Thermoplastic composite material, preparation method therefor and use thereof

Patent metadata

Field	Value
Publication number	US-12508784-B2
Application number	US-202118250234-A
Country	US
Kind code	B2
Filing date	Oct 30, 2021
Priority date	Oct 30, 2020
Publication date	Dec 30, 2025
Grant date	Dec 30, 2025

Abstract

A thermoplastic composite material has an inner layer material and at least one layer of outer layer material. The inner layer material is a core layer that contains fiber bundles, a first thermoplastic resin and a first auxiliary agent; and the at least one layer of outer layer material wraps the core layer and is a resin layer comprising a second thermoplastic resin and an optional second auxiliary agent. The fiber bundles extend continuously from one end of the core layer to the opposite end thereof. The inner layer-outer layer composite structure improves the processing performance of the thermoplastic composite material and the lubricity between fibers and resin matrixes during injection molding, and improves the fluidity of the fibers in a resin matrix melt.

First claim

The invention claimed is:

1 . A thermoplastic composite material, comprising an inner core embedded in at least one layer of outer layer material, wherein:
the inner core comprises a plurality of fiber bundles distributed in a mixture of a first thermoplastic resin and a first auxiliary agent, the at least one layer of outer layer material is a resin layer comprising a second thermoplastic resin and an optional second auxiliary agent, the plurality of fiber bundles extend continuously from a first end of the inner core to a second end thereof, the first thermoplastic resin and the second thermoplastic resin are the same or different, and each is independently at least one selected from polypropylene, polyethylene, polystyrene, polyvinyl chloride, polyacrylonitrile-butadiene-styrene copolymer, polyacrylonitrile-styrene copolymer, polyformaldehyde, polyamide, polyethylene terephthalate, polybutylene terephthalate, polymethyl methacrylate, polycarbonate, polyphenyl ether, polyurethane, polyether ether ketone, polyphenylene sulfide, and alloy polymers thereof, and a melt flow rate of the first thermoplastic resin under conditions of 230° C. and 2.16 kg load is 60-8000 g/10 min, a melt flow rate of the second thermoplastic resin under conditions of 230° C. and 2.16 kg load is 0.1-8000 g/10 min, and the melt flow rate of the first thermoplastic resin at 230° C. and under a 2.16 kg load differs from the melt flow rate of the second thermoplastic resin at 230° C. and under a 2.16 kg load.

2 . The thermoplastic composite material according to claim 1 , wherein the thermoplastic composite material in the shape of strips, rods, or granules, and the length of the thermoplastic composite material in the shape of strips, rods, or granules is 5-30 mm.

3 . The thermoplastic composite material according to claim 1 , wherein in the inner core, an amount of the first thermoplastic resin is 1-90 parts by weight; and an amount of the plurality of fiber bundles is 10-110 parts by weight; and/or
in the inner core, a weight ratio of the plurality of fiber bundles to the first thermoplastic resin is 0.25-6:1; and/or in the outer layer material, an amount of the second thermoplastic resin is 1-110 parts by weight.

4 . The thermoplastic composite material according to claim 1 , wherein the inner core does not contain non-orientated short fibers, or the outer layer material does not contain fiber.

5 . The thermoplastic composite material according to claim 1 , wherein the outer layer material contains short fibers.

6 . The thermoplastic composite material according to claim 1 , wherein the plurality of fiber bundles comprises at least one fiber selected from glass fiber, carbon fiber, basalt fiber, aromatic polyamide fiber, stainless steel fiber, synthetic resin fiber, and mineral fiber.

7 . The thermoplastic composite material according to claim 1 , wherein when the melt flow rate of the second thermoplastic resin under conditions of 230° C. and 2.16 kg load is 800-8000 g/10 min, the weight ratio of the second thermoplastic resin to the first thermoplastic resin is less than 0.25:1; and/or
when the first thermoplastic resin and the second thermoplastic resin are selected from nylon 6, nylon 66, and a mixture of nylon 6 and nylon 66, a viscosity of the nylon 6 and nylon 66 is 1.8-3.5.

8 . The thermoplastic composite material according to claim 1 , wherein on a basis that the first thermoplastic resin has a mass of 100 parts by weight, the first auxiliary agent comprises 0.5-15 parts by weight of a compatilizer, 0.05-3 parts by weight of an antioxidant, and 0.05-2.5 parts by weight of a lubricant;
on a basis that the second thermoplastic resin has a mass of 100 parts by weight, the second auxiliary agent independently comprises 0.5-15 parts by weight of a compatilizer, 0.05-3 parts by weight of an antioxidant, and 0.05-2.5 parts by weight of a lubricant; and/or the compatilizer is at least one selected from graft modified polymers of polar monomers; and/or the antioxidant is at least one selected from tetra [β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionic acid] pentaerythritol ester, tri [2,4-di-tert-butylphenyl] phosphite ester, octadecyl β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, 2,2′-methylene bis (4-methyl-6-tert-butylphenol), 1,1,3-tri (2-methyl-4-hydroxyl-5-tert-butylphenyl) butane, and bis (2,4-di-tert-butylphenol) pentaerythritol diphosphite; and/or the lubricant is at least one selected from ethylene bis stearamide, calcium stearate, polyethylene wax, pentaerythritol stearate, silicone, polyethylene glycol, and fluorine-containing resin; and/or the first auxiliary agent comprises at least one selected from slip agent, antistatic agent, and plasticizer; and/or the second auxiliary agent comprises at least one selected from slip agent, antistatic agent, plasticizer, nucleating agent, light stabilizer, flame retardant, heat stabilizer, color master, and filler.

9 . The thermoplastic composite material according to claim 8 , wherein the first auxiliary agent and the second auxiliary agent each independently comprises 2-30 parts by weight of an electrical insulation modifier.

10 . The thermoplastic composite material according to claim 9 , wherein on the basis of the first thermoplastic resin and the second thermoplastic resin having a mass of 100 parts by weight, the first auxiliary agent and the second auxiliary agent each independently comprise 5-25 parts by weight of the electrical insulation modifier;
and/or, the electrical insulation modifier is at least one of the following a) to e): a) alkyl and/or alkoxy graft modified polypropylene, which comprises a structural unit derived from co-polypropylene and a structural unit derived from acrylate monomer and optional acrylic monomer; b) aromatic olefin graft modified polypropylene, which comprises a structural unit derived from co-polypropylene and a structural unit derived from styrene monomer; c) silane modified polypropylene graft, which comprises a structural unit derived from co-polypropylene and a structural unit derived from silane monomer containing alkenyl; d) polypropylene graft containing an acid anhydride group, which comprises a structural unit derived from co-polypropylene, a structural unit derived from maleic anhydride monomer, and a structural unit derived from alkenyl-containing polymeric monomer; and/or e) polypropylene graft heterocyclic ring modified material, which comprises a structural unit derived from co-polypropylene and a structural unit derived from heterocyclic ring monomer containing alkenyl.

11 . The thermoplastic composite material according to claim 8 , wherein on the basis of the first thermoplastic resin and the second thermoplastic resin respectively having a mass of 100 parts by weight, the first auxiliary agent and the second auxiliary agent each independently comprise at least one of 1-15 parts by weight of the compatilizer, 0.1-1 parts by weight of the antioxidant, and 0.5-2.5 parts by weight of the lubricant; and/or
the polar monomer is selected from at least one of a group consisting of maleic anhydride, maleic anhydride derivative, propenoic acid, and acrylate derivative; and/or the polymer is selected from at least one of a group consisting of polyethylene, polypropylene, ethylene-α-olefin copolymer, and propylene-α-olefin copolymer.

12 . The thermoplastic composite material according to claim 1 , wherein in the inner core, an amount of the first thermoplastic resin is 20-70 parts by weight; and
an amount of the plurality of fiber bundles is 20-110 parts by weight; and/or in the inner core, a weight ratio of the plurality of fiber bundles to the first th

Assignees

• China Petroleum & Chem Corp
• Beijing Res Inst Chemical Ind China Petroleum & Chemical Corp

Inventors

• Gao Dali
• Li Changjin
• Zhang Shijun
• Xu Kai
• Kang Peng
• Zhang Qi
• Yin Hua
• Lv Mingfu
• Kong Dehui
• Xin Qi
• Cai Tao
• Dong Mu
• Shao Jingbo
• Shi Hongwei
• Sun Changhui
• Bai Yiqing
• Tan Yigang
• Li Guang
• Gao Xiaoyong
• He Jinqi
• Li meijie
• Xu Meng
• Chou Baige
• Lv Yun
• Ren Yueming

Classifications

• D02G3/36

  Cored or coated yarns or threads ({D02G3/34, D02G3/40 take precedence}; elastic yarns or threads D02G3/32) · CPC title

• B29K2105/0872

  Prepregs · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• B29C70/16 Primary

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title

• B29C70/52 Primary

  Pultrusion, i.e. forming and compressing by continuously pulling through a die · CPC title