U.S. patent application number 16/129931 was filed with the patent office on 2019-04-18 for fiber composite and manufacturing method thereof.
The applicant listed for this patent is INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE. Invention is credited to Shir-Joe Liou, Jih-Hsiang Yeh.
Application Number | 20190111667 16/129931 |
Document ID | / |
Family ID | 66097248 |
Filed Date | 2019-04-18 |
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United States Patent
Application |
20190111667 |
Kind Code |
A1 |
Liou; Shir-Joe ; et
al. |
April 18, 2019 |
FIBER COMPOSITE AND MANUFACTURING METHOD THEREOF
Abstract
A fiber composite and manufacturing method thereof are provided.
The fiber composite material includes: a plurality of fiber prepreg
layers each including a first resin and fibers impregnated with the
first resin; and at least one composite resin layer disposed
between two of the fiber prepreg layers and including multi-layered
carbon nanotubes and a second resin, wherein the surface of the
multi-layered carbon nanotube has reactive functional groups
containing an amine group, a carboxyl group, a hydroxyl group or an
acyl chloride group, wherein the at least one composite resin layer
and the fiber prepreg layers together form a hollow tube and the
layer ratio of the at least one composite resin film layer to the
fiber prepreg layers is 1:4 to 1:7.
Inventors: |
Liou; Shir-Joe; (Hsinchu,
TW) ; Yeh; Jih-Hsiang; (Hsinchu, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE |
Hsinchu |
|
TW |
|
|
Family ID: |
66097248 |
Appl. No.: |
16/129931 |
Filed: |
September 13, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62573721 |
Oct 18, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 38/10 20130101;
B32B 27/34 20130101; B32B 27/20 20130101; B32B 27/38 20130101; B32B
37/14 20130101; B32B 37/12 20130101; B32B 27/306 20130101; B32B
27/12 20130101; B32B 27/08 20130101 |
International
Class: |
B32B 27/08 20060101
B32B027/08; B32B 37/12 20060101 B32B037/12; B32B 37/14 20060101
B32B037/14; B32B 27/12 20060101 B32B027/12; B32B 27/20 20060101
B32B027/20; B32B 27/30 20060101 B32B027/30; B32B 27/34 20060101
B32B027/34; B32B 27/38 20060101 B32B027/38 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 27, 2017 |
TW |
106145989 |
Claims
1. A fiber composite material, comprising: a plurality of fiber
prepreg layers each comprising a first resin and fibers impregnated
with the first resin; and at least one composite resin layer
disposed between two of the fiber prepreg layers to form a hollow
tube with the plurality of fiber prepreg layers, wherein the at
least one composite resin layer comprises multi-layered carbon
nanotubes and a second resin, and each of the multi-layered carbon
nanotubes has reactive functional groups containing an amine group,
a carboxyl group, a hydroxyl group or an acyl chloride group on its
surface, and wherein the layer ratio of the at least one composite
resin layer to the fiber prepreg layers is 1:4 to 1:7.
2. The fiber composite material of claim 1, wherein the first resin
and the second resin are identical.
3. The fiber composite material of claim 1, wherein the first resin
and the second resin are different.
4. The fiber composite material of claim 1, wherein the first resin
is a thermoplastic resin or a thermosetting resin.
5. The fiber composite material of claim 1, wherein the second
resin is a thermoplastic resin or a thermosetting resin.
6. The fiber composite material of claim 1, wherein the surface
area of the multi-layered carbon nanotube is 100 m.sup.2/g to 300
m.sup.2/g.
7. The fiber composite material of claim 1, wherein the amount of
the multi-layered carbon nanotubes in the at least one composite
resin layer is 0.5 wt % to 8 wt %.
8. The fiber composite material of claim 1, wherein the fibers are
carbon fibers, glass fibers, aromatic polyamide fibers, boron
fibers, nylon fibers, polyethylene terephthalate fibers, cotton
fibers, wool fibers, steel fibers, aluminum fibers or ceramic
whisker fibers.
9. A method for manufacturing a fiber composite material,
comprising: placing at least one composite resin layer on a fiber
prepreg layer comprising a first resin and fibers impregnated with
the first resin, wherein the at least one composite resin layer
comprises multi-layered carbon nanotubes and a second resin and
each of the multi-layered carbon nanotubes has reactive functional
groups containing an amine group, a carboxyl group, a hydroxyl
group or an acyl chloride group; wrapping the fiber prepreg layer
and the at least one composite resin layer to form a hollow tube,
with the layer ratio of the at least one composite resin layer to
the fiber prepreg layer between the outer wall and the inner wall
of the hollow tube to be 1:4 to 1:7; and molding the hollow
tube.
10. The method of claim 9, wherein placing at least one composite
resin layer comprises placing a plurality of composite resin layers
on the fiber prepreg layer.
11. The method of claim 10, wherein the plurality of the composite
resin layers are spaced apart.
12. The method of claim 9, wherein the first resin and the second
resin are identical.
13. The method of claim 9, wherein the first resin and the second
resin are different.
14. The method of claim 9, wherein the first resin is a
thermoplastic resin or a thermosetting resin.
15. The method of claim 9, wherein the second resin is a
thermoplastic resin or a thermosetting resin.
16. The method of claim 9, wherein the surface area of the
multi-layered carbon nanotube is 100 m.sup.2/g to 300
m.sup.2/g.
17. The method of claim 9, wherein the amount of the multi-layered
carbon nanotubes in the at least one composite resin layer is 0.5
wt % to 8 wt %.
18. The method of claim 9, wherein the fibers are carbon fibers,
glass fibers, aromatic polyamide fibers, boron fibers, nylon
fibers, polyethylene terephthalate fibers, cotton fibers, wool
fibers, steel fibers, aluminum fibers or ceramic whisker fibers.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Taiwan
Application Serial No. 106145989, filed on Dec. 27, 2017, and U.S.
Provisional Application No. 62/573,721, filed on Oct. 18, 2017. The
entirety of the above-mentioned patent applications is hereby
incorporated by reference herein.
TECHNICAL FIELD
[0002] The present disclosure relates to a fiber composite material
with vibration damping characteristic and a manufacturing method
thereof.
BACKGROUND
[0003] It is an essential development trend nowadays to use high
molecular fiber composite material combined with other products of
various functionality and uses in view of today's demand for
properties such as light weighted, high strength and high
flexibility in design to develop products of various use. Due to
the demand for low-profile and light weighted products, design
generally focuses on high strength. However, high physical strength
often comes with the disadvantage of increased brittleness, causing
the material to break when subject to a force. In order to solve
this problem, it is necessary to increase the damping
characteristic to increase the vibration damping effect when
subject to a force.
[0004] When a transport used robotic arm moves at a high speed (2.8
m/s), or rotates (210.degree./s), it will cause displacement,
deformation and vibration. And when the time it took for the
vibration of the high molecular fiber composite material fabricated
robotic arm to stop is too long, it is required to wait for longer
time for the swing to stop or the vibration to reduce to an
acceptable degree for the next movement. As a result, this will
affect the productivity. Therefore, it is required to reduce the
decay time of the vibration to ensure good productivity.
[0005] Several references have indicated that a fiber composite
material has the effect of vibration damping; however, the extent
of vibration damping is still insufficient. Thus, there is a need
to increase the vibration damping as well as maintaining the
material hardness.
SUMMARY
[0006] The present disclosure provides a fiber composite material,
including: a plurality of fiber prepreg layers each including a
first resin and fibers impregnated with the first resin; and at
least one composite resin layer disposed between two of the fiber
prepreg layers to form a hollow tube with the plurality of fiber
prepreg layers, wherein the at least one composite resin layer
includes multi-layered carbon nanotubes and a second resin, and
each of the multi-layered carbon nanotubes has reactive functional
groups containing an amine group, a carboxyl group, a hydroxyl
group or an acyl chloride group on its surface, and wherein the
layer ratio of the at least one composite resin layer to the fiber
prepreg layers is 1:4 to 1:7.
[0007] The present disclosure further provides a manufacturing
method for the fiber composite material, including: placing at
least one composite resin layer on a fiber prepreg layer which
includes a first resin and fibers impregnated with the first resin,
wherein the at least one composite resin layer includes
multi-layered carbon nanotubes and a second resin and each of the
multi-layered carbon nanotubes has reactive functional groups
containing an amine group, a carboxyl group, a hydroxyl group or an
acyl chloride group; wrapping the fiber prepreg layers and the at
least one composite resin layer to form a hollow tube, with the
layer ratio of the at least one composite resin layer to the fiber
prepreg layers between the outer wall and the inner wall of the
hollow tube to be 1:4 to 1:7; and molding the hollow tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic view of the manufacturing method of a
fiber composite material in accordance with the present
disclosure;
[0009] FIG. 2 is a cross-sectional view of a fiber composite
material in accordance with the present disclosure; and
[0010] FIG. 3 is a side cross-sectional view of a fiber composite
material in accordance with the present disclosure.
DETAILED DESCRIPTION
[0011] In the following detailed description, for purposes of
explanation, numerous specific details are set forth in order to
provide a thorough understanding of the disclosed embodiments. It
will be apparent, however, that one or more embodiments may be
practiced without these specific details. In other instances,
well-known structures and devices are schematically shown in order
to simplify the drawing. In the fiber composite material of the
present disclosure, it is discovered that the layer ratio of the at
least one composite resin layer to the fiber prepreg layers between
the outer wall and the inner wall of the hollow tube at 1:4 to 1:7
can greatly increase the vibration damping effect while maintaining
the material hardness.
[0012] The present disclosure further discloses a manufacturing
method for the fiber composite material, including: placing at
least one composite resin layer on a fiber prepreg layer which
includes a first resin and fibers impregnated with the first resin,
wherein the at least one composite resin layer include
multi-layered carbon nanotubes and a second resin and each of the
multi-layered carbon nanotubes has reactive functional groups
containing an amine group, a carboxyl group, a hydroxyl group or an
acyl chloride group; wrapping the fiber prepreg layer and the at
least one composite resin layer to form a hollow tube, such that
the layer ratio of the at least one composite resin layer to the
fiber prepreg layer between the outer wall and the inner wall of
the hollow tube is 1:4 to 1:7; and molding the hollow tube.
[0013] In general, the manufacturing method of the fiber prepreg
layers comprises hand lay-up layer method, spraying, lamination,
continuous lamination, resin transfer molding, filament winding,
sheet molding compound (SMC), bulk molding compound (BMC), prepreg
molding, autoclaving, etc. In an embodiment, the fiber can be
selected from at least one of the followings:
[0014] carbon fiber, glass fiber, aromatic polyamide fiber (such as
Kevlar), boron fiber, nylon fiber, polyethylene terephthalate fiber
(such as Tetoron), cotton fiber, wool fiber, steel fiber, aluminum
fiber or ceramic whisker fiber. In the present disclosure, the
fibers of the fiber prepreg layers are impregnated with the first
resin and the composite resin layer is formed by mixing
multi-layered carbon nanotubes with second resin, wherein the first
resin and the second resin can be the same or different, which
includes thermoplastic resin or thermosetting resin. Thermoplastic
resins may include, e.g., polycarbonate (PC), nylon, polypropylene
(PP), polyphenylene sulfide (PPS) orpolyetheretherketone (PEEK);
and thermosetting resin may include, e.g., epoxy resin.
[0015] In an embodiment, the thickness of the fiber prepreg layer
may range from 50 .mu.m to 200 .mu.m. The thickness of the
composite resin layer may range from 5 .mu.m to 200 .mu.m. Said
thickness can be adjusted according to the rigid strength
requirements of the prepared components.
[0016] It is believed that when the force cause the resin result in
a relative displacement (sliding) with respect to the wall of the
carbon nanotube, the integration of the displacement difference and
the shear force at the interface equals to the energy loss
produced, which is the principal of vibration damping.
[0017] In an embodiment, multi-layered carbon nanotubes with
multiple layered walls are utilized to provide more micro sliding
compared to single layered carbon nanotubes, such that the
accumulated damping characteristic can be amplified quickly, to
provide more efficient vibration damping.
[0018] On the other hand, the surface of the carbon nanotube is
modified to have reactive functional groups containing an amine
group, a carboxyl group, a hydroxyl group or an acyl chloride
group, but not limited thereto. Please refer to J. Mater. Chem.,
2011, 21, 7337-7342 for the modification method.
[0019] In addition, in an embodiment, the surface area of the
carbon nanotube is in a range from 100 to 300 m.sup.2/g, and the
carbon nanotubes with such range of surface area can be more mixed
with the second resin, and 0.5-8wt % carbon nanotubes are present
in at least one composite resin layer while 92-99.5 wt % of second
resin is present in the at least one composite resin layer.
[0020] According to the manufacturing method of the present
disclosure, the fiber composite material is heated to be molded.
During the heating process, the reactive functional groups of the
carbon nanotubes bonded with the first resin and the second resin
to cure.
[0021] In general, the manufacturing method for forming fiber
composite material adopts traditional stacking method, i.e.,
superimposing layers of different materials until reaching certain
numbers of layers, followed by wrapping and molding. However this
method can only produce one fiber composite material at a time, and
is therefore less economical for large industrial scale
production.
[0022] Hence, in another embodiment, the manufacturing method of
the fiber composite material of the present disclosure involves
placing at least one composite resin layer on a fiber prepreg
layer, and based on the practical needs, it is applicable to place
a plurality of composite resin layers on the fiber prepreg layer,
allowing the plurality of composite resin layers to be spaced
apart, such that after the hollow tube is formed, the layer ratio
of the at least one composite resin layer and the fiber prepreg
layer is 1:4 to 1:7 between the outer wall to and the inner wall of
the hollow tube. Specifically, when placing the plurality of
composite resin layers, each of the composite resin layer is placed
with a space from each other along the wrapping direction of the
fiber prepreg layer such that it is possible to more economically
produce fiber composite materials in large quantities by the
machine, in accordance with the manufacturing method of the present
disclosure.
[0023] Moreover, according to the manufacturing method of the
present disclosure, the shape of the hollow tube includes, but not
limited to, circular, elliptical, square, and rectangular
shape.
[0024] The following embodiments are provided below to illustrate
the details of the present disclosure, however it should be noted
that the present disclosure should not be limited by the
illustrations of the embodiments below.
First Embodiment
[0025] The manufacturing method and the condition of the first
embodiment of the present disclosure (number: 4L) are described as
follows. Fiber: carbon fiber (Toray, T700SC, 12K); resin: epoxy
resin (Dow Chemical, Epon 828); multi-layered carbon nanotubes
(A-MWCNT1020, Scientech); modified functional group amine group
(based on the method of J. Mater. Chem., 2011, 21, 7337-7342).
[0026] As shown in FIG. 1, a composite resin layer 110 (70 .mu.m
thickness, 5 wt % of multi-layered carbon nanotubes in the
composite resin layer) is placed on the fiber prepreg layers 100
(100 .mu.m thickness). The composite is formed by alternately
placing the composite resin layer so that the composite resin layer
and the fiber prepreg layer are in a layer ratio of 1:5. During
molding, a core mold is prepared with a plastic air pocket,
wrapping the composite structure in the direction indicated by the
arrow, then placing the core mold that is covered by the composite
structure into another aluminum molding equipment and leaving the
plastic air bag in while removing the core mold, then pumping air
(25-30 psi) into the space without the core mold to support the
hollow tube to be formed. Meanwhile, applying a pressure of 20-25
psi at the side of the aluminum molding equipment and heated at
160.degree. C. for 40 minutes. Afterwards, the fiber composite
material can be taken out until the temperature drops to room
temperature. The wrapped composite resin layer is positioned
between layer 4 and layer 5 of the fiber prepreg layer, between
layer 8 and layer 9 of the fiber prepreg layer, between layer 12
and layer 13 of the fiber prepreg layer and between layer 16 and
layer 17 of the fiber prepreg layer.
[0027] As shown in FIG. 2, the fiber composite material 1 is in a
form of a hollow tube, including: fiber prepreg layer 100 and
composite resin layer 110, where the cross-sectional view is shown
in FIG. 3. The size of the manufactured fiber composite material is
as follows: 450 mm in length; 20 mm in diameter, 4.0 mm in
thickness.
Second Embodiment
[0028] The manufacturing method and condition of the second
embodiment (number: 2L) of the present disclosure are the same as
that in the first embodiment, where the spacing relation between
the composite resin layer and the fiber prepreg layer is changed
such that the wrapped composite resin layer is located between
layer 7 and layer 8 and between layer 13 and layer 14 of the fiber
prepreg layers, and the ratio of the layers of the composite resin
layer to the layer of the fiber prepreg layers is 1:10.
Third Embodiment
[0029] The manufacturing method and condition of the third
embodiment (number: 3L) of the present disclosure are the same as
that in the first embodiment, where the spacing relation between
the composite resin layer and the fiber prepreg layer is changed
such that the wrapped composite resin layer is located between
layer 5 and layer 6, between layer 10 and layer 11, and between
layer 15 and layer 16 of the fiber prepreg layers, and the ratio of
the layers of the composite resin layer to the layers of the fiber
prepreg layer is 1:6.7.
Forth Embodiment
[0030] The manufacturing method and condition of the forth
embodiment (number: 5L) of the present disclosure are the same as
that in the first embodiment, where the spacing relation between
the composite resin layer and the fiber prepreg layer is changed
such that the wrapped composite resin layer is located between
layer 4 and layer 5, between layer 7 and layer 8, between layer 10
and layer 11, between layer 13 and layer 14, and between layer 16
and 17 of the fiber prepreg layers, and the ratio of the layers of
the composite resin layer to the layers of the fiber prepreg layer
is 1:4.0.
Fifth Embodiment
[0031] The manufacturing method and condition of the fifth
embodiment (number: 6L) of the present disclosure are the same as
that in the first embodiment, where the spacing relation between
the composite resin layer and the fiber prepreg layer is changed
such that the wrapped composite resin layer is located between
layer 3 and layer 4, between layer 6 and layer 7, between layer 9
and layer 10, between layer 11 and layer 12, and between layer 14
and 15 and between layer 17 and layer 18 of the fiber prepreg
layers, and the ratio of the layers of the composite resin layer to
the layers of the fiber prepreg layer is 1:3.3.
Comparative Example 1
[0032] The manufacturing method and condition of comparative
example 1 (number: 0) of the present disclosure are the same as
that in the first embodiment, where no composite resin layer is
placed on a fiber prepreg layer to obtain a fiber composite
material having 20 layers of fiber prepreg layers after
wrapping.
[0033] Measuring of vibration decay time (s) is carried out using
laser displacement meter (Polytec OFV 350 Sensor hand), to measure
the time it takes from the start of vibration until vibration is
stopped (fix one end of the sample while apply a 2 Kg loading then
release the tension to allow vibration). The results are listed in
table 1.
[0034] According to table 1, comparing with the comparison example
1 without a composite resin layer, the embodiments from 2L to 6L
having composite resin layer can reach 53.5% to 89.2% full
amplitude reduction. Besides, the natural frequency of table 1
refers to the dynamic characteristic existed in an object which is
directly proportional to the square root of the rigid strength of
the system and inversely proportional to the square root of the
mass. As such, as shown in table 1, even though more layers of the
composite resin layers produce greater full amplitude reduction,
composite resin layers are softer than fiber prepreg layers, such
that it is not possible to increase the layers of composite resin
layer infinitely. The optimal layer ratio of composite resin layers
to fiber prepreg layers is at a range from 1:4 to 1:7. In such
range, the vibration damping efficiency and the strength of the
fiber composite material increase simultaneously, whereas when the
layer ratio between composite resin layers and fiber prepreg layers
is 1:3.3 (number: 6L), even though the vibration damping efficiency
continues to increase, the strength of the fiber composite material
drops, which not suitable for products that has a high demand for
rigid strength.
[0035] It will be apparent to those skilled in the art that various
modifications and variations can be made to the disclosed methods
and materials. It is intended that the specification and examples
be considered as exemplary only, with the true scope of the
disclosure being indicated by the following claims and their
equivalents.
TABLE-US-00001 TABLE 1 Composite Carbon Fiber prepreg resin layer
Carbon nanotube No. layer number number nanotube amount Locations
of composite resin layers 0 20 0 none 0 wt % -- 2L 20 2
multi-layered 5 wt % between layer 7 and layer 8; between layer 13
carbon and layer 14 nanotube 3L 20 3 multi-layered 5 wt % between
layer 5 and layer 6; between layer 10 carbon and layer 11; and
between layer 15 and layer nanotube 16 4L 20 4 multi-layered 5 wt %
between layer 4 and layer 5; between layer 8 carbon and layer 9;
between layer 12 and layer 13; nanotube and between layer 16 and
layer 17 5L 20 5 multi-layered 5 wt % between layer 4 and layer 5;
between layer 7 carbon and layer 8; between layer 10 and layer 11;
nanotube between layer 13 and layer 14; and between layer 16 and
layer 17 6L 20 6 multi-layered 5 wt % between layer 3 and layer 4;
between layer 6 carbon and layer 7, between layer 9 and layer 10;
nanotube between layer 11 and layer 12; between layer 14 and layer
15; and between layer 17 and layer 18 Layer ratio between Full
amplitude reduction composite resin layers and Full amplitude at %
in comparison with the Natural frequency No. fiber prepreg layers
0.2 seconds comparative example (Hz) 0 -- 0.575 nm N/A 140.0 2L
1:10.0 0.267 nm 53.50% 143.0 3L 1:6.7 0.202 nm 64.80% 147.0 4L
1:5.0 0.162 nm 72.20% 148.0 5L 1:4.0 0.150 nm 73.80% 145.0 6L 1:3.3
0.063 nm 89.20% 122.0
* * * * *