TW202220833A - A production method of a fiber composite material - Google Patents

Abstract

Present invention is related to a production method of a fiber composite material having steps of: providing a dry fiber cloth, placing the dry fiber cloth in to a mold without toughing the inner surface of the mold, and injecting a melted plastic material into the mold to cover both sides of the dry fiber cloth to form a final product with 3D shape. The present invention introduces directly the dry fiber cloth into the injection procedure to form the final product which could improve or solve the problems of conventional prepreg material with thermosetting plastic for requiring low temperature preservation condition and the preservation time. Also, the present invention could be produce by injecting thermoplastic material which is considered a more easy and cost saving process.

Description

Manufacturing method of fiber composite material

The present invention relates to a manufacturing method of a fiber composite material product.

Carbon fiber composite materials are widely used in many fields due to their high strength, wear resistance, corrosion resistance, high temperature resistance and other performance advantages. At present, carbon fiber products on the market are processed and formed by carbon fiber prepreg. The so-called carbon fiber prepreg mainly uses epoxy resin and thermosetting resin to pre-impregnate carbon fiber cloth into carbon fiber prepreg cloth, and then use the carbon fiber The prepreg is heated and cured after being shaped.

However, due to the characteristics of the selected thermosetting epoxy resin, the carbon fiber prepreg needs to be stored at low temperature and has a limited storage period, and it needs to be softened in advance before being processed and shaped, resulting in numerous processing procedures. and high production costs.

Therefore, it is necessary to provide a novel and progressive fiber composite product and its manufacturing method to solve the above problems.

The main purpose of the present invention is to provide a fiber composite material product and a manufacturing method thereof. The steps are simple and the three-dimensional fiber composite material product can be efficiently manufactured.

In order to achieve the above object, the present invention provides a manufacturing method of a fiber composite material product, which comprises the following steps: Step 1: Provide a dry fiber cloth that is deformable and not impregnated with any resin; Step 2: place the fiber dry cloth in a mold, the mold includes a male mold and a female mold, the male mold is provided with a punch, the female mold is provided with a cavity corresponding to the punch, the fiber dry cloth is A three-dimensional structure is formed by force and deformation in the mold, and the three-dimensional structure formed by the dry fiber cloth in the mold is not in contact with the cavity of the male mold and the female mold, but is maintained in a suspended state. ;as well as Step 3: inject a hot-melted resin material into the gap of the mold by means of injection molding, and integrate with the fiber dry cloth to form a three-dimensional fiber composite product.

Wherein, further, the three-dimensional fiber composite material product contains a surplus material beyond the range framed by the punch and the mold cavity, and the surplus material is removed.

Wherein, the fiber dry cloth is deformed by force in the mold by being laid on the punch or the mold cavity by gravity or suction deformation to form the three-dimensional structure.

Wherein, the surfaces of the punch and the cavity respectively extend a plurality of convex ribs with suitable shapes, which can be used to support the dry fiber cloth in a suspended state to form the three-dimensional structure.

Wherein, the dry fiber cloth is laminated in the mold in multiple layers, and the weaving method, arrangement method or density of the dry fiber cloth of each layer is different.

Wherein, the fiber dry cloth includes carbon fiber dry cloth, glass fiber dry cloth, Kevlar fiber dry cloth or polyester fiber dry cloth.

Wherein, the resin material includes thermoplastic polyurethane (Thermoplastic polyurethane, TPU), polypropylene (Polypropylene, PP), LCP plastic material (Liquid crystal polymer), polyaryletherketone (polyetherketoneketone, PAEK), polycarbonate (Polycarbonate, PC) , Polysulfone (Polysulfone, PSU) or polyether-ether-ketone (poly-ether-ether-ketone, PEEK).

Wherein, the injection pressure range of the injection molding is 30.00Mpa to 300.00Mpa, so that the thickness of the resin material is less than or equal to 1.00mm for injection.

Wherein, the injection pressure range of the injection molding is 60.00Mpa to 80.00Mpa, so that the thickness of the resin material is less than or equal to 0.50mm for injection.

In order to achieve the above object, the present invention further provides a fiber composite product manufactured by the above method, comprising: a fiber layer, which is made of the fiber dry cloth; and at least one resin layer, each of which is integrally connected to the Fiber layers, each resin layer is formed by curing the hot-melting resin material; wherein, the fiber layer and each resin layer together form a predetermined three-dimensional structure.

By directly replacing the existing impregnating material with the fiber dry cloth, the present invention can improve the shortcomings of the existing fiber prepreg material, which needs to be stored at low temperature and has a limited storage period due to the selected resin characteristics, and also needs to be prepared in advance in manufacturing. It can only be processed and shaped after softening, which leads to the problems of numerous processing processes and high production costs.

Further, the fiber dry cloth is suspended in the mold accommodating space and injected from both sides, so as to achieve a high-efficiency resin distribution state and a high-quality fiber composite product.

In order to illustrate the technical solutions of the embodiments of the present invention more clearly, the following briefly introduces the accompanying drawings that need to be used in the description of the embodiments. Obviously, the accompanying drawings in the following description are only some examples or embodiments of the present invention. For those of ordinary skill in the art, the present invention can also be applied to the present invention according to these drawings without any creative effort. other similar situations. Unless obvious from the locale or otherwise specified, the same reference numbers in the figures represent the same structure or operation.

As shown in this specification and the claims, unless the context clearly dictates otherwise, the words "a", "an", "an" and/or "the" are not intended to be specific in the singular and may include the plural. Generally speaking, the terms "comprising" and "comprising" only imply that the clearly identified steps and elements are included, and these steps and elements do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

Please refer to FIG. 1, which shows a preferred embodiment of the present invention, the manufacturing method of the fiber composite material product of the present invention, including the following steps.

Step S1): providing a dry fiber cloth 10, the dry fiber cloth 10 being deformable and not impregnated with any resin. The fibrous dry cloth 10 can be directly deformed by external force including but not limited to pressure, gravity, suction and the like. In this embodiment, the fiber dry cloth 10 can be carbon fiber dry cloth, glass fiber dry cloth, Kevlar fiber dry cloth or polyester fiber dry cloth;

Step S2): Please refer to FIGS. 2 to 4A together, and place the fiber dry cloth 10 in a mold 20. The mold 20 includes a male mold 22 and a female mold 23. The male mold 22 is provided with a punch 24. The female mold 23 is provided with a cavity 25 corresponding to the punch 24 , and the fiber dry cloth 10 is deformed by force in the mold 20 to form a three-dimensional structure 12 . Attractive deformation, suction) on the punch 24 or the cavity 25 to form the three-dimensional structure 12 , or the fiber cloth 10 can also be placed between the male mould 22 and the female mould 23 and pressed down by the male mould 22 The deformation is not limited to this. When the male mold 22 and the female mold 23 are clamped, a gap 21 is formed between the three-dimensional structure 12 and the punch 24 and the mold cavity 25 respectively. What is important is the fiber dry cloth 10 The three-dimensional structure 12 formed in the mold 20 is not in contact with the punch 24 of the male mold 22 and the cavity 25 of the female mold 23 up and down, but is maintained in a suspended state, so that the resin material can be selected. 30 is integrally bonded to the double-sided wrapping of the fibrous dry cloth 10; and

Further, referring to FIG. 4B , another method of the present invention to prevent the three-dimensional structure 12 from contacting the punch 24 of the male mold 22 and the cavity 25 of the female mold 23 and forming the gap 21 can be as follows: The surfaces of the punch 24 and the cavity 25 respectively extend a plurality of protruding ribs 28 , which are used to support the dry fiber cloth 10 in a suspended state.

Further, another preferred embodiment of the present invention is that the dry fiber cloth 10 is laminated in the mold 10 in multiple layers, and the weaving method, arrangement method and density of the dry fiber cloth 10 of each layer may be different, so as to achieve different finished product characteristics. .

Step S3 : as shown in FIGS. 5 to 7 , inject a hot-melted resin material 30 into the gap 21 of the mold 20 by injection molding, and integrate with the fiber dry cloth 10 to form a three-dimensional fiber composite product. 1. Specifically, the resin material 30 can be injected into the gap 21 on both sides through a male mold runner 26 of the male mold 22 and a female mold runner 27 of the female mold 23; and simplified processing steps to form the three-dimensional fiber composite product 1, which has the advantages of high manufacturing efficiency and low manufacturing cost. In this way, the three-dimensional fiber composite material product 1 can basically be divided into the middle layer of the fiber dry cloth 10 similar to the sandwich structure and the resin material on the two outer sides.

Step S4 (optional): If the three-dimensional fiber composite material product 1 contains a residual material 1″ that exceeds the range framed by the punch 24 and the cavity 25, then cutting means can be adapted to The remaining material 1″ is partially removed.

Specifically, as shown in FIGS. 7 and 8 , the dry fiber cloth 10 is initially made of a plurality of dry fiber tows 11 woven with each other, so that the plurality of dry fiber tows 11 are positioned. The plural fiber dry tows 11 include plural unimpregnated carbon fiber dry tows or plural unimpregnated glass fiber dry tows or the plural carbon fiber dry tows and the plural glass fiber dry tows. Then, through the aforementioned process steps of the present invention, the resin material 30 is integrally bonded to the plurality of fiber dry tows 11, so the fiber dry cloth 10 and the cured resin material 30 have high bonding strength, and the resin material 30 can be integrated into The plurality of dry fiber tows 11 on both sides of the dry fiber cloth 10 form a highly impregnated state, which increases the structural strength and durability of the three-dimensional fiber composite product 1, and is less likely to cause the problem of resin fiber delamination.

The resin material 30 is integrally welded to the fiber dry cloth 10, and the resin material 30 wraps the fiber dry cloth 10, so that the three-dimensional fiber composite product 1 can be manufactured in simple steps, and the resin material 30 and the fiber dry cloth 10 have high bonding strength ; The resin material 30 is cured and combined with the fiber dry cloth 10 to form a predetermined three-dimensional structure 40, and the predetermined three-dimensional structure 40 is the structure corresponding to the punch 24 and the cavity 25; The fiber composite product 1 ′ of the portion of the remaining material 1 ″ of the composite product 1 .

The resin material 30 includes thermoplastic polyurethane (Thermoplastic polyurethane, TPU), polypropylene (Polypropylene, PP), LCP plastic material (Liquid crystal polymer), polyaryletherketone (polyetherketoneketone, PAEK), polycarbonate (Polycarbonate, PC) ), polysulfone (PSU) and poly-ether-ether-ketone (PEEK), one of the materials in the group, the injection molding pressure range is 30.00Mpa to 300.00Mpa, which can reach The resin material 30 is filled with a thickness of 1.00 mm or less. Preferably, the resin material is polypropylene (PP), and the injection pressure range of the injection molding is 60.00Mpa to 80.00Mpa, so the injection pressure is moderately favorable for filling, and the thickness of the resin material 30 is less than or equal to 0.50mm. filling.

Further, as shown in FIG. 8 , the present invention provides a fiber composite product manufactured by the above-mentioned method, comprising: a fiber layer 13 and at least one resin layer 14 . The fiber layer 13 is made of the fiber dry cloth 10; at least one resin layer 14, each of the resin layers 14 is integrally connected to the fiber layer 13, and each of the resin layers 14 is formed by curing the hot-melt resin material 30, in this embodiment In the example, each of the resin layers 14 is welded to the surface of the fiber layer 13 ; wherein, the fiber layer 13 and each of the resin layers 14 co-form the predetermined three-dimensional structure 40 .

To sum up, the finished fiber composite material of the present invention and the manufacturing method thereof are arranged by placing the fiber dry cloth in the mold, and injecting a hot-melt resin material into the mold, so that the resin material is integrally combined with the fiber dry cloth and together. The finished product of the three-dimensional fiber composite material is formed to simplify the processing steps, with high manufacturing efficiency and low cost.

In some of the above embodiments, numbers describing the quantities of components and attributes are used, and it should be understood that such numbers used for the description of the embodiments use the modifiers "about", "approximately" or "substantially" in some examples to modify. Unless stated otherwise, "about", "approximately" or "substantially" means that a variation of ±20% is allowed for the stated number. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximations that may vary depending upon the desired characteristics of individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and use a general digit reservation method. Notwithstanding that the numerical fields and parameters used in some embodiments of the invention to confirm the breadth of their ranges are approximations, in particular embodiments such numerical values are set as precisely as practicable.

S1~S4: Steps 1, 1’: Finished fiber composite material 1'': surplus material 10: Fiber dry cloth 11: Fiber Dry Tow 12: 3D Structure 13: Fiber layer 14: Resin layer 20: Mold 21: Gap 22: Male mold 23: Master mold 24: Punch 25: Mold cavity 26, 27: runner 28: Ribs 30: Resin material 40: Predetermined three-dimensional structure

The present invention will be further illustrated by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These examples are not limiting, and in these examples, the same numbers refer to the same structures, wherein: FIG. 1 is a block diagram of a manufacturing process of a preferred embodiment of the present invention. Figure 2 is a schematic diagram of a preferred embodiment of the fiber dry cloth of the present invention. 3 is a cross-sectional view of a preferred embodiment of the mold and the fiber dry cloth of the present invention. 4A, 4B, and 5 are cross-sectional views of several preferred embodiments of the mold of the present invention. FIG. 6 is a schematic diagram of a preferred embodiment of the mold of the present invention to complete the finished fiber composite material. FIG. 7 is a finished fiber composite material according to a preferred embodiment of the present invention. FIG. 8 is a partial enlarged view of FIG. 7 .

S1-S4: Steps

Claims (9)

A method for manufacturing a fiber composite material, the steps comprising: Step 1: Provide a dry fiber cloth that is deformable and not impregnated with any resin; Step 2: place the fiber dry cloth in a mold, the mold includes a male mold and a female mold, the male mold is provided with a punch, the female mold is provided with a cavity corresponding to the punch, the fiber dry cloth is A three-dimensional structure is formed by force and deformation in the mold, and the three-dimensional structure formed by the dry fiber cloth in the mold is not in contact with the cavity of the male mold and the female mold, but is maintained in a suspended state. ;as well as Step 3: inject a hot-melted resin material into the gap of the mold by means of injection molding, and integrate with the fiber dry cloth to form a three-dimensional fiber composite product. The method for manufacturing a fiber composite material according to claim 1, wherein the three-dimensional fiber composite material product further includes a residual material beyond the range of the punch and the cavity, and the residual material is removed. The method for manufacturing a fiber composite material according to claim 1 or 2, wherein the fiber dry cloth is deformed by force in the mold by being laid by gravity or deformed by suction on the punch or the mold cavity to form the three-dimensional structure . The method for manufacturing a fiber composite material as claimed in claim 1 or 2, wherein a plurality of suitable ribs are respectively extended from the surfaces of the punch and the cavity, which can be used to support the dry fiber cloth in a suspended state. to form the three-dimensional structure. The manufacturing method of the fiber composite material according to claim 1 or 2, wherein the dry fiber cloth is laminated in the mold in multiple layers, and the weaving method, arrangement method or density of the dry fiber cloth of each layer is different. The method for producing a fiber composite material according to claim 1 or 2, wherein the fiber dry cloth comprises a carbon fiber dry cloth, a glass fiber dry cloth, a Kevlar dry cloth or a polyester fiber dry cloth. The manufacturing method of the fiber composite material according to claim 1 or 2, wherein the resin material comprises thermoplastic polyurethane (Thermoplastic polyurethane, TPU), polypropylene (Polypropylene, PP), LCP plastic material (Liquid crystal polymer), polyarylene Ether ketone (polyetherketoneketone, PAEK), polycarbonate (Polycarbonate, PC), polysulfone (Polysulfone, PSU) or polyether-ether-ketone (poly-ether-ether-ketone, PEEK). The manufacturing method of the fiber composite material according to claim 1 or 2, wherein the injection pressure range of the injection molding is 30.00Mpa to 300.00Mpa, so that the resin material thickness is less than or equal to 1.00mm for injection. The manufacturing method of the fiber composite material according to claim 8, wherein the injection pressure range of the injection molding is 60.00Mpa to 80.00Mpa, so that the thickness of the resin material is less than or equal to 0.50mm for injection.

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