基于碳纤维自阻加热的热塑性复合材料注射成型机理研究

由于单一材料难以最大程度地满足汽车结构的轻量化要求，纤维增强树脂基复合材料、轻质金属等多材料体系混合是轻量化材料发展的重要趋势。连续纤维增强热塑性复合材料混合结构，凭借其较高的比刚度在汽车领域受到广泛关注。但由于热塑性树脂的粘度太高，采用传统注射成型工艺实现热塑性复合材料混合结构的模内一体化制造难度较大。针对该问题，本项目创新性地提出基于碳纤维自阻加热的热塑性复合材料注射成型方法，并对其成型机理展开研究：①探明碳纤维预制体的自阻加热机制；②分析自阻加热注射成型过程，研究注射压力作用下预制体温度场的分布规律和调控机制；③基于分子动力学理论，研究电-热耦合作用下聚合物-碳纤维的界面粘结机理及强度调控机制；④基于上述理论，实现热塑性复合材料自阻加热注射成型制造。项目可望首次建立自阻加热条件下热塑性复合材料注射成型成性分析理论，为其混合结构的高效、低成本、绿色制造提供新的理论基础与技术支撑。

It is difficult to meet the requirements from automotive lightweight construction using one material, therefore the economic multi-material lightweight construction were developed. Hybrid continuous fiber reinforced thermoplastics (hybrid composites) are one of the competitive materials because of their excellent mechanical properties，high specific stiffness. However, the integrated manufacturing of hybrid composites using injection molding technology faces more challenges because of high viscosity of thermoplastic matrix. In terms of this challenge, the novel method that injection molding of thermoplastic composites by using the direct resistance heating to carbon fiber is proposed in this proposal. This new processing method for continuous fiber reinforced composites will be further investigated: ①to investigate the self-heating behavior of carbon fiber perform ② to analyze the injection molding process and study the influence of injection pressure on the temperature distribution of carbon fiber perform ③ to investigate the matrix-fiber interface bonding mechanism and interfacial shear strength using Molecular Dynamics method ④ to achieve the fast process of thermoplastic composites according to the above results. The outcomes from this proposal will be expected to provide a new method for the mass production of the hybrid thermoplastic composites.