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KR-20260066221-A - CARBON FIBER PREPREG LAMINATED PLATE WITH IMPROVED FLATNESS

KR20260066221AKR 20260066221 AKR20260066221 AKR 20260066221AKR-20260066221-A

Abstract

A carbon fiber prepreg laminate with improved flatness according to one embodiment of the present invention comprises an intermediate prepreg layer comprising a first carbon fiber and a first matrix resin, and a second carbon fiber and a second matrix resin, and includes a surface prepreg layer laminated on both sides of the intermediate prepreg layer, wherein the first carbon fiber of the intermediate prepreg layer and the second carbon fiber of the surface prepreg layer are laminated in an arrangement direction orthogonal to each other, and the tensile modulus in the direction of the first carbon fiber is 1.5 times or more of the tensile modulus in the direction of the second carbon fiber, thereby having excellent flatness of 150 μm or less at a thickness of 50 to 200 μm.

Inventors

  • 김현석
  • 이재원

Assignees

  • 도레이첨단소재 주식회사

Dates

Publication Date
20260512
Application Date
20241104

Claims (9)

  1. An intermediate prepreg layer comprising a first carbon fiber and a first matrix resin; and A surface prepreg layer comprising a second carbon fiber and a second matrix resin, laminated on both sides of an intermediate prepreg layer; Includes, The first carbon fiber of the intermediate prepreg layer and the second carbon fiber of the surface prepreg layer are stacked in an arrangement direction orthogonal to each other, and A carbon fiber prepreg laminate with improved flatness, wherein the tensile modulus in the first carbon fiber direction is at least 1.5 times the tensile modulus in the second carbon fiber direction.
  2. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, having a thickness of 50 to 200 μm.
  3. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, wherein the thickness ratio of the intermediate prepreg layer to the surface prepreg layer is 2:1 to 5:1.
  4. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, wherein the ratio of the elastic modulus of the first carbon fiber and the second carbon fiber is 1:1 to 2.5:1.
  5. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, wherein the weight ratio of the first carbon fiber of the intermediate prepreg layer to the second carbon fiber of the surface prepreg layer is 2:1 to 6:1.
  6. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, wherein the intermediate prepreg layer comprises 30 to 40 parts by weight of a first matrix resin per 100 parts by weight of the entire intermediate prepreg layer.
  7. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, wherein the surface prepreg layer comprises 38 to 50 parts by weight of a second matrix resin per 100 parts by weight of the entire surface prepreg layer.
  8. In paragraph 1, A carbon fiber prepreg laminate with improved flatness, wherein the first matrix resin and the second matrix resin comprise at least one selected from epoxy resin, vinyl ester resin, and phenolic resin.
  9. In paragraph 1, A carbon fiber prepreg laminate with improved flatness is a carbon fiber prepreg laminate with improved flatness having a flatness of 150㎛ or less at a thickness of 50 to 200㎛.

Description

Carbon fiber prepreg laminated plate with improved flatness The present invention relates to a carbon fiber prepreg laminate with improved flatness, and more specifically, to a carbon fiber prepreg laminate with improved flatness that has excellent flatness by suppressing the occurrence of bending due to residual stress while having a thin thickness of 200 μm or less when manufacturing carbon fiber composite materials. In general, carbon fiber composites are widely used in sports and leisure, aircraft, automobiles, railways, electronics, and other general industries due to their high specific strength and specific modulus of elasticity. Furthermore, particularly in the automotive sector, there is a growing demand for vehicle lightweighting in recent years driven by regulations on carbon dioxide emissions and fuel efficiency, and carbon fiber composites are attracting attention as a material capable of meeting these demands. Prepreg, an intermediate product in which carbon fibers are pre-impregnated with a matrix resin, is applied as a method for manufacturing such carbon fiber composites. When manufacturing carbon fiber composites using prepreg, it is easy to increase the fiber content, which significantly affects the mechanical properties of the carbon fiber composite, or to uniformly manage the target fiber content; it is also easy to reduce internal defects such as voids and improve properties such as heat resistance or impact strength. Unidirectional carbon fiber prepregs, widely used as such prepregs, are representative anisotropic materials characterized by differences in physical properties between the fiber direction and the direction perpendicular to the fibers. Due to these differences in properties depending on the fiber direction, carbon fiber composites formed by laminating unidirectional carbon fiber prepregs exhibit warping of the molded plate caused by differences in the coefficient of thermal expansion depending on the direction and the resulting residual stress. In particular, carbon fiber composite materials used as structural materials generally have a thick thickness, so residual stress caused by the high bending stiffness of the material itself can be ignored. However, as the thickness of the carbon fiber composite molded plate decreases, residual stress becomes higher than the bending stiffness, making it easier for bending to occur, and there is a problem of reduced flatness due to localized bending. FIG. 1 is a cross-sectional view showing a carbon fiber prepreg laminate with improved flatness according to one embodiment of the present invention. Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the present invention. The present invention may be embodied in various different forms and is not limited to the embodiments described herein. In order to clearly explain the invention in the drawings, parts unrelated to the description have been omitted, and the same reference numerals are assigned to identical or similar components throughout the specification. Additionally, thicknesses have been enlarged in the drawings to clearly represent various layers and regions. Furthermore, where it is stated in this specification that one component is placed "on" or "above" another component, the component may be placed directly on the other component, or there may be components interposed between said components. Conversely, where it is stated that one component is placed "directly" or "on" another component, there may be no interposed components. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention pertains. In the event of a conflict, the present specification, including definitions, shall prevail. Additionally, methods and materials similar or equivalent to those described herein may be used in the practice or testing of the present invention, but suitable methods and materials are described herein. In this specification, "~-type resin," "~-type polymer," or/and "~-type copolymer" are broad concepts that include all of "~-type resin," "~-type polymer," "~-type copolymer," or/and "derivatives of ~-type resin, polymer, or copolymer." Additionally, in this specification, the term "polymer or copolymer cross-linked with these resins" means "polymer or copolymer cross-linked with the aforementioned resins." In this specification, the term “compound” is a broad concept that includes “monatomic molecules,” “oligomers,” and “polymer compounds including homopolymers and copolymers.” In this specification, the term "includes" means that, unless specifically stated otherwise, it does not exclude other components but may include additional components. In this specification, the term “combination of these” means a mixture or combination with one or more of the des