214a and the powder resin protective layer 214b are, for example, the same as those of the two side layers 214.

[0054] Figure 9 shows test data for a rim with a heat-resistant layer installed on the inside. The test results, with a rim plate thickness of 3.89 mm, show that when the inside of the rim is heated by a heat source at approximately 230°C (as shown by temperature curve L1), the temperature measured on the outside of the rim is only approximately 170°C (as shown by temperature curve L2), resulting in a 60°C temperature difference between the inside and outside. This demonstrates the excellent heat-resistant properties of the composite component of the present invention.

[0055] The above are preferred embodiments of the present invention and the technical principles used therein. For those skilled in the art, any obvious changes such as equivalent transformations, simple replacements, etc. based on the technical solution of the present invention, without departing from the spirit and scope of the present invention, are within the scope of protection of the present invention.

Claims

1. A composite material component, characterized in that: include: a substrate comprising a bonding material and a fiber material layer, wherein a plurality of fibers of the fiber material layer are bonded to the bonding material; and A heat-resistance layer is bonded to a surface of the substrate and comprises an adhesive material and a plurality of hollow particles. The plurality of hollow particles are distributed in the adhesive material and connected by the adhesive material.

2. The composite member according to claim 1, wherein: The substrate is a rim.

3. The composite member according to claim 1, wherein: The fiber material layer is a carbon fiber material layer, and the adhesive material includes adhesive and resin material.

4. The composite member according to claim 3, wherein: The resin material includes at least one of epoxy resin, phenol epoxy resin, acrylic resin, polyurethane acrylic resin and acrylic resin.

5. The composite member according to any one of claims 1 to 4, characterized in that: The mixing ratio of the plurality of hollow particles and the adhesive material is A:B, wherein A is 10-100, and B is 10-100.

6. The composite member according to claim 5, wherein: A:B is 40:60, 50:50, or 60:

50.

7. The composite member according to claim 1, wherein: The substrate further includes a roughened surface, and the adhesive material is bonded to the roughened surface.

8. The composite member according to claim 7, wherein: The adhesive material includes a middle layer and two side layers located on both sides of the middle layer. The plurality of hollow particles are distributed at least in the middle layer. One of the two side layers is bonded to the roughened surface. The two side layers are resin materials, and the resin material includes at least one of epoxy resin, phenol epoxy resin, acrylic resin, polyurethane acrylic resin and acrylic resin.

9. The composite member according to any one of claims 1 to 8, wherein: The hollow particles are ceramic hollow closed-pore microspheres or hollow glass microspheres. The adhesive material combines the bonding material and the fiber material layer.

10. The composite member according to any one of claims 1 to 9, characterized in that: The hollow particles include silicon dioxide and metal oxides. The hollow particles further include iron oxide, titanium dioxide, calcium oxide, magnesium oxide and sodium oxide. The metal oxide includes aluminum oxide or zirconium oxide.

11. The composite member according to claim 10, wherein: The content of silicon dioxide is 50% to 70%, the content of aluminum oxide or zirconium oxide is 20% to 50%, the content of iron oxide is 1.5% to 2.5%, the content of titanium dioxide is 1.4% to 1.6%, the content of calcium oxide is 1% to 10%, the content of magnesium oxide is 0.5% to 1%, and the content of sodium oxide is 0.5% to 1%.

12. The composite member according to any one of claims 1 to 11, characterized in that: The particle size of the hollow microparticles is 10 microns to 500 microns.

13. The composite member according to any one of claims 1 to 12, characterized in that: The density of the hollow particles is 0.5 g / cm 3 to 0.8g / cm 3 .

14. The composite member according to claim 13, wherein: The bulk density of the hollow fine particles is 0.3 g / cm 3 to 0.4g / cm 3 .

15. The composite member according to claim 13, wherein: The compressive strength of the hollow particles is greater than or equal to 350 MPa.

16. The composite member according to claim 13, wherein: The thermal conductivity of the hollow particles is 0.000903m 2 / h to 0.0015m 2 / h.

17. The composite member according to claim 13, wherein: The thermal conductivity of the hollow fine particles is 0.054 W / m·K to 0.095 W / m·K.

18. The composite member according to claim 13, wherein: The hollow fine particles have an oil absorption rate of 0.68 g (oil) / g to 0.69 g (oil) / g.

19. A method for manufacturing a composite material component, characterized in that: The following steps are involved: A heat-resistant coating is applied to the surface of a substrate, wherein the heat-resistant coating comprises an adhesive material and a plurality of hollow particles, and the substrate comprises a bonding material and a fiber material layer; and The heat-resistant coating is heated and cured to form a heat-resistant layer bonded to the surface of the substrate.

20. The method for manufacturing a composite member according to claim 19, wherein: The heat-resistant coating is sprayed on the surface of the substrate.

21. The method for manufacturing a composite member according to claim 19, wherein: The mixing ratio of the plurality of hollow particles in the heat-resistant coating and the adhesive material is A:B, wherein A is 10-100, and B is 10-100.

22. The method for manufacturing a composite member according to claim 19, wherein: The adhesive material includes an adhesive and a resin material. The resin material includes at least one of epoxy resin powder resin, phenolic epoxy resin powder, acrylic resin powder, polyurethane acrylic resin powder and acrylic resin powder. During the heating process of the heat-resistant coating, the resin material melts and bonds to the surface of the substrate and the plurality of hollow particles.

23. The method for manufacturing a composite member according to claim 19, wherein: Before coating the heat-resistant coating, the method further includes a step of roughening the surface of the substrate.

24. The method for manufacturing a composite member according to claim 23, wherein: The surface of the substrate is roughened by sandblasting.

25. The method for manufacturing a composite member according to any one of claims 19 to 24, wherein: Before coating the heat-resistant coating, the method further includes a step of causing the heat-resistant coating to have static charges, so that the heat-resistant coating with static charges can be adsorbed on the surface of the substrate.

26. The method for manufacturing a composite member according to claim 23, wherein: The step of roughening the surface of the substrate comprises the following steps: preheating the substrate; Electrostatically spraying a powder resin base layer on the roughened surface of the substrate; Electrostatically spraying the heat-resistant coating onto the powder resin base layer; pre-curing the heat-resistant coating; Electrostatically spraying a powder resin protective layer on the pre-cured heat-resistant coating; and curing the powder resin bottom layer, the heat-resistant coating and the powder resin protective layer.

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