R-CF-Plate Customizable Sizes And Thicknesses, Drillable And Die-cut Carbon Fiber Sheets And Plates

Application of Carbon Fiber Sheets

Aerospace

Used in the manufacture of aircraft fuselages, wings, tail fins, satellite supports, and other structural components, significantly reducing weight (approximately 75% lighter than steel), improving fuel efficiency and load capacity. Carbon fiber sheets are also commonly used in the center plates and arms of drones, reducing weight by 15%-20%, extending range, and enhancing flight stability.

Automotive and Rail Transportation

In the automotive industry, carbon fiber sheets are used in body panels, chassis, battery pack covers, and other components to reduce vehicle weight and improve fuel efficiency or electric vehicle range. High-performance racing cars and new energy vehicles have high demand for them. In rail transportation, carbon fiber sheets are used in car bodies and equipment compartments to achieve weight reduction and speed improvement.

Building Reinforcement

As a structural reinforcement material, carbon fiber sheets are used to reinforce concrete beams, columns, bridges, and tunnels. The reinforcement effect is comparable to steel plates but with almost no increase in self-weight. Construction is convenient, and it is corrosion-resistant, extending the service life of the structure.

Sports Equipment

Manufactures high-end sports equipment, such as skis and diving fins, utilizing their lightweight and high rigidity to enhance athletic performance and help athletes push their limits.

Medical Equipment

Used as a medical bed board material in radiological diagnostic equipment such as CT scanners and X-ray machines. Its high X-ray transmittance and low absorption rate improve image clarity, while its lightweight design optimizes ease of operation.

Electronic and Industrial Equipment

Used in drones, robotic arms, and precision instrument bases, providing high rigidity and dimensional stability; for the casings or internal structural components of electronic devices (such as mobile phones and laptops), balancing thinness, shock resistance, and heat dissipation.

The Manufacturing Process of Carbon Fiber Sheets

Introduction

Carbon fiber sheets are advanced composite materials renowned for their exceptional strength-to-weight ratio, stiffness, and durability. These properties make them indispensable in high-performance industries such as aerospace, automotive racing, and high-end sporting goods. The production of a carbon fiber sheet is a multi-stage process that begins with the creation of the carbon fibers themselves and culminates in the precise lamination and curing of the final composite material.

1. The Foundation: Carbon Fiber Production

The carbon fiber sheet manufacturing process fundamentally relies on the quality of the raw carbon fibers. These fibers are typically derived from a polymer precursor, most commonly polyacrylonitrile (PAN). The conversion of PAN to carbon fiber involves a series of thermal and chemical treatments:

Precursor Spinning: The PAN polymer is spun into continuous filaments, which are then bundled into tow.

Stabilization (Oxidation): The PAN fibers are heated in an oxygen-rich environment at temperatures between 200°C and 300°C. This process, which can take several hours, chemically stabilizes the material and prepares it for carbonization.

Carbonization: The stabilized fibers are heated in an inert atmosphere (such as nitrogen) at extremely high temperatures, often ranging from 1,000°C to 3,000°C. This intense heat drives out non-carbon atoms, leaving behind long, tightly interlocked chains of pure carbon atoms.

Surface Treatment and Sizing: The carbonized fibers undergo a slight surface oxidation to improve their chemical bonding with the resin matrix. Finally, a protective coating, known as "sizing," is applied to the fibers before they are wound onto spools. This sizing protects the fibers during handling and further enhances the bond with the final resin [1].

2. Manufacturing Carbon Fiber Sheets

Once the carbon fibers are produced, they are woven into a fabric (such as a twill or plain weave) and then combined with a polymer matrix, typically an epoxy resin, to form the composite sheet. While several methods exist, the Prepreg Lamination technique is the industry standard for producing high-strength, high-quality carbon fiber sheets [2].

The Prepreg Lamination Process

The term "prepreg" refers to the carbon fiber fabric that has been pre-impregnated with a precisely controlled amount of resin and is kept frozen to prevent premature curing. This method ensures an optimal fiber-to-resin ratio, which is critical for achieving maximum strength and stiffness.

The process involves the following steps:

Prepreg Cutting: The frozen prepreg material is cut into specific shapes and sizes, often using automated CNC cutters, to match the mold geometry.

Layup: The cut prepreg plies are meticulously stacked onto a flat mold or tool. Each ply is oriented at a specific angle (e.g., 0°, +45°, -45°, 90°) to engineer the final mechanical properties of the sheet, such as directional strength and stiffness.

Vacuum Bagging: The entire layup stack is sealed within a vacuum bag system. A vacuum is drawn to remove any trapped air or volatile compounds between the layers, ensuring a dense, void-free laminate.

Curing: The vacuum-bagged assembly is placed into an autoclave (a pressurized oven). The combination of high heat (to activate the resin) and high pressure (to consolidate the layers) cures the epoxy resin, permanently bonding the carbon fiber plies into a solid, monolithic sheet.

Comparison of Carbon Fiber Sheet Manufacturing Methods

While prepreg lamination is preferred for high-performance applications, other methods are used depending on the required quality, complexity, and cost.

3. Finishing and Quality Control

After the sheet is cured, it undergoes final processing to meet the required specifications:

Demolding and Trimming: The cured sheet is removed from the mold. Excess material is trimmed using precision tools, such as CNC routers or waterjet cutters, to achieve the final dimensions.

Surface Finishing: The sheet may be sanded, polished, or coated with a clear, UV-resistant resin to enhance its aesthetic appeal and protect the epoxy matrix from degradation by sunlight.

Quality Assurance: The final product is rigorously inspected for defects such as delamination, voids, or thickness variations using non-destructive testing methods like ultrasonic inspection.

The meticulous, multi-step process of carbon fiber sheet production ensures that the final product delivers the exceptional performance characteristics demanded by modern engineering applications.