Gold foil-modified fiber-based composite material product, forming method therefor and use thereof

Abstract

Disclosed are a gold foil-modified fiber-based composite material product, a forming method therefor and a use thereof. The forming method for the foil-modified fiber-based composite material product comprises the following steps: S1: preheating a mold; S2: calculating the weight of a required fiber-based material sheet on the basis of the mold size, and performing weighing; S3: placing the fiber-based material sheet into the mold at a preheating temperature, then spreading a gold foil on the outer surface of the fiber-based material sheet, closing the mold, reserving a certain space, applying a set pressure at the same time, and then performing vacuumizing treatment; and S4: completely closing the mold, ending the vacuumizing step, performing heat preservation, and upon the completion of heat preservation, opening the mold, and taking out a product from the mold, so as to obtain the foil-modified fiber-based composite material product.

Description

Gold foil-modified fiber-based composite materials, their molding methods and applications

[0001] Cross-references to related applications

[0002] This application is based on and claims priority to Chinese Patent Application No. 202410823566.8, filed on June 24, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure belongs to the field of fiber-based composite materials technology. Specifically, this disclosure relates to a gold foil-modified fiber-based composite material article, its molding method, and its uses. Background Technology

[0004] Fiber-based composite materials typically possess excellent properties such as lightweight, high strength, and corrosion resistance, and are therefore widely used in aerospace, automotive manufacturing, construction engineering, and everyday consumer goods.

[0005] As people's living standards improve, their demands for products also increase. They require products to not only maintain high performance but also possess aesthetic appeal, such as embellishing a substrate with gold leaf for decoration and aesthetic purposes. Traditionally, the process of decorating a substrate with gold leaf involves first preparing the product from the substrate, then fixing the gold leaf onto the surface, and finally smoothing and polishing the surface to fully reveal the gold leaf and achieve the decorative effect. However, the varnishing and polishing processes have high environmental requirements, leading to processing difficulties and high manufacturing costs.

[0006] In view of this, this disclosure is hereby made. Summary of the Invention

[0007] This disclosure aims to at least partially address one of the technical problems in the related art. To this end, embodiments of this disclosure provide a gold foil-modified fiber-based composite material article, its molding method, and its uses.

[0008] In a first aspect, embodiments of this disclosure provide a molding method for a gold foil-modified fiber-based composite material article, comprising the following steps:

[0009] S1: Preheat the mold;

[0010] S2: Calculate the required weight of the fiber base material sheet according to the mold size, and weigh the fiber base material sheet;

[0011] S3: Place the fiber base sheet into a mold at a preheated temperature, then sprinkle gold foil on the outer surface of the fiber base sheet, close the mold, leaving a certain space, apply a set pressure, and then perform vacuuming.

[0012] S4: Completely close the mold and end the vacuuming step. Insulate the temperature. After the insulation is completed, open the mold and remove the product from the mold to obtain the gold foil modified fiber-based composite material product.

[0013] This embodiment of the invention achieves integrated molding of the gold foil and the fiber matrix sheet by sprinkling gold foil onto the preheated fiber matrix sheet during the injection molding process, resulting in a stronger bond between the gold foil and the fiber matrix sheet. Furthermore, the gold foil is not pressed into the interior of the fiber matrix sheet, but only exists on the shallow surface of the molded fiber matrix sheet, improving the utilization rate of the gold foil and resulting in a better display effect. Moreover, using the molding process of this embodiment, the resulting gold foil-modified fiber matrix composite material product does not require subsequent post-processing steps such as spraying varnish and polishing, simplifying the production process, improving production efficiency, and reducing production costs, thus possessing high practical application value.

[0014] In some embodiments, in step S1, the preheating temperature of the mold is 100–170°C.

[0015] In some embodiments, in step S2, the fiber matrix sheet includes at least one of carbon fiber reinforced resin matrix molding compound, carbon fiber, glass fiber, basalt fiber, and aramid fiber. Optionally, the fiber matrix sheet is carbon fiber reinforced resin matrix molding compound.

[0016] And / or, the error during weighing is ≤ 3% of the total weight.

[0017] In some embodiments, the range of the set pressure in step S3 is 300 to 1500T;

[0018] And / or, when closing the mold, leave a space of 1 to 10 mm;

[0019] And / or, the vacuum level during evacuation is ≤-0.9 Bar, and the evacuation time is 30-60 s.

[0020] In some embodiments, the heat preservation time in step S4 is 10 to 20 minutes.

[0021] Secondly, this disclosure also provides a gold foil-modified fiber-based composite material article, which is prepared by the molding method described in the first aspect.

[0022] Thirdly, embodiments of this disclosure also propose the use of a gold foil-modified fiber-based composite material article as described in the second aspect in decorative panels.

[0023] In some embodiments, the gold foil-modified fiber-based composite material articles are used to prepare automotive trim panels, bags, and composite tabletops. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below. Obviously, the described embodiments are only some, not all, of the embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the described embodiments of this disclosure without creative effort are within the protection scope of this disclosure.

[0025] In a first aspect, embodiments of this disclosure provide a molding method for a gold foil-modified fiber-based composite material article, comprising the following steps:

[0026] S1: Preheat the mold;

[0027] S2: Calculate the required weight of the fiber base material sheet according to the mold size, and weigh the fiber base material sheet;

[0028] S3: Place the fiber base sheet into a mold at a preheated temperature, then sprinkle gold foil on the outer surface of the fiber base sheet, close the mold, leaving a certain space, apply a set pressure, and then perform vacuuming.

[0029] S4: Completely close the mold and end the vacuuming step. Insulate the temperature. After the insulation is completed, open the mold and remove the product from the mold to obtain the gold foil modified fiber-based composite material product.

[0030] In some embodiments, in step S1, the preheating temperature of the mold is 100 to 170°C, for example, it can be 100°C, 120°C, 130°C, 145°C, 150°C or 170°C, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0031] In some embodiments, in step S2, the fiber matrix sheet includes at least one of carbon fiber reinforced resin sheet molding compound, carbon fiber, glass fiber, basalt fiber, and aramid fiber. Optionally, the fiber matrix sheet is carbon fiber reinforced resin sheet molding compound (CF-SMC).

[0032] And / or, the weighing error is ≤ 3% of the total weight, for example, it can be 1%, 1.5%, 2% or 3%, but is not limited to the listed values, other unlisted values ​​within this range also apply.

[0033] In some embodiments, in step S3, the range of the set pressure is 300 to 1500T, for example, it can be 300T, 500T, 800T, 1000T, 1200T or 1500T, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable. By applying a certain pressure in the mold, the fluid fiber base sheet can be wetted with each surface of the gold foil, thereby completing the shaping of the gold foil while the composite material is curing.

[0034] And / or, when closing the mold, a space of 1 to 10 mm is reserved, for example, a space of 1 mm, 3 mm, 5 mm, 8 mm or 10 mm can be reserved, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable. By reserving a vacuum channel on the mold, the surface condition of the obtained product can be guaranteed.

[0035] And / or, the vacuum degree during vacuuming is ≤ -0.9 Bar; the vacuuming time is 30–60 s, for example, 30 s, 35 s, 40 s, 46 s, 50 s, 52 s, 58 s, or 60 s, but is not limited to the listed values; other unlisted values ​​within this range are also applicable. Vacuuming can remove air bubbles from the fiber substrate sheet, resulting in a better product surface condition.

[0036] In this embodiment, the fiber substrate sheet is placed into a preheated mold, causing the fiber substrate sheet to melt and have sufficient fluidity. At the same time, pressure is applied to the mold, causing the fluid fiber substrate sheet to wet the surface of the gold foil under pressure, and thus embed it into the surface of the fiber substrate sheet.

[0037] It should be noted that because there are fibers (including continuous and discontinuous fibers) in the fiber base material, the gold foil is not pressed into the interior of the fiber base material. It only exists in the shallow surface layer of the formed fiber base material, thereby improving the utilization rate of the gold foil and the display effect of the gold foil is also better.

[0038] In some embodiments, the heat preservation time in step S4 is 10 to 20 minutes, for example, 10 minutes, 12 minutes, 15 minutes, 18 minutes, or 20 minutes, but is not limited to the listed values; other unlisted values ​​within this range are also applicable. The heat preservation process allows the molten fiber-based sheet (with gold foil embedded on its surface) to solidify rapidly.

[0039] Secondly, this disclosure also provides a gold foil-modified fiber-based composite material article, which is prepared by the molding method described in the first aspect.

[0040] Thirdly, embodiments of this disclosure also propose the use of a gold foil-modified fiber-based composite material article as described in the second aspect in decorative panels.

[0041] In some embodiments, the gold foil-modified fiber-based composite material articles are used to prepare automotive trim panels, bags, and composite tabletops.

[0042] As a specific exemplary embodiment, this embodiment provides a molding method for a gold foil-modified fiber-based composite material article, including the following steps:

[0043] S1: Preheat the mold to a temperature of 130℃;

[0044] S2: Calculate the required weight of carbon fiber reinforced resin sheet molding compound (CF-SMC) according to the mold size, and weigh the carbon fiber reinforced resin sheet molding compound. The weighing error shall be ≤ 3% of the total weight.

[0045] S3: Place the carbon fiber reinforced resin sheet molding compound into a mold at a preheated temperature, then sprinkle gold foil on the outer surface of the carbon fiber reinforced resin sheet molding compound (i.e. the exposed decorative surface), close the mold, leaving a 3mm space, apply a set pressure of 500T, then open the vacuum valve to perform vacuuming, with a vacuum degree ≤ -0.9Bar, and vacuum for 60s.

[0046] S4: Then completely close the mold and shut off the vacuum valve to stop vacuuming. Keep it warm to allow the molten carbon fiber reinforced resin matrix sheet molding compound (with gold foil embedded on the surface) to solidify quickly. After keeping it warm for 15 minutes, open the mold and remove the product from the mold to obtain the gold foil modified fiber matrix composite product.

[0047] This embodiment of the invention involves sprinkling gold foil onto a preheated fiber substrate sheet within a mold during the injection molding process. The fiber substrate sheet melts upon heating and becomes impregnated with the gold foil, allowing the gold foil to be embedded in the surface of the fiber substrate sheet and achieving integrated molding of the gold foil and the fiber substrate sheet. Compared to traditional processes, this method results in a stronger bond between the gold foil and the fiber substrate. Furthermore, in the gold foil-modified fiber substrate composite product obtained in this embodiment, the gold foil exists only in the shallow surface layer (not the interior) of the molded fiber substrate, resulting in higher gold foil utilization and a better visual effect. Moreover, this gold foil-modified fiber substrate composite product eliminates the need for subsequent post-processing steps such as spraying clear varnish and polishing, simplifying the production process, improving production efficiency, and reducing production costs.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification and claims of this application are intended to cover non-exclusive inclusion.

[0049] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0050] The "range" disclosed in this application is defined by a lower limit and an upper limit. A given range is defined by selecting a lower limit and an upper limit, which define the boundaries of the particular range. The range defined in this way can include or exclude endpoints and can be arbitrarily combined; that is, any lower limit can be combined with any upper limit to form a range.

[0051] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0052] In this application, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0053] Although embodiments of the present disclosure have been shown and described above, it is to be understood that the above embodiments are exemplary and should not be construed as limiting the present disclosure. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present disclosure.

Claims

1. A molding method for a gold foil-modified fiber-based composite material product, comprising the following steps: S1: Preheat the mold; S2: Calculate the required weight of the fiber base material sheet according to the mold size, and weigh the fiber base material sheet; S3: Place the fiber base sheet into a mold at a preheated temperature, then sprinkle gold foil on the outer surface of the fiber base sheet, close the mold, leaving a certain space, apply a set pressure, and then perform vacuuming. S4: Completely close the mold and end the vacuuming step. Insulate the temperature. After the insulation is completed, open the mold and remove the product from the mold to obtain the gold foil modified fiber-based composite material product.

2. The molding method for the gold foil-modified fiber-based composite material product according to claim 1, wherein, In step S1, the preheating temperature of the mold is 100-170°C.

3. The molding method for the gold foil-modified fiber-based composite material product according to claim 1, wherein, In step S2, the fiber matrix sheet includes at least one of carbon fiber reinforced resin matrix sheet molding compound, carbon fiber, glass fiber, basalt fiber, and aramid fiber. And / or, the error during weighing is ≤ 3% of the total weight.

4. The molding method for the gold foil-modified fiber-based composite material article according to claim 3, wherein, The fiber matrix sheet is a carbon fiber reinforced resin matrix sheet molding compound.

5. The molding method for the gold foil-modified fiber-based composite material article according to any one of claims 1-4, wherein, In step S3, the range of the set pressure is 300 to 1500T; And / or, when closing the mold, leave a space of 1 to 10 mm; And / or, the vacuum level during evacuation is ≤-0.9 Bar, and the evacuation time is 30-60 s.

6. The molding method for the gold foil-modified fiber-based composite material article according to any one of claims 1-5, wherein, In step S4, the heat preservation time is 10 to 20 minutes.

7. A gold foil-modified fiber-based composite material article, wherein the gold foil-modified fiber-based composite material article is prepared by the molding method according to any one of claims 1-6.

8. Use of a gold foil-modified fiber-based composite material article as described in claim 7 in decorative panels.

9. The use according to claim 8, wherein, The gold foil-modified fiber-based composite material products are used to prepare automotive trim panels, bags, and composite tabletops.