CN112677581A - Carbon fiber prepreg and preparation method and application thereof - Google Patents
Carbon fiber prepreg and preparation method and application thereof Download PDFInfo
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Abstract
The invention relates to a carbon fiber prepreg and a preparation method and application thereof. The carbon fiber prepreg consists of a bottom resin layer, a carbon fiber layer and a surface resin layer; the bottom resin layer is added with inorganic filler, so that the thermal expansion coefficients of the carbon fiber prepreg and metal, ceramic or other matrixes are matched better, and the surface resin layer is reactive flexible polymer modified epoxy resin and can improve the toughness of the resin. The carbon fiber prepreg provided by the invention can solve the problems that the composite material is easy to crack and poor in reliability after the existing carbon fiber epoxy resin prepreg is hot-pressed with metal and ceramic. In addition, the invention also provides preparation and application of the carbon fiber prepreg.
Description
Technical Field
The invention relates to the technical field of materials, in particular to a carbon fiber prepreg and a preparation method and application thereof.
Background
The carbon fiber composite material formed by hot-pressing and compounding the carbon fiber prepreg sheet and the base materials such as metal, ceramic or plastic has the performances of low density, high specific strength, corrosion resistance and the like, and can be used in the fields of aerospace, war industry, automobiles and the like, and also can be used as decorative parts such as structural members or panels of household appliances.
The carbon fiber prepreg is a key intermediate raw material for preparing the carbon fiber composite material, and has important influence on the performance, particularly the reliability, of the carbon fiber composite material. The most common carbon fiber prepreg is prepared by impregnating unidirectional or woven carbon fiber cloth with liquid epoxy resin and drying to partially crosslink the epoxy resin in a semi-cured state.
However, the matrix resin of conventional carbon fiber/epoxy prepregs is a pure epoxy resinHaving a coefficient of thermal expansion of about 100 x 10-6V. C, while the coefficient of thermal expansion of common metals (steel, copper, aluminum) is (10-30) x 10-6The coefficient of thermal expansion of the ceramic is lower to 1 x 10 DEG C-6Around/° c. Because the thermal expansion coefficient of the epoxy resin is greatly different from that of metal and ceramic, the carbon fiber composite material laminated by the prepreg and the metal or ceramic can generate certain internal stress in the material, particularly a resin/matrix interface, the internal stress is increased along with the change of environmental temperature, and interface cracking or resin cracking is easy to occur when external force impacts or the environmental temperature changes.
Disclosure of Invention
The present invention is directed to solving at least one of the problems of the prior art described above. Therefore, the invention provides a novel carbon fiber prepreg to solve the problem of interface cracking or resin cracking of a composite material in the application process of the carbon fiber prepreg in the prior art.
Specifically, the first aspect of the present invention provides a carbon fiber prepreg, which is composed of a bottom resin layer, a carbon fiber layer, and a surface resin layer; the bottom resin layer is epoxy resin added with inorganic filler.
According to one embodiment of the present invention, the primer resin layer, the carbon fiber layer and the surface resin layer are impregnated with each other.
According to an embodiment of the present invention, the resin of the primer resin layer and the resin of the top resin layer may be independently selected from one or more of a phenol-formaldehyde type epoxy resin, a bisphenol a type epoxy resin, and a bisphenol S type epoxy resin.
According to the technical scheme of the invention, the inorganic filler is added into the bottom resin layer, so that the thermal expansion coefficient of the epoxy resin can be reduced, the epoxy resin is matched with other matrix materials such as ceramics or metal, and the problem that the existing carbon fiber resin is easy to crack after being compounded with other materials is solved.
According to an embodiment of the present invention, the inorganic filler may be one or a mixture of two or more of silica, alumina, boron nitride, aluminum nitride, and silicon carbide.
According to one embodiment of the present invention, the mass ratio of the epoxy resin to the inorganic filler is 100: 10-80.
According to the embodiment of the present invention, the mass ratio of the epoxy resin and the inorganic filler in the preferable primer resin layer differs depending on the matrix material to be compounded with the carbon fiber prepreg. Specifically, when the epoxy resin is compounded with ceramic, the mass ratio of the epoxy resin to the inorganic filler in the bottom resin layer is 100: 40-80, preferably 100: 40-70. And metal, such as aluminum or its alloy, the mass ratio of the epoxy resin and the inorganic filler in the bottom resin layer is 100: 10-45, preferably 100: 10-40.
According to one embodiment of the invention, the top resin layer is a reactive flexible polymer modified epoxy resin.
According to one embodiment of the present invention, the reactive flexible polymer is a hydroxy styrene butadiene liquid rubber, an epoxy-terminated polyether or a combination thereof. Compared with common epoxy resin, the reactive flexible polymer is copolymerized with the epoxy resin, so that the surface layer resin has higher toughness, microcracks of the surface layer resin can be avoided under internal stress or mechanical external force, and the surface layer resin is transparent after being cured, so that the pattern appearance display of the carbon fibers is not influenced; but also to improve the aesthetic and aesthetic properties of parts made from the prepreg.
According to one embodiment of the present invention, the carbon fiber layer may be a unidirectional or woven carbon fiber layer.
According to one embodiment of the invention, the carbon fiber tows in the carbon fiber layer are between 3K and 12K; preferably between 3K and 7K.
According to one embodiment of the present invention, the carbon fiber bottom resin layer, the carbon fiber layer, and the carbon fiber top resin layer are impregnated and fused together between resins and fibers.
Another aspect of the present invention relates to a method for preparing the carbon fiber prepreg, specifically, the carbon fiber prepreg can be prepared by the following method steps:
1) respectively preparing a bottom resin adhesive film and a surface resin adhesive film;
2) forming a sandwich structure by the bottom resin adhesive film, the carbon fibers and the surface resin adhesive film;
3) heating to melt the resin, thereby obtaining a carbon fiber prepreg in which the primer resin layer, the carbon fiber layer and the surface resin layer are mutually impregnated.
According to an embodiment of the present invention, the bottom resin adhesive film is prepared by the following steps:
1) mixing inorganic filler, curing agent, defoaming agent and epoxy resin to prepare dipping and gluing;
according to one embodiment of the present invention, the curing agent is a dicyandiamide-based curing agent; the defoaming agent is modified silicon polyether, modified polyether defoaming agent or combination thereof.
According to one embodiment of the present invention, the epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 10-80: 0.5-5: 0.5 to 5; preferably 100: 10-70: 0.7-4: 0.7-4.
Also, according to the embodiment of the present invention, the amount of the inorganic filler added in the primer resin layer preferably differs depending on the matrix material to be compounded with the carbon fiber prepreg. Specifically, the inorganic filler is compounded with the ceramic in an amount of 40 to 80 parts by mass, preferably 40 to 70 parts by mass, based on 100 parts by mass of the charged epoxy resin. When compounded with a metal, for example, aluminum or an alloy thereof, the inorganic filler is contained in the primer resin layer in an amount of 10 to 45 parts by mass, preferably 10 to 40 parts by mass.
According to one embodiment of the invention, the temperature of the mixing is between room temperature and 70 ℃.
According to one embodiment of the invention, the temperature of the mixing is from 30 ℃ to 70 ℃.
2) And coating the dip-coating glue into a glue film.
According to one embodiment of the invention, the coating of the dip coating glue into a film comprises in particular the following steps: and (3) uniformly coating the dip-coating glue on release paper through a glue spreader, and preparing glue films with different thicknesses by adjusting the distance and speed of the glue spreader.
According to one embodiment of the invention, the resin adhesive film of the surface layer is prepared by the following steps: uniformly coating reactive flexible polymer modified epoxy resin on release paper through a glue spreader, and preparing glue films with different thicknesses by adjusting the distance and speed of the glue spreader;
according to one embodiment of the present invention, a carbon fiber prepreg is prepared by:
and leading out prefabricated glue films from the upper glue roller and the lower glue roller, forming a sandwich structure with the carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot press rollers, embedding the carbon fibers into the resin matrix, cooling, and covering a PE protective film on the carbon fiber resin surface layer to obtain the carbon fiber prepreg.
According to one embodiment of the invention, wherein the hot press roll temperature is 60 ℃ to 120 ℃ and the pressure is 0.5MPa to 1 MPa; the temperature of the hot press roller is preferably 70-110 ℃, and the pressure is preferably 0.6-0.8 MPa.
The carbon fiber prepreg effectively solves the problem of stress cracking of the interface or the interior of prepreg resin when the existing carbon fiber prepreg is compounded with other materials.
Another aspect of the present invention relates to a composite material, which comprises the carbon fiber prepreg and the matrix.
According to an embodiment of the invention, the substrate is a metal or a ceramic.
According to one embodiment of the invention, wherein the metal is aluminum and its alloys, copper and its alloys, magnesium and its alloys, iron and its alloys.
According to an embodiment of the invention, wherein the ceramic is an alumina ceramic or a zirconia ceramic.
Another aspect of the invention relates to the use of the above carbon fiber prepreg for the preparation of the above composite material.
According to another aspect, the invention relates to the use of the above-mentioned composite material as a structural part or a decorative part of an air conditioner.
Another aspect of the invention relates to a device comprising a structural or decorative element made of the composite material according to the invention as described above.
According to an embodiment of the invention, the device is a household appliance or an air treatment device.
According to an embodiment of the invention, the device is an air conditioner.
According to one embodiment of the invention, the structural or decorative part made of the composite material is a decorative strip, a panel or other structural parts. The decorative strip, the panel or other structural members comprise the carbon fiber layer and the surface resin layer, the surface resin layer has the effects of transparency and toughening, the carbon fiber layer has the characteristics of light carbon fiber and good strength and toughness, and various grain patterns can be realized by the carbon fiber layer, so that the decorative strip, the panel or other structural members have more personalized and scientific and technological appearances, can be used for replacing various plastic members, metal members and the like, and the structure and the appearance performance of the decorative strip, the panel or other structural members are improved.
Drawings
FIG. 1 is a schematic structural view of a carbon fiber prepreg according to an embodiment of the present invention; the composite material comprises 100 carbon fiber layers, 200 bottom resin layers and 300 surface resin layers.
FIG. 2 is an exploded view of an air conditioner according to an embodiment of the present invention; the air conditioner comprises a panel assembly 400, an air duct component 500, an air duct 510, a switch door 520, an air outlet frame 530, an air duct 530, an evaporator assembly 600, a rear shell 700 and an air inlet grille 800.
Detailed Description
The foregoing and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings.
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
In the description of the present invention, if there are first, second, third, etc. described only for the purpose of distinguishing technical features, it is not to be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated or implicitly indicating the precedence of the technical features indicated.
In the description of the present invention, it should be understood that the orientation or positional relationship referred to in the description of the orientation, such as the upper, lower, left, right, etc., is based on the orientation or positional relationship shown in the drawings, and is only for convenience of description and simplicity of description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention.
In the description of the present invention, it should be noted that unless otherwise explicitly defined, terms such as arrangement, installation, connection and the like should be broadly understood, and those skilled in the art can reasonably determine the specific meanings of the above terms in the present invention in combination with the specific contents of the technical solutions.
The carbon fiber prepreg is a key intermediate material for designing and preparing the carbon fiber reinforced composite material, resin in the traditional carbon fiber prepreg is pure epoxy resin, and because the thermal expansion coefficient of the epoxy resin is far greater than that of metal, ceramic or other matrixes, the carbon fiber reinforced composite material prepared by hot pressing the epoxy resin and the metal and ceramic is easy to generate stress cracking in the temperature change process. The carbon fiber prepreg provided by the invention is composed of a bottom resin layer, a carbon fiber layer and a surface resin layer, wherein the bottom resin layer can be more matched with the thermal expansion coefficient of metal, ceramic or other matrixes by adding a certain content of inorganic filler, so that the thermal stress of the final carbon fiber composite material is reduced; the surface resin is reactive flexible polymer modified epoxy resin and has high toughness and transparency. The carbon fiber prepreg provided by the invention can solve the problems that the composite material is easy to crack and poor in reliability after the existing carbon fiber/epoxy resin prepreg and matrixes such as metal and ceramic are hot-pressed.
Meanwhile, the preparation method of the carbon fiber prepreg provided by the invention can ensure that the carbon fiber, the bottom resin and the surface resin are fully impregnated and fused with each other and have good interface bonding force, and can adjust the type and content of the inorganic filler according to different properties of the base materials to be compounded of the carbon fiber prepreg, design the components and the performance of the inorganic filler and provide a proper prepreg intermediate for obtaining the carbon fiber composite material which is free of bubbles, high in transparency and good in adhesion reliability in the later period.
Example 1
A carbon fiber prepreg according to a first aspect of an embodiment of the present invention will be described with reference to fig. 1.
The carbon fiber prepreg of the present embodiment includes a primer resin layer 200, a carbon fiber layer 100, and a surface resin layer 300.
The bottom resin comprises the following components in percentage by mass: epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 50: 1: 2;
the epoxy resin is bisphenol A type epoxy resin;
the inorganic filler is spherical alumina;
the curing agent is dicyandiamide curing agent;
the defoaming agent is modified silicon polyether;
the surface resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is hydroxy styrene-butadiene liquid rubber;
the carbon fiber layer 100 is woven carbon fiber, and the carbon fiber tow is 9K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) the inorganic filler, the curing agent, the defoaming agent and the epoxy resin are put into a container to be uniformly mixed to prepare the dip coating adhesive, and the mixing temperature is 60 ℃. And (3) uniformly coating the dip-coating glue on release paper through a glue coating roller and cooling to obtain a bottom resin glue film.
2) Uniformly coating the hydroxy styrene-butadiene liquid rubber modified epoxy resin on release paper through a glue spreader and cooling to obtain the surface resin adhesive film.
3) Leading out pre-prepared resin adhesive films of a bottom layer and a surface layer from an upper adhesive roller and a lower adhesive roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot-pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering a PE protective film to prepare the carbon fiber prepreg. Wherein the temperature of the hot-pressing roller is 100 ℃, and the pressure is 0.7 MPa.
Example 2:
referring to fig. 1, the carbon fiber prepreg of this example includes a carbon fiber layer 100, a primer resin layer 200, and a surface resin layer 300.
The bottom resin comprises the following components in percentage by mass: epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 80: 0.5: 1.2;
the epoxy resin is phenolic epoxy resin;
the inorganic filler is irregular silica;
the curing agent is dicyandiamide curing agent;
the defoaming agent is modified polyether;
the surface resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fiber, and the carbon fiber tow is 6K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) placing the inorganic filler, the curing agent, the defoaming agent and the epoxy resin into a container, and uniformly mixing to prepare the dip coating adhesive, wherein the mixing temperature is 100 ℃. And (3) uniformly coating the dip-coating glue on release paper through a glue coating roller and cooling to obtain a bottom resin glue film.
2) And (3) uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader and cooling to obtain the surface resin adhesive film.
3) Leading out pre-prepared resin adhesive films of a bottom layer and a surface layer from an upper adhesive roller and a lower adhesive roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot-pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering a PE protective film to prepare the carbon fiber prepreg. Wherein the temperature of the hot-pressing roller is 110 ℃ and the pressure is 0.9 MPa.
Example 3:
referring to fig. 1, the carbon fiber prepreg of this example includes a carbon fiber layer 100, a primer resin layer 200, and a surface resin layer 300.
The bottom resin comprises the following components in percentage by mass: epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 50: 0.5: 1.2;
the epoxy resin is bisphenol S type epoxy resin;
the inorganic filler is irregular silica and spherical alumina, and the mass ratio of the irregular silica to the spherical alumina is 3: 1;
the curing agent is dicyandiamide curing agent;
the defoaming agent is modified silicon polyether;
the surface resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fiber, and the carbon fiber tow is 3K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) the inorganic filler, the curing agent, the defoaming agent and the epoxy resin are put into a container to be uniformly mixed to prepare the dip coating adhesive, and the mixing temperature is 90 ℃. And (3) uniformly coating the dip-coating glue on release paper through a glue coating roller and cooling to obtain a bottom resin glue film.
2) And (3) uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader and cooling to obtain the surface resin adhesive film.
3) Leading out pre-prepared resin adhesive films of a bottom layer and a surface layer from an upper adhesive roller and a lower adhesive roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot-pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering a PE protective film to prepare the carbon fiber prepreg. Wherein the temperature of the hot-pressing roller is 100 ℃, and the pressure is 0.5 MPa.
Examples 4 to 6
Respectively coating the carbon fiber prepregs of the embodiments 1 to 3 on the surface of zirconia ceramics, heating and pressurizing by a mould at the temperature of 160 ℃ to 190 ℃ for 5h to 7h and under the pressure of 0.5MPa to 1MPa so as to compound the carbon fiber prepregs with the ceramics through bottom resin, and finally cooling to the normal temperature to obtain the carbon fiber ceramic composite structure.
Example 7
A carbon fiber prepreg according to a first aspect of an embodiment of the present invention will be described with reference to fig. 1.
The carbon fiber prepreg of the present embodiment includes a primer resin layer 200, a carbon fiber layer 100, and a surface resin layer 300.
The bottom resin comprises the following components in percentage by mass: epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 30: 1: 2;
the epoxy resin is bisphenol A type epoxy resin;
the inorganic filler is spherical alumina;
the curing agent is dicyandiamide curing agent;
the defoaming agent is modified silicon polyether;
the surface resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is hydroxy styrene-butadiene liquid rubber;
the carbon fiber layer 100 is woven carbon fiber, and the carbon fiber tow is 9K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) the inorganic filler, the curing agent, the defoaming agent and the epoxy resin are put into a container to be uniformly mixed to prepare the dip coating adhesive, and the mixing temperature is 60 ℃. And (3) uniformly coating the dip-coating glue on release paper through a glue coating roller and cooling to obtain a bottom resin glue film.
2) Uniformly coating the hydroxy styrene-butadiene liquid rubber modified epoxy resin on release paper through a glue spreader and cooling to obtain the surface resin adhesive film.
3) Leading out pre-prepared resin adhesive films of a bottom layer and a surface layer from an upper adhesive roller and a lower adhesive roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot-pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering a PE protective film to prepare the carbon fiber prepreg. Wherein the temperature of the hot-pressing roller is 100 ℃, and the pressure is 0.7 MPa.
Example 8:
referring to fig. 1, the carbon fiber prepreg of this example includes a carbon fiber layer 100, a primer resin layer 200, and a surface resin layer 300.
The bottom resin comprises the following components in percentage by mass: epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 25: 0.5: 1.2;
the epoxy resin is phenolic epoxy resin;
the inorganic filler is irregular silica;
the curing agent is dicyandiamide curing agent;
the defoaming agent is modified polyether;
the surface resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fiber, and the carbon fiber tow is 6K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) placing the inorganic filler, the curing agent, the defoaming agent and the epoxy resin into a container, and uniformly mixing to prepare the dip coating adhesive, wherein the mixing temperature is 100 ℃. And (3) uniformly coating the dip-coating glue on release paper through a glue coating roller and cooling to obtain a bottom resin glue film.
2) And (3) uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader and cooling to obtain the surface resin adhesive film.
3) Leading out pre-prepared resin adhesive films of a bottom layer and a surface layer from an upper adhesive roller and a lower adhesive roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot-pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering a PE protective film to prepare the carbon fiber prepreg. Wherein the temperature of the hot-pressing roller is 110 ℃ and the pressure is 0.9 MPa.
Example 9:
referring to fig. 1, the carbon fiber prepreg of this example includes a carbon fiber layer 100, a primer resin layer 200, and a surface resin layer 300.
The bottom resin comprises the following components in percentage by mass: epoxy resin: inorganic filler: curing agent: the defoaming agent is 100: 10: 0.5: 1.2;
the epoxy resin is bisphenol S type epoxy resin;
the inorganic filler is irregular silica and spherical alumina, and the mass ratio of the irregular silica to the spherical alumina is 3: 1;
the curing agent is dicyandiamide curing agent;
the defoaming agent is modified silicon polyether;
the surface resin is reactive flexible polymer modified epoxy resin, and the reactive flexible polymer is epoxy-terminated polyether;
the carbon fiber layer 100 is woven carbon fiber, and the carbon fiber tow is 3K.
The preparation method of the carbon fiber prepreg of the embodiment is as follows:
1) the inorganic filler, the curing agent, the defoaming agent and the epoxy resin are put into a container to be uniformly mixed to prepare the dip coating adhesive, and the mixing temperature is 90 ℃. And (3) uniformly coating the dip-coating glue on release paper through a glue coating roller and cooling to obtain a bottom resin glue film.
2) And (3) uniformly coating the epoxy-terminated polyether modified epoxy resin on release paper through a glue spreader and cooling to obtain the surface resin adhesive film.
3) Leading out pre-prepared resin adhesive films of a bottom layer and a surface layer from an upper adhesive roller and a lower adhesive roller through a pre-dipping machine, forming a sandwich structure with carbon fibers, melting the resin matrix of the bottom layer and the surface layer through a plurality of groups of hot-pressing rollers, embedding the carbon fibers into the resin matrix, and finally cooling and covering a PE protective film to prepare the carbon fiber prepreg. Wherein the temperature of the hot-pressing roller is 100 ℃, and the pressure is 0.5 MPa.
Examples 10 to 12
Respectively coating the carbon fiber prepregs of the embodiments 7 to 9 on the surface of the aluminum alloy, heating and pressurizing by a mold at the temperature of 160 ℃ to 190 ℃ for 5h to 7h and under the pressure of 0.5MPa to 1MPa to compound the carbon fiber prepregs with the aluminum alloy through bottom resin, and finally cooling to the normal temperature to obtain the carbon fiber aluminum alloy composite structure.
Comparative example 1
A carbon fiber prepreg was prepared following a similar process route to example 2, except that: the carbon fiber bottom resin is common phenolic epoxy resin without adding inorganic filler; the carbon fiber surface resin is also common phenolic epoxy resin, but non-reactive flexible polymer modified epoxy resin.
Comparative example 2
Carbon fiber ceramic composites were prepared following a similar process route as examples 4-6, except that: the carbon fiber prepreg of comparative example 1 was used to be composited with zirconia ceramics.
Comparative example 3
A carbon fiber prepreg was prepared following a similar process route to example 8, except that: the carbon fiber bottom resin is common phenolic epoxy resin without adding inorganic filler; the carbon fiber surface resin is also common phenolic epoxy resin, but non-reactive flexible polymer modified epoxy resin.
Comparative example 4
Carbon fiber metal composites were prepared following a similar process route as examples 10-12, except that: the carbon fiber prepreg of comparative example 3 was used to composite with an aluminum alloy.
Test example
The carbon fiber ceramic/aluminum alloy composite materials prepared according to the examples 4-6 and 10-12, the comparative examples 2 and the comparative examples 4 are placed in a high-low temperature test chamber to be subjected to a high-low temperature impact aging test of-40 ℃/1h to 60 ℃/1h in a circulating manner, the high-low temperature conversion time is not more than 30min, and after the test is finished, a sample is taken out to observe whether the carbon fiber ceramic/aluminum alloy composite materials have interface cracking or resin cracking, and the results are shown in table 1.
TABLE 1
As can be seen from the data in Table 1, the carbon fiber ceramic/aluminum alloy composite material provided by the embodiment of the invention can effectively solve the problem of stress cracking of the interface or resin inside the existing carbon fiber (ceramic/aluminum alloy) composite material in the temperature change process.
Application example
An air conditioner, wherein an exploded view of an interior thereof is shown in fig. 2, comprising a panel member 400 made of the carbon fiber-aluminum alloy composite material according to any one of embodiments 10 to 12. The panel member 400, which includes the carbon fiber prepreg according to the present invention therein, has a specific inorganic filler and a specific ratio of the resin layer of the bottom layer as shown in table 1 above, thereby improving the bonding between the carbon fiber layer and the aluminum alloy of the substrate; the surface resin layer has the effects of transparency and toughening, the carbon fiber layer has the characteristics of light carbon fiber and good strength and toughness, and the carbon fiber layer can realize various grain patterns, so that the appearance of the decorative strip, the panel or other structural parts has more individuation and scientific and technological feelings, even the customization of the appearance can be carried out according to different requirements of customers, the traditional plastic part, metal parts and the like are replaced, the parts can not crack and the like in the long-term use of the air conditioner, and the panel can be made very thin, for example, the total thickness is lower than 1mm, the very high strength and toughness can still be kept due to the characteristics of light carbon fiber and high strength, the high ductility, the toughness and the like of the aluminum alloy, and the like, the parts can reduce the overall quality of the air conditioner, but improve the performances of wear resistance, scratch resistance, corrosion resistance and the like, and can be applied to the conventional indoor environment, the paint can also be applied to various severe or extremely severe environments, such as high temperature, strong corrosion and the like, and still can keep good appearance. On the other hand, the panel component is not damaged or deformed even if the panel component is frequently disassembled or collided and the like on the basis of the strong fatigue resistance of metal and carbon fiber; the air conditioner can keep good appearance for a long time, and the requirement of durable household appliances is really met.
The embodiments of the present invention have been described in detail with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the gist of the present invention.
Claims (14)
1. The carbon fiber prepreg is characterized by consisting of a bottom resin layer, a carbon fiber layer and a surface resin layer; the bottom resin layer is epoxy resin doped with inorganic filler.
2. The carbon fiber prepreg according to claim 1, wherein the resin in the face resin layer is a reactive flexible polymer-modified epoxy resin.
3. The carbon fiber prepreg of claim 2, wherein the reactive flexible polymer is a hydroxy styrene butadiene liquid rubber, an epoxy terminated polyether, or a combination of both.
4. The carbon fiber prepreg according to claim 1 or 2, wherein the epoxy resin is one or a combination of two or more of a phenol epoxy resin, a bisphenol a epoxy resin, and a bisphenol S epoxy resin.
5. The carbon fiber prepreg according to claim 1, wherein the inorganic filler is a mixture of one or more of silica, alumina, boron nitride, aluminum nitride, and silicon carbide.
6. The carbon fiber prepreg according to claim 1, wherein a mass ratio of the epoxy resin to the inorganic filler is 100: 10-80.
7. The carbon fiber prepreg according to claim 1, wherein the primer resin layer, the carbon fiber layer and the face resin layer are impregnated with each other.
8. The method for producing a carbon fiber prepreg according to any one of claims 1 to 7, characterized by comprising the steps of:
respectively preparing a bottom resin adhesive film and a surface resin adhesive film;
forming a sandwich structure by the bottom resin adhesive film, the carbon fibers and the surface resin adhesive film;
and heating to melt the resin, thereby obtaining the carbon fiber prepreg in which the bottom resin layer, the carbon fiber layer and the surface resin layer are mutually impregnated.
9. The manufacturing method according to claim 8, wherein the bottom resin adhesive film is manufactured by: mixing the inorganic filler, the curing agent, the defoaming agent and epoxy resin to prepare dipping glue; and then coating the dip-coating glue into a film.
10. The production method according to claim 9, wherein the curing agent is a dicyandiamide-based curing agent; the defoaming agent is modified silicon polyether, modified polyether defoaming agent or the combination of the two.
11. A composite material comprising the carbon fiber prepreg according to any one of claims 1 to 7 and a matrix.
12. The composite material of claim 11, wherein the matrix is a metal or a ceramic.
13. A device comprising a structural or decorative member made from the composite material of claim 10 or 11.
14. The device of claim 13, which is an air treatment device; and the structural parts or the decorative parts made of the composite material are decorative strips, panels and other structural parts.
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| CN115044168A (en) * | 2022-07-06 | 2022-09-13 | 江苏澳盛复合材料科技有限公司 | Epoxy resin prepreg and carbon fiber composite material manufactured by using same |
| CN115593078A (en) * | 2022-10-17 | 2023-01-13 | 江苏联能电子技术有限公司（Cn） | Piezoelectric ceramic device based on vacuum hot-pressing curing bonding and preparation method thereof |
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