CN115703279A - A thermoplastic composite sheet for product structure molding and its manufacturing method - Google Patents

Abstract

The invention relates to the technical field of thermoplastic plates and hot-press molding, in particular to a thermoplastic composite plate for product structure molding and a manufacturing method thereof. The thermoplastic composite sheet material comprises: the composite material comprises two fiber layers and a middle core layer, wherein the middle core layer is arranged between the two fiber layers, the fiber layers are impregnated by carbon fibers and polycarbonate, and the middle core layer is a thickened polycarbonate or polycarbonate and short carbon fiber reinforced resin sheet; the manufacturing method has the advantages that the manufacturing method is simple in process, the fiber layers and the middle core layer are convenient to lay, and the thickness of the composite board can be adjusted according to different requirements of products.

Description

A thermoplastic composite sheet for product structure molding and its manufacturing method

【Technical field】

The invention relates to the technical field of thermoplastic plates and hot press forming, in particular to a thermoplastic composite plate used for product structure forming and a manufacturing method thereof.

【Background technique】

With the development of electronic and information equipment such as notebook computers, tablet notebooks, portable phones, portable information terminals or cameras, products on the market are increasingly thinner and lighter. Thin and light products require thin-walled and light-weight shells or internal parts that make up the product, as well as high strength and high rigidity. Composite panels have the advantages of light weight, high strength and high modulus, chemical corrosion resistance, fatigue resistance, and easy overall molding, and are widely used in the production of military, aircraft, automobile, wind power and other products. Due to the excellent mechanical properties of the composite sheet, it can also be used in the casing of portable information terminals such as notebook computers, tablet notebooks, portable phones, etc., and plays the role of making the casing thinner and reducing the weight of the equipment.

At present, thermoplastic composite sheet products used in electronic appliances, automobiles, sports equipment and other products mostly use continuous carbon fiber, continuous glass fiber, etc. When the board is processed into products, most of them use the process of hot pressing the board first and then burying it. The desired structure must be obtained through burying molding.

In view of this, it is necessary to develop a method for manufacturing composite boards, so as to manufacture composite boards to save processes and improve production efficiency.

【Content of invention】

The technical problem to be solved by the present invention is: most of the products processed by the composite plate currently need to use the process of hot pressing the plate and then burying the plate, and the desired structure can only be obtained by burying the molding. The product does not need to be injection molded, and therefore, a process is required to manufacture composite panels.

The technical solution for solving the problem of the present invention is: a method for manufacturing a thermoplastic composite sheet for product structure molding, comprising the following steps:

S1: cutting the impregnated thermoplastic carbon fiber layer and the thickened thermoplastic resin layer or the thermoplastic resin layer reinforced by chopped fibers to the required size;

S2: Lay up and adjust according to the sequence of fiber layer, middle core layer, fiber layer and the designed thickness and strength requirements;

S3: Heat up the pressing mold of the hot press, and the temperature depends on the physical properties of the thermoplastic used;

S4: Put the stacked layers into the mold;

S5: The mold is pressurized and kept at the set temperature;

S6: After reaching the set pressing time, start cooling until the resin of the plate in the mold cools down;

S7: Open the mold and take out the product.

Optionally, the designed thickness needs to be calculated according to the resin consumption of the final product mechanism.

Optionally, the hot pressing mold is heated to 250-350°C.

Optionally, the pressurization and constant temperature holding time is 60-80 seconds.

Optionally, the cooling to the required temperature is 30-80°C.

The composite board contains two layers of fiber layers and an intermediate core layer, and is characterized in that:

Optionally, the fiber layer is continuous fiber impregnated with thermoplastic (such as PC, PA, PPS) resin.

Preferably, the fiber layer is impregnated with polycarbonate (PC).

Optionally, the continuous fiber may be carbon fiber, glass fiber, aramid fiber, graphite fiber, etc.; the carbon fiber uses unidirectional or woven carbon fiber to maximize the strength of the plate while retaining the carbon fiber pattern;

Preferably, the fiber layer adopts 3K carbon fiber.

The middle core layer is a thickened thermoplastic resin sheet (such as PC, PPS, etc.), or a thermoplastic resin sheet reinforced by chopped fibers (such as PC+GF, PC+CF, PBT+GF, PPS+GF, etc. ); the length of the chopped fibers is between 0.2-5mm; the intermediate core layer is arranged between two fiber layers; the thermoplastic resin used in the intermediate core layer is consistent with the thermoplastic resin impregnated in the fiber layers.

Preferably, the intermediate core layer resin is polycarbonate (PC) or polycarbonate (PC+CF) reinforced by chopped carbon fibers.

Compared with the prior art, the present invention is a thermoplastic composite sheet for product structure forming and its manufacturing method, which has the following technical effects:

1. The manufacturing method has a simple process, and the fiber layer and the middle core layer are conveniently stacked, and the thickness of the composite board can be adjusted according to different requirements of the product.

2. Using a thickened thermoplastic resin sheet or a thermoplastic resin sheet reinforced by chopped fibers in the middle core layer of the composite sheet can maintain the high strength and high modulus properties of the composite sheet.

3. The hot-pressing process is simple, and the whole process can use conventional hot-pressing equipment.

【Description of drawings】

Fig. 1 is a flow chart of steps of a method for manufacturing a thermoplastic composite sheet for product structure molding according to the present invention.

Fig. 2 is a cross-sectional view of the composite sheet in Example 1 of a thermoplastic composite sheet for product structure forming and its manufacturing method according to the present invention.

3 is a cross-sectional view of a thermoplastic composite sheet used for product structure molding and a manufacturing method thereof in Example 2 of the present invention.

【Detailed ways】

In order to further illustrate the technical means and effects adopted by the present invention, the following will be described in detail in conjunction with the embodiments of the present invention and the accompanying drawings:

Please refer to Figures 1 to 2, Figure 1 depicts a flow chart of the steps of a thermoplastic composite sheet for product structure forming and its manufacturing method of the present invention, and Figure 2 depicts a process flow chart for product structure forming of the present invention The cross-sectional view of the composite board of Example 1 in the thermoplastic composite board and its manufacturing method, and Fig. 3 depicts a cross-sectional view of the composite board of Example 2 in a thermoplastic composite board used for product structure molding and its manufacturing method of the present invention .

Example 1

Please refer to Fig. 2, the composite board (100) includes two fiber layers (101) and an intermediate core layer (102), wherein the intermediate core layer (102) is arranged between the two fiber layers (101).

In this embodiment, the two fiber layers (101) are continuous 3K carbon fibers impregnated with polycarbonate.

In this embodiment, the middle core layer (102) is a polycarbonate sheet (PC+20% CF) reinforced by chopped carbon fibers.

Next, referring to Fig. 1 and Fig. 2, a kind of thermoplastic composite sheet for product structure molding and its manufacturing method provided by the present invention includes the following steps:

S1: cutting the fiber layer (101) impregnated with polycarbonate (PC) and the intermediate core layer (102) of polycarbonate (PC+20% CF) reinforced by chopped carbon fibers into length: 1m, width: 1m in size;

S2: The fiber layer (101) impregnated with polycarbonate (PC) and the intermediate core layer (102) of polycarbonate (PC+20% CF) reinforced by chopped carbon fibers are carried out according to the designed thickness and strength requirements The thickness is adjusted, and the laying is performed according to the order of the fiber layer (101), the middle core layer (102), and the fiber layer (101);

S3: Heat up the pressing mold of the hot press to 250-350°C;

S4: Put the stacked layers into the mold;

S5: The mold is pressurized and kept at the set temperature for 60-80 seconds;

S6: Turn on the cooling, open the mold when the mold temperature is cooled to 30-80°C, and take out the plate;

S7: Open the mold and take out the composite plate (100).

Example 2

Please refer to FIG. 3 , the composite board ( 200 ) includes two fiber layers ( 201 ) and an intermediate core layer ( 202 ), wherein the intermediate core layer ( 202 ) is arranged between the two fiber layers ( 201 ).

In this embodiment, the two fiber layers (201) are continuous 3K carbon fibers impregnated with polycarbonate.

In this embodiment, the middle core layer (202) is polycarbonate.

Next, referring to Fig. 1 and Fig. 3, a kind of thermoplastic composite sheet for product structure molding and its manufacturing method provided by the present invention includes the following steps:

S1: cutting the fiber layer (201) impregnated with polycarbonate (PC) and the polycarbonate intermediate core layer (202) into length: 1m, width: 1m;

S2: adjust the thickness of the fiber layer (201) impregnated with polycarbonate (PC) and the polycarbonate middle core layer (202) according to the designed thickness and strength requirements, and adjust the thickness according to the fiber layer (201), middle core layer (202), the fiber layer (201) is sequentially laid up;

S3: Heat up the pressing mold of the hot press to 250-350°C;

S4: Put the stacked layers into the mold;

S5: The mold is pressurized and kept at the set temperature for 60-80 seconds;

S6: Turn on the cooling, open the mold when the mold temperature is cooled to 30-80°C, and take out the plate;

S7: Open the mold and take out the composite plate (200).

Compared with the prior art, a thermoplastic composite sheet used for product structure molding and its manufacturing method has the following technical effects:

1. The manufacturing method has a simple process, and the fiber layer and the middle core layer are conveniently stacked, and the thickness of the composite board can be adjusted according to different requirements of the product.

2. Using a thickened thermoplastic resin sheet or a thermoplastic resin sheet reinforced by chopped fibers in the middle core layer of the composite sheet can maintain the high strength and high modulus properties of the composite sheet.

3. The hot-pressing process is simple, and the whole process can use conventional hot-pressing equipment.

It should be pointed out that the present invention is not limited to the above-mentioned specific implementation methods, any simple modifications, equivalent changes and modifications made to the above-mentioned embodiments by any skilled person based on the technical solution of the present invention shall fall within the scope of protection of the present invention Inside.

Claims (11)

1. A method of manufacturing a thermoplastic composite sheet for structural molding of a product, the method comprising the steps of:

s1: cutting the impregnated thermoplastic carbon fiber layer and the thickened thermoplastic resin layer or the chopped fiber reinforced thermoplastic resin layer into required sizes;

s2: the fiber layers, the middle core layer and the fiber layers are laid and adjusted according to the sequence of the fiber layers and the design thickness and strength requirements of the product;

s3: heating a pressing mold of the hot press, wherein the temperature is determined according to the physical properties of the used thermoplasticity;

s4: placing the laid stack in a mould;

s5: pressurizing the mold at a set temperature and keeping the temperature constant;

s6: starting cooling after the set pressing time is reached until the resin of the plate in the mold is cooled;

s7: opening the mold and taking out the composite board.

2. The method for manufacturing a thermoplastic composite sheet for structural molding of a product according to claim 1, wherein: the cutting size is length: 1m, width: 1m, and a solvent.

3. The method of manufacturing a thermoplastic composite sheet for structural molding of products according to claim 1, wherein: and heating the hot-pressing die to 250-350 ℃.

4. The method of manufacturing a thermoplastic composite sheet for structural molding of products according to claim 1, wherein: the pressurizing and constant-temperature holding time is 60-80 seconds.

5. The method of manufacturing a thermoplastic composite sheet for structural molding of products according to claim 1, wherein: and cooling to the required temperature of 30-80 ℃.

6. The utility model provides a be used for fashioned thermoplasticity composite board of product structure which characterized in that, the composite board main part comprises two-layer fibrous layer and middle sandwich layer, middle sandwich layer is located between two-layer fibrous layer, the fibrous layer is for having the continuous fibers that resin soaks, middle sandwich layer is the resin sheet of bodiness.

7. A thermoplastic composite sheet for structural molding of products according to claim 6, wherein: the resin impregnated in the fiber layer is polycarbonate.

8. A thermoplastic composite sheet for structural molding of products according to claim 6, wherein: the fiber layer is 3K woven grain carbon fiber.

9. A thermoplastic composite sheet for structural molding of products according to claim 6, wherein: the resin of the middle core layer is polycarbonate.

10. The thermoplastic composite sheet for product structural molding according to claim 6, wherein: the resin of the middle core layer is a composite resin of polycarbonate and 20% of carbon fiber.

11. A thermoplastic composite sheet for structural molding of products according to claim 6, wherein: the thermoplastic resin used for the middle core layer is consistent with the thermoplastic resin impregnated in the fiber layer.

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