CN101500771A - 制造复合材料的方法及装置 - Google Patents
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Abstract
本发明涉及制造复合片材的装置和方法，所述方法包括：a.在基本上为大气压的压力下以等离子体在辐照区(33)辐照纤维片材(20)和/或基质(11、13)，和b.在粘接区(32)以所述基质浸渍所述纤维片材；其中，工序a.和工序b.同时进行。
Description
技术领域
本发明涉及制造复合材料的方法和装置。
背景技术
在US5108780中，强化丝的单根纤维在以热塑性涂料涂覆之前在真空室中用等离子体辐照。以热塑性涂料立即涂覆经等离子体处理的纤维产生了比当纤维在被涂覆前即暴露于空气或其它自由基淬灭物种时更强的界面抗剪强度。
JP2005171432的摘要描述了用于聚合物复合物强化的纤维的制造方法。该纤维在常压下经受第一等离子体处理，随后于常压下在含有气态烯烃或炔烃的介质中经受第二等离子体处理。在等离子体处理之后施以粘合剂。
发明内容
本发明的第一方案提供了制造复合片材的方法，该方法包括：
a.在基本上为大气压的压力下以等离子体在辐照区辐照纤维片材和/
或基质，和
b.在粘接区以所述基质浸渍所述纤维片材；
其中，工序a.和b.同时进行。
本发明的第一方案辐照纤维片材(而不是单根纤维)并且同时进行浸渍工序从而产生以基质浸渍过的纤维片材(通常在本领域中称为“预浸料”)。这与只生产纤维的单丝的上述在先技术形成了对比。本方法使得不必以中间产品(例如US5108780中的热塑性涂料或者JP2005171432中的烯烃/炔烃)处理纤维就能形成片材。
所述纤维片材可以完全浸渍，也可以只有部分浸渍从而形成所谓的“部分预浸料”。
在基本上为大气压的压力下辐照是指辐照区不需要特殊的封闭体系。
通常来说工序b也在基本上为大气压的压力下进行，通常是在空气中进行。这与需要在受控环境中(即，在真空中或者惰性气体中)涂覆纤维的US5108780的教导相反。
可以通过施用流体基质熔融物来浸渍所述纤维片材，所述基质也可以在工序b期间处于片状。直接施用流体基质熔融物提供了可省去加工步骤(形成基质片材)的优势。然而，优选的是使用基质片材，这是因为这对常规制造方法需要的修改较少，使得基质更容易被辐照，并且如果需要，可制备部分预浸料。
优选所述纤维片材和/或所述基质在步骤a期间保持移动，并且优选所述纤维片材在步骤b期间保持移动。这提高了该方法的速度，并且确保均匀的辐照。
优选该方法进一步包括用少于30秒将所述纤维片材和/或所述基质从所述辐照区移动到所述粘接区。
本发明的第二方案提供了复合预浸料的制造装置，该装置包括：
等离子体源，所述等离子体源用于在基本上为大气压的压力下以等离子体辐照纤维片材和/或基质，和
用于以所述基质浸渍所述纤维片材的单元。
本发明的第三方案提供了复合材料的制造方法，该方法包括：
以等离子体辐照基质，和
以经辐照的所述基质被覆填料。
本发明的第三方案认识到辐照所述基质可以(必要时与辐照所述填料相结合)用于增强所述填料和所述基质之间的粘接。所述填料可以是纤维片材(与本发明的第一方案相符)，也可以是非纤维材料或单根纤维。
本发明的第四方案提供了用于制造复合材料的装置，该装置包括：
用于以等离子体辐照基质的等离子体源，和
用于以经辐照的所述基质被覆填料的单元。
附图说明
现在将通过参照以下附图描述本发明的实施方式：
图1显示了复合预浸料的制造方法的第一步骤；和
图2显示了该方法的第二步骤。
具体实施方式
参见图1，所示的是用于制造基质膜的装置1。涂覆头2包括装有液态基质材料4(“熔融物”或者分散液)的漏斗3。漏斗3的开口位于一对辊筒5之间。液态基质材料4通过辊筒5而被施用于从隔离纸卷7连续送出的隔离纸6的片材的上表面。基质膜8和隔离纸6的片材被卷绕在辊筒10上。当已经形成所需尺寸的卷时，停止从涂覆头流出基质4，并倒转辊筒10。基质膜8经由导辊12被卷绕在辊筒上从而形成基质膜卷11。与此同时将隔离纸6回卷到隔离纸卷7上。随后移去卷11并且重复该工序以形成图2所示的基质膜的另一卷13。
基质材料4通常是聚合物，并且可以是热固性的(例如环氧树脂)或热塑性的(例如聚醚醚酮——PEEK)。
参见图2，将纤维片材20从辊筒(未显示)经由一对导辊21、22送出。构成片材20的纤维可以由诸如碳、玻璃、天然纤维或热塑性塑料等任何有机材料或无机材料制成。片材20可以是单向带的形式或机织织物的形式。将一对基质膜从基质膜卷11、13经由辊筒22、23退卷。随后将该三层组装体以加热器24加热并在三对压固辊25之间压缩。这使片材浸渍有基质材料从而形成预浸料26的片材。预浸料26在图2中显示为两层，但其实际上有效地变为单层的经基质浸渍的纤维。随后将预浸料26与一层隔离纸28共同卷在辊筒27上，所述隔离纸28从隔离纸卷29退卷并通过一对辊筒30、31而被施用于预浸料。
在进入粘接区(概括地在32标出，由辊筒22、33、加热器24和压固辊25界定)之前，纤维片层20和/或来自卷11、13的基质膜在辐照区(概括性地标为33)受到等离子体的辐照。图2中显示了三个等离子体源：
●第一源40，其指向辊筒22的辊隙从而辐照纤维片材与下部基质膜的相对的那些面；
●第二源41，其指向辊筒23的辊隙从而辐照纤维片材与上部基质膜的相对的那些面；和
●第三源42，其只指向上部基质膜。
虽然图2中显示了三个源，但可以按照需要使用更多或更少的等离子体源。因此一般来说，可以使用等离子体源只辐照纤维片材；只辐照一层或两层基质膜；或者辐照纤维片材和一层或两层基质膜(如图2所示)。
每一等离子体源可以是例如：
●由加拿大蒙特利尔的Plasmatec Inc.提供的“Plasmatec”等离子体单元；
●由英国塔姆沃思的Dyne Technology Ltd.提供的“Tantec”等离子体单元；或者
●由英国豪斯罗工商区(Hounslow Business Park)的Adtec EuropeLtd(UK)提供的“AX系列”等离子体单元。
等离子体源在基本上为大气压的压力下产生等离子体。这意味着不需要将等离子体源像在US5108780中那样安放在真空室中，而是可以与装置的其余部分一起在正常条件(即在大气压力下的空气中)下安放。
辐照工序和浸渍工序同时进行，而不是像分批法(batch process)那样依次进行。这使得纤维片材在辐照之后当活性自由基依然存在时即被迅速浸渍。
辊筒持续运转，从而使纤维片材和基质膜在辐照和浸渍期间保持移动。
等离子体可以在环境温度或更高温度中产生，并且可以是诸如氧、氩和氮等气体以任意比例混合从而形成处理材料所需的离子物种的任意混合物。例如，等离子体可以是：
●氮/氩
●氮/氧
●氮/氧/氩
●空气
虽然图2中只显示了三个等离子体源，但取决于片材20的幅宽，可以以阵列(即，在图2的平面之外)布置更多的等离子体源以辐照纤维片材和/或基质膜的全部幅宽。所述幅宽可以为3毫米～20米。
对纤维和/或基质的辐照在它们的表面上产生自由基并且增强预浸料中这些成分之间的粘接。这些自由基具有有限的停留时间(dwell time)，因此将等离子体源40～42放置得足够接近辊筒22、23，并且辊筒以足够的速度运转，从而确保在辐照之后尽快(通常在辐照之后不到30秒，优选在辐照之后不到1秒)通过辊筒22、23将这些片层聚集在一起。虽然这一工序的速度可以高达400米/分钟，但通常以2米/分钟～10米/分钟进行。
在纤维片材与基质结合之前不对纤维片材施用单独的粘合剂。
预浸料可以用于形成诸如机翼蒙皮(wing skin)、长桁(stringer)、翼梁(spar)、机翼通路板(wing access panel)或扰流器等飞行器部件；或诸如自行车架、工业制品、体育用品、汽车产品、风能产品或航海产品(如船壳)等非飞行器部件。
虽然以上通过参照一个或多个优选的实施方式对本发明进行了描述，但应该认识到的是可以做出各种变化或修改，而不背离如所附权利要求书中所限定的本发明的范围。
Claims (20)
1.一种制造复合片材的方法，所述方法包括：
a.在基本上为大气压的压力下以等离子体在辐照区辐照纤维片材和/或基质，和
b.在粘接区以所述基质浸渍所述纤维片材；
其中，工序a.和b.同时进行。
2.如权利要求1所述的方法，其中，工序b.在基本上为大气压的压力下进行。
3.如前述权利要求中任一项所述的方法，其中，所述基质在工序b.期间为片状。
4.如前述权利要求中任一项所述的方法，其中，所述纤维片材和/或所述基质在工序a.期间保持移动。
5.如前述权利要求中任一项所述的方法，其中，所述纤维片材在工序b.期间保持移动。
6.如前述权利要求中任一项所述的方法，其中，工序b.在空气中进行。
7.如前述权利要求中任一项所述的方法，所述方法进一步包括用少于30秒将所述纤维片材和/或所述基质从所述辐照区移动至所述粘接区。
8.通过前述权利要求中任一项所述的方法制造的复合片材。
9.一种复合片材的制造装置，所述装置包括：
a.用于在基本上为大气压的压力下以等离子体辐照纤维片材和/或基质的等离子体源，和
b.用于以所述基质浸渍所述纤维片材的单元。
10.一种制造复合材料的方法，所述方法包括：
a.以等离子体辐照基质，和
b.以经辐照的所述基质被覆填料。
11.如权利要求10所述的方法，其中，工序a.在基本上为大气压的压力下进行。
12.如权利要求10或11所述的方法，其中，工序b.在基本上为大气压的压力下进行。
13.如权利要求10～12中任一项所述的方法，其中，所述填料包括片材。
14.如权利要求10～13中任一项所述的方法，其中，所述基质包括片材。
15.如权利要求10～14中任一项所述的方法，其中，所述基质在工序a.中随着其移动穿过辐照区而被辐照；并且在工序b.中随着其移动穿过粘接区而被覆所述填料。
16.如权利要求10～15中任一项所述的方法，其中，工序a.和工序b.同时进行。
17.如权利要求10～16中任一项所述的方法，其中，工序b.在空气中进行。
18.如权利要求10～17中任一项所述的方法，其中，所述基质在工序a.中在辐照区被辐照，并在工序b.中在粘接区被覆所述填料，并且其中，所述方法进一步包括用少于30秒将所述基质从所述辐照区移动至所述粘接区。
19.通过权利要求10～18中任一项所述的方法制造的复合材料。
20.一种复合材料的制造装置，所述装置包括：
a.用于以等离子体辐照基质的等离子体源，和
b.用于以经辐照的所述基质被覆填料的单元。
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0615644A GB0615644D0 (en) | 2006-08-07 | 2006-08-07 | Method of manufacturing composite material |
| GB0615644.2 | 2006-08-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN101500771A true CN101500771A (zh) | 2009-08-05 |
Family
ID=37027350
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNA2007800293797A Pending CN101500771A (zh) | 2006-08-07 | 2007-08-01 | 制造复合材料的方法及装置 |
Country Status (9)
| Country | Link |
|---|---|
| US (2) | US8241711B2 (zh) |
| EP (1) | EP2049312B1 (zh) |
| JP (1) | JP2010500441A (zh) |
| CN (1) | CN101500771A (zh) |
| BR (1) | BRPI0714911A2 (zh) |
| CA (1) | CA2660256A1 (zh) |
| GB (1) | GB0615644D0 (zh) |
| RU (1) | RU2009106583A (zh) |
| WO (1) | WO2008017882A1 (zh) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104723582A (zh) * | 2015-03-27 | 2015-06-24 | 解廷秀 | 一种连续纤维增强热塑性复合材料的制造设备及其应用 |
| CN106715548A (zh) * | 2014-09-29 | 2017-05-24 | 可隆工业株式会社 | 用于燃料电池分离板的热塑性预浸料中间材料及使用其制造用于燃料电池分离板的热塑性预浸料的方法 |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB201222934D0 (en) * | 2012-12-19 | 2013-01-30 | Cytec Ind Inc | Particle toughening for improving fracture toughness |
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| JPS5774115A (en) | 1980-10-27 | 1982-05-10 | Res Dev Corp Of Japan | Manufacture of prepreg sheet |
| DE3277873D1 (en) | 1981-04-04 | 1988-02-04 | Nat Res Dev | Polymers in matrix reinforcement |
| US4496415A (en) * | 1982-04-08 | 1985-01-29 | Westinghouse Electric Corp. | Method for impregnating resin powder directly into a laminate lay up |
| US4606930A (en) * | 1984-03-02 | 1986-08-19 | Sumitomo Chemical Company, Limited | Method for treating fibers |
| US4664936A (en) | 1985-01-30 | 1987-05-12 | Shin-Etsu Chemical Co., Ltd. | Aromatic polyamide fiber-based composite prepreg |
| JPH01272731A (ja) | 1988-04-22 | 1989-10-31 | Ube Ind Ltd | 繊維強化金属複合材料の製造方法 |
| US5180780A (en) * | 1989-01-12 | 1993-01-19 | Idemitsu Petrochemical Company Limited | Rubber-modified styrene-based copolymer |
| US5549780A (en) | 1990-10-23 | 1996-08-27 | Semiconductor Energy Laboratory Co., Ltd. | Method for plasma processing and apparatus for plasma processing |
| US5108780A (en) | 1991-01-28 | 1992-04-28 | Brigham Young University | Enhanced thermoplastic adhesion to fibers by using plasma discharge |
| US5391855A (en) | 1991-08-01 | 1995-02-21 | Komoto Tech, Inc. | Apparatus for atmospheric plasma treatment of a sheet-like structure |
| GB9216186D0 (en) | 1992-07-30 | 1992-09-09 | Ciba Geigy Ag | Product and production method |
| US5266139A (en) * | 1992-10-02 | 1993-11-30 | General Dynamics Corporation, Space Systems Division | Continuous processing/in-situ curing of incrementally applied resin matrix composite materials |
| KR960702844A (ko) | 1993-05-28 | 1996-05-23 | 앤 제이. 로버슨 | 중합체 물질을 대기압하에서 글로우 방전 플라즈마로 처리하는 방법 및 장치(nethod and apparatus for glow discharge plasma treatment of polymer materials at atmospheric pressure) |
| DE19610113C2 (de) * | 1996-03-14 | 1998-01-22 | Reinhausen Maschf Scheubeck | Verfahren zur Herstellung eines faserverstärkten Isolierkörpers |
| US5895622A (en) * | 1997-04-07 | 1999-04-20 | Purdue Research Foundation | Method and apparatus for composite manufacture |
| JP3430897B2 (ja) * | 1998-01-27 | 2003-07-28 | 松下電工株式会社 | プリプレグ及び積層板 |
| US6066826A (en) | 1998-03-16 | 2000-05-23 | Yializis; Angelo | Apparatus for plasma treatment of moving webs |
| US6828578B2 (en) | 1998-12-07 | 2004-12-07 | Meridian Research And Development | Lightweight radiation protective articles and methods for making them |
| US6709718B2 (en) | 2001-04-10 | 2004-03-23 | Exxonmobil Oil Corporation | Porous plasma treated sheet material |
| US6555778B1 (en) * | 2001-11-19 | 2003-04-29 | Geomat Insights, Llc | Plasma enhanced sheet bonding method and device |
| JP2005171432A (ja) | 2003-12-12 | 2005-06-30 | Teijin Techno Products Ltd | 高分子複合体補強用繊維の製造方法 |
| GB0410749D0 (en) * | 2004-05-14 | 2004-06-16 | Dow Corning Ireland Ltd | Coating apparatus |
-
2006
- 2006-08-07 GB GB0615644A patent/GB0615644D0/en not_active Ceased
-
2007
- 2007-08-01 WO PCT/GB2007/050462 patent/WO2008017882A1/en active Application Filing
- 2007-08-01 RU RU2009106583/05A patent/RU2009106583A/ru not_active Application Discontinuation
- 2007-08-01 EP EP07766474.6A patent/EP2049312B1/en not_active Not-in-force
- 2007-08-01 CN CNA2007800293797A patent/CN101500771A/zh active Pending
- 2007-08-01 BR BRPI0714911-5A patent/BRPI0714911A2/pt not_active IP Right Cessation
- 2007-08-01 JP JP2009523353A patent/JP2010500441A/ja active Pending
- 2007-08-01 CA CA 2660256 patent/CA2660256A1/en not_active Abandoned
- 2007-08-01 US US12/375,108 patent/US8241711B2/en not_active Expired - Fee Related
-
2012
- 2012-08-01 US US13/564,289 patent/US8420183B2/en not_active Expired - Fee Related
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106715548A (zh) * | 2014-09-29 | 2017-05-24 | 可隆工业株式会社 | 用于燃料电池分离板的热塑性预浸料中间材料及使用其制造用于燃料电池分离板的热塑性预浸料的方法 |
| CN104723582A (zh) * | 2015-03-27 | 2015-06-24 | 解廷秀 | 一种连续纤维增强热塑性复合材料的制造设备及其应用 |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2010500441A (ja) | 2010-01-07 |
| BRPI0714911A2 (pt) | 2013-05-28 |
| WO2008017882A1 (en) | 2008-02-14 |
| RU2009106583A (ru) | 2010-09-20 |
| CA2660256A1 (en) | 2008-02-14 |
| US20090297726A1 (en) | 2009-12-03 |
| US20120292828A1 (en) | 2012-11-22 |
| EP2049312A1 (en) | 2009-04-22 |
| US8241711B2 (en) | 2012-08-14 |
| GB0615644D0 (en) | 2006-09-13 |
| US8420183B2 (en) | 2013-04-16 |
| EP2049312B1 (en) | 2016-12-28 |
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