The Manufacturing Process of Carbon Fiber Panels Explained
Carbon fiber panels are among the widely used products in the evolution of carbon fiber technology. Known for their lightweight nature, strong malleability, corrosion resistance, high hardness, and tensile strength, these panels find extensive applications across various industries, including the rail transit sector for vehicle bodies and the industrial machinery sector for components. Let's delve into the manufacturing process of carbon fiber panels.
I. Product Specification Analysis
For carbon fiber panels, different application fields and environments call for varying production processes. Before production, we typically start with an analysis of drawings and requirements. Based on strength demands, special performance needs, and other aspects such as panel thickness, we select materials, forming processes, additives, and conduct a comprehensive analysis before proceeding with manufacturing.
II. Pre-preg Selection
After analyzing the product's performance and determining the desired outcomes for the carbon fiber panel, we select the appropriate pre-preg. Carbon fiber pre-preg is the primary raw material, with specifications like 1k, 3k, 6k, and 12k, which refer to the number of carbon fiber tows in the pre-preg. The higher the number, the greater the hardness of the carbon fiber. Most products use 3k carbon fiber tows, which are conducive to molding and have good plasticity in later stages.
Pre-pregs must also be cut according to the product's requirements and panel thickness. Different thicknesses require varying numbers of pre-preg layers, and our carbon fiber pre-pregs are stacked in multiple layers to enhance their usage efficiency.
III. Layering
Once the product's connections are clear, we calculate the number of layers needed. Each layer's orientation affects the mechanical properties of the carbon fiber product. Common layer orientations are 0°, 45°, 90°, and 135°, corresponding to direct stress, while ±45° layers provide stronger shear stress, and 90° layers offer better direct pressure. The choice of carbon fiber pre-preg layer orientation is based on the product's performance requirements.
IV. Molding Process
After layering, the carbon fiber panel undergoes a molding process, typically using an autoclave. The pre-preg is heated and pressed in a mold to gradually cure. Our carbon fiber engineers control the heating time and temperature based on product performance requirements. Common forming temperatures for carbon fiber panels are above 150°C, not exceeding 180°C, with a molding time of about 30 minutes.
V. Surface Treatment
Carbon fiber panels, due to their varied application environments, may require painting or surface grinding to achieve a smoother appearance, all according to product specifications. Traditional glass fiber, in comparison, rarely requires such treatments and is more often subjected to machining operations like drilling.
The entire manufacturing process of carbon fiber panels demonstrates the need for skilled labor, which contributes to their higher cost compared to other panels. The choice of carbon fiber panels is driven by their lighter weight, reducing energy consumption, and superior mechanical strength. The strength of carbon fiber panels is 6-8 times that of steel, leading to their widespread application.
