TWI887164B - Prepreg material - Google Patents

Abstract

A prepreg material comprising a plurality of prepreg structures, wherein each prepreg structure is a multilayer structure, prepreg structure has a fiber-resin layer, a first resin layer, a metal layer, and a second resin layer. The multilayer structure features different materials, expansion coefficients, viscosities, and thicknesses. After pre-curing, the prepreg structures are stacked in layers to form the prepreg material. An interface is formed between the fiber-resin layer and the second resin layer, which reduces the displacement of the layered stack of the prepreg structure and further enhances the overall strength of the prepreg material.

Description

Prepreg materials

A prepreg material.

Prepregs are widely used in many high-performance applications. The traditional prepreg structure is composed of fiber layers and resin layers. Although it can provide basic strength and rigidity, in applications that require long-term high loads, high strength, high temperatures or corrosive environments, the traditional prepreg structure will deteriorate rapidly, resulting in unsatisfactory durability or protection, affecting its life and performance.

In addition, when traditional impregnated structures are subjected to directional forces such as drilling or cutting, the resin layer often fails to support the fiber layer, resulting in delamination or fiber layer breakage, making it difficult to maintain precise shapes and sizes, increasing processing difficulty and risk.

From this, it can be seen that developing a prepreg structure with high strength and reducing the damage to the fiber layer during processing is the goal of the relevant field.

In order to solve the problem that the prepreg structure can maintain high strength and reduce the damage of the fiber layer during processing, the present invention provides a prepreg material, which is a multi-layer structure, which includes at least two prepreg structures, wherein the prepreg structure includes: a fiber resin layer, which is impregnated with a first resin from a fiber layer, the first resin permeates the fiber layer and covers each fiber of the fiber layer; a first resin layer, which is laid on the first surface of a metal layer, and the first resin permeates the first surface of the metal layer to form the The first resin layer; the metal layer is a sheet or a mesh, including the first surface and a second surface; and a second resin layer is laid on the second surface of the metal layer, wherein the thickness of the second resin layer is greater than the thickness of the first resin layer; each of the prepreg structures is stacked in layers, wherein the fiber resin layer is combined with the second resin layer, wherein the first resin and the second resin layer form an interface through the resin adhesion of each other, wherein the first resin and the second resin layer are different resins.

Wherein, the thickness of the first resin layer is less than 0.01 micron.

Wherein, the fiber layer includes a unidirectional fiber or a non-unidirectional fiber.

Among them, the pre-curing method includes temperature-controlled pre-curing, time-controlled pre-curing, pressure-controlled pre-curing, light pre-curing and chemical pre-curing.

The unidirectional fiber includes carbon fiber, glass fiber, aramid fiber (Kevlar), polyethylene fiber, steel fiber or linen fiber.

The non-unidirectional fiber includes nylon fiber, silicon fiber, bamboo fiber, copper fiber or tin fiber.

Wherein, the metal layer comprises a single metal or an alloy.

The single metal includes aluminum (Al), titanium (Ti), stainless steel, copper (Cu), steel (Steel), nickel (Ni), magnesium (Mg), lead (Pb), platinum (Pt), chromium (Cr) or silver (Ag).

The first resin includes a thermosetting resin or a thermoplastic resin, wherein the thermosetting resin includes one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), maleic anhydride resin (BMI), and the thermoplastic resin includes but is not limited to one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), styrene resin (SAN).

The second resin layer includes the thermosetting resin or the thermoplastic resin, wherein the thermosetting resin includes one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), and maleic anhydride resin (BMI), and the thermoplastic resin includes but is not limited to one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), and styrene resin (SAN).

Through the above content, the present invention has the following effects:

1. The metal layer in the prepreg material significantly increases the strength and rigidity of the prepreg material. The metal layer is stronger than the fiber layer, which helps to strengthen the structure of the prepreg material and improve the ability of the prepreg material to withstand external loads, thereby enhancing the overall performance of the prepreg material.

2. The metal layer provides excellent fire resistance, thermal stability and corrosion resistance, and can protect the prepreg material in a high wear environment or a special environment (such as a high temperature or corrosive environment), extending the service life of the prepreg material. In addition, the presence of the metal layer also improves the wear resistance of the prepreg material.

3. The prepreg material is easier to handle during processing, such as cutting and drilling, because of the second resin layer. The second resin layer provides good processing performance, helps the prepreg material maintain its shape and size during the manufacturing process, and reduces the difficulties and damage risks during the processing.

4. The bonding of the first resin layer and the second resin layer strengthens the bonding between the multi-layer structure of the prepreg structure. The first resin layer and the second resin layer form the interface during the final curing, and improve the adhesion between the layers in the multi-layer structure, thereby preventing separation or delamination between the layers, and greatly enhancing the overall strength and stability of the prepreg material.

10: Prepreg structure

11: Fiber resin layer

111:Fiber layer

112: First Resin

12: First resin layer

13:Metal layer

14: Second resin layer

Figure 1 is a schematic diagram of a preferred embodiment of the present invention

Figure 2 is a schematic diagram of a preferred embodiment of the present invention

Please refer to FIG. 1 , the present invention provides a prepreg material, which is composed of a plurality of prepreg structures 10 stacked.

The prepreg structure 10 is a multi-layer structure, which includes a fiber resin layer 11, a first resin layer 12, a metal layer 13 and a second resin layer 14. The prepreg structure 10 has a different material, expansion coefficient, viscosity coefficient or thickness in the multi-layer structure, so that the multi-layer structure in the prepreg structure 10 can be combined with each other and the displacement of the multi-layer structure is reduced, further improving the overall strength of the prepreg structure 10.

Furthermore, the prepreg structure 10 is pre-cured after forming the multi-layer structure, so that the prepreg structure 10 can protect the multi-layer structure and enhance the firmness between the multi-layer structures.

The fiber resin layer 11 is a fiber layer 111 impregnated with a first resin 112, so that the first resin 112 evenly permeates the fiber layer 111 and covers each fiber of the fiber layer 111.

Among them, the pre-curing method includes temperature-controlled pre-curing, time-controlled pre-curing, pressure-controlled pre-curing, light pre-curing and chemical pre-curing.

The fiber layer 111 includes a unidirectional fiber or a non-unidirectional fiber. The unidirectional fiber refers to the fibers arranged in the same direction with relatively few gaps between the fibers, so that the fibers are tightly bonded. The unidirectional fiber can provide the prepreg structure 10 with high strength and high rigidity in one fiber direction, and can also reduce the weight of the prepreg structure 10, so that the prepreg structure 10 can withstand high tensile load applications and has strong rigidity and tensile resistance.

Among them, the non-unidirectional fiber refers to the fiber arranged in multiple directions, and the gap is formed between each fiber, so that the fiber layer 111 has strong toughness and flexibility, and can provide certain strength and rigidity in different directions. The non-unidirectional fiber can provide the prepreg structure 10 with excellent impact resistance and durability.

Preferably, the fiber layer 111 of the present invention uses the unidirectional fiber, which makes the fiber layer 111 unidirectional. The unidirectional fiber includes carbon fiber, glass fiber, aramid fiber (Kevlar), polyethylene fiber, steel fiber or linen fiber, wherein the non-unidirectional fiber includes nylon fiber, silicon fiber, bamboo fiber, copper fiber or tin fiber.

The first resin 112 fully penetrates the fibers of the fiber layer 111, covers each of the fibers, and fills the gaps between the fibers, so that each of the fibers maintains a stable arrangement and distribution. The first resin 112 also provides sufficient fluidity and viscosity, so that the first resin 112 is fully fused and contacts an interface, and enhances the adhesion between the fiber resin layer 11 and the interface, which helps the prepreg material to form a good bond between the multi-layer structure during the subsequent curing process, thereby improving the overall strength and stability of the prepreg material.

Preferably, the first resin 112 can be a thermosetting resin or a thermoplastic resin, wherein the thermosetting resin includes but is not limited to epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), maleic anhydride resin (BMI) or a combination thereof, wherein the thermoplastic resin includes but is not limited to polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), styrene resin (SAN) or a combination thereof.

The first resin layer 12 is part of the first resin 112. When the fiber resin layer 11 is laid on the first surface of the metal layer 13, part of the first resin 112 penetrates the fiber resin layer 11 to the first surface of the metal layer 13 and forms the first resin layer 12.

Preferably, in the embodiment of the present invention, the first resin layer 12 is formed on the first surface of the metal layer 13 to a thickness of less than 0.01 microns.

The metal layer 13 can be a single metal or a mixture of alloys. The metal layer 13 can be a thin sheet or a mesh. Furthermore, the metal layer 13 is pre-treated. The pre-treatment is to cut or stamp the metal and then deoxidize or degrease its surface to form the metal layer 13, so as to further improve the adhesion between the metal layer 13 and the first resin layer 12.

The metal layer 13 provides strength and rigidity to the prepreg structure 10. Since the rigidity of the metal layer 13 is greater than that of the fiber layer 111, the metal layer 13 can strengthen the overall structure of the prepreg structure 10 and increase the ability of the prepreg structure 10 to withstand external loads.

In addition, the metal layer 13 can also improve the durability of the prepreg structure 10 and enhance the wear resistance of the prepreg structure 10. When the prepreg structure 10 is in a high wear environment or requires additional protection, such as a high temperature or corrosive environment, the metal layer 13 provides excellent fire resistance, thermal stability and corrosion resistance.

In the field of electronic equipment and communications, the conductivity and electromagnetic shielding effect of the metal layer 13 can effectively prevent electromagnetic interference, protect electronic components, and improve the electrical performance of the prepreg structure 10. The metal layer 13 enhances the functionality of the prepreg structure 10 and also provides better thermal conductivity, which helps to dissipate heat or maintain the thermal stability of the material.

The fiber resin layer 11 is laid on the first surface of the metal layer 13 by manual lamination, vacuum extrusion and injection.

The material of the metal layer 13 includes one or a combination of aluminum (Al), titanium (Ti), stainless steel, copper (Cu), steel (Steel), nickel (Ni), magnesium (Mg), lead (Pb), platinum (Pt), chromium (Cr) or silver (Ag) or other metal materials or their combinations.

The second resin layer 14 can be the thermosetting resin or the thermoplastic resin. The second resin layer 14 prevents the second surface of the metal layer 13 from being damaged by environmental corrosion, reduces the defects of the second surface of the metal layer 13, and prolongs the service life of the metal layer 13. The second resin layer 14 is laid on the second surface of the metal layer 13. The second resin layer 14, the metal layer 13, the first resin layer 12 and the fiber resin layer 11 together form the multi-layer structure, wherein the expansion coefficient, the viscosity coefficient and the thickness of the second resin layer 14 and the first resin layer 12 can be the same or different.

Preferably, in the embodiment of the present invention, the thickness of the second resin layer 14 is thicker than the first resin layer 12, in order to further prevent the second surface of the metal layer 13 from being damaged by an external force or an external environment.

Furthermore, the second resin layer 14 provides processing performance for the prepreg structure 10, making the prepreg structure 10 easier to handle during processing, such as cutting or drilling, and contributing to the shape and size of a final product.

The preferred embodiment of the present invention does not limit the resin of the second resin layer 14. The resin of the second resin layer 14 can refer to the resin of the first resin 112 mentioned above.

Furthermore, after the prepreg structure 10 forms the multi-layer structure, the pre-curing is performed, and the first resin 112 and the second resin layer 14 are partially cured by the pre-curing. At this time, the first resin 112 and the second resin layer 14 have a higher viscosity and a lower fluidity. The pre-curing helps to provide the bonding strength between the multi-layer structure layers. The pre-curing process can improve the density and uniformity of the multi-layer structure, and can also discharge the air bubbles between the first resin layer 112 and the second resin layer 14, thereby improving the density and uniformity between the multi-layer structure layers. At the same time, after the pre-curing process, the fiber layer 111 and the metal layer 13 can be prevented from contacting the outside world, thereby increasing the material storage life of the fiber layer 111 and the metal layer 13.

Please refer to FIG. 2 , the prepreg material is stacked in layers by at least two prepreg structures 10, wherein the prepreg structures 10 have been precured, wherein each prepreg structure 10 is combined with the second resin layer 14 through the fiber resin layer 11, wherein the first resin 112 and the second resin layer 14 form an interface through the resin adhesion between each other.

Furthermore, the prepreg material can be subjected to a final curing, wherein the first resin 112 and the second resin layer 14 still have unreacted resin. When the final curing is performed, the unreacted resin in the first resin 112 and the second resin layer 14 continues to react through a temperature, and at the same time, the resin between the first resin 112 and the second resin layer 14 produces a cross-linked structure, making the interface more solid, and improving the interlayer adhesion between each prepreg structure 10, avoiding separation or delamination between each prepreg structure 10.

Furthermore, when the prepreg material is processed, such as drilling, cutting, grinding or screw setting, the interface can reduce a directional force that directly destroys the prepreg structure 10. Through the different properties of the first resin 112 and the second resin layer 14, such as the expansion coefficient, the hardness of the resin or the environmental resistance of the resin, the direct fracture or brittle fracture of the multi-layer structure in the prepreg material can be reduced.

Through the above content, the present invention has the following effects:

1. The metal layer 13 in the prepreg material significantly increases the strength and rigidity of the prepreg material, wherein the metal layer 13 is stronger than the fiber layer 111, which helps to strengthen the structure of the prepreg material and improve the ability of the prepreg material to withstand external loads, thereby enhancing the overall performance of the prepreg material.

2. The metal layer 13 provides excellent fire resistance, thermal stability and corrosion resistance, and can protect the prepreg material in a high wear environment or a special environment (such as a high temperature or corrosive environment), extending the service life of the prepreg material. In addition, the presence of the metal layer 13 also improves the wear resistance of the prepreg material.

3. The prepreg material is easier to handle during processing, such as cutting and drilling, because of the second resin layer 14. The second resin layer 14 provides good processing performance, helps the prepreg material maintain its shape and size during the manufacturing process, and reduces the difficulties and damage risks during the processing.

4. The bonding of the first resin 112 and the second resin layer 14 strengthens the bonding between the multi-layer structure of the prepreg structure 10. The first resin 112 and the second resin layer 14 form the interface during the final curing, and improve the adhesion between the layers in the multi-layer structure, thereby preventing separation or delamination between the layers, and greatly enhancing the overall strength and stability of the prepreg material.

10: Prepreg structure

11: Fiber resin layer

111:Fiber layer

112: First Resin

12: First resin layer

13:Metal layer

14: Second resin layer

Claims (10)

A prepreg material is a multi-layer structure, which includes at least two prepreg structures, wherein the prepreg structure includes: A fiber resin layer, which is formed by impregnating a first resin into a fiber layer, the first resin permeating the fiber layer and covering each fiber of the fiber layer; A first resin layer, which is formed by laying the fiber resin layer on the first surface of a metal layer, and the first resin permeating the first surface of the metal layer to form the first resin layer; The metal layer is in the form of a thin sheet or a mesh, and includes the first surface and a second surface; and A second resin layer is laid on the second surface of the metal layer, wherein the thickness of the second resin layer is greater than the thickness of the first resin layer; The prepreg structures are stacked in layers, wherein the fiber resin layer is combined with the second resin layer, wherein an interface is formed between the first resin and the second resin layer through the resin adhesion between each other, wherein the first resin and the second resin layer are different resins. In the prepreg material as described in claim 1, the thickness of the first resin layer is less than 0.01 microns. In the prepreg material as described in claim 2, the fiber layer includes a unidirectional fiber or a non-unidirectional fiber. The prepreg material as described in claim 3, wherein the precuring method includes temperature-controlled precuring, time-controlled precuring, pressure-controlled precuring, light precuring and chemical precuring. In the prepreg material as described in claim 4, the unidirectional fiber includes carbon fiber, glass fiber, aramid fiber (Kevlar), polyethylene fiber, steel fiber or linen fiber. In the prepreg material as described in claim 4, the non-unidirectional fiber includes nylon fiber, silicon fiber, bamboo fiber, copper fiber or tin fiber. In the prepreg material as described in any one of claims 1 to 6, the metal layer comprises a single metal or an alloy. In the prepreg material as described in claim 7, the single metal includes aluminum (Al), titanium (Ti), copper (Cu), steel (Steel), nickel (Ni), magnesium (Mg), lead (Pb), platinum (Pt), chromium (Cr) or silver (Ag). As for the prepreg material described in claim 8, the first resin comprises a thermosetting resin or a thermoplastic resin, wherein the thermosetting resin comprises one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), maleic anhydride resin (BMI), and the thermoplastic resin comprises one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), styrene resin (SAN). In the prepreg material as described in claim 9, the second resin layer comprises the thermosetting resin or the thermoplastic resin, wherein the thermosetting resin comprises one or a combination of epoxy resin (EP), polyester resin (UP), phenolic resin (PF), vinyl ester resin (VE), maleic anhydride resin (BMI), and the thermoplastic resin comprises one or a combination of polyetheretherketone (PEEK), polyurethane resin (PUR), polyamide resin (PA), polyetherimide (PEI), styrene resin (SAN).