CN101541514B - 制造复合部件的改进方法 - Google Patents

制造复合部件的改进方法 Download PDF

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CN101541514B
CN101541514B CN2007800439642A CN200780043964A CN101541514B CN 101541514 B CN101541514 B CN 101541514B CN 2007800439642 A CN2007800439642 A CN 2007800439642A CN 200780043964 A CN200780043964 A CN 200780043964A CN 101541514 B CN101541514 B CN 101541514B
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马塞尔·巴克利
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Abstract

一种制造复合部件的方法，所述方法包括以下步骤：将预成型体(5)装入部件成型框架(3)中，用溶液或悬浮液形式的含有催化剂物质的溶剂填充所述框架，将该液体(6)从模具中排出，由此使剩余的催化剂物质保留在预成型体上和/或所述成型框架的内表面上，加热所述成型框架并随后或者同时在此条件下引入含碳气体(7)，从而在预成型体上和/或成型框架表面上生长碳纳米管结构，除去含碳气体，并将液态树脂材料(9)引入成型框架中，由此使树脂通过预成型体和碳纳米管结构分散，从而在树脂固化或固定后形成最终复合部件。

Description

制造复合部件的改进方法
技术领域
本发明涉及形成复合结构的改进方法。更具体但不唯一的是，本发明涉及树脂传递模塑复合结构的改进方法，从而提高成品的韧性并因此提高其耐损伤性。本发明还涉及通过上述方法形成的改进的复合结构。
背景技术
用于例如树脂传递模塑过程的液体复合材料模塑，对于制造复杂的厚的复合结构具有很大的工业价值。目前，将这种结构广泛引入先进工程应用中的一个明显缺点是适用于这些过程的树脂系统的韧性较低。在对复合物的材料性质要求极端严格的民航领域，这种缺点尤为明显。
液态复合材料模塑所需的低粘度不包括使用热塑性增韧剂。这导致复合结构的韧性较低，因而其抗损伤性能有限。
解决该问题的一种方案就是向常规的复合结构中添加碳纳米管(CNT)。已经有文献证实，次级碳纳米管可以在初级碳纤维的表面上生长。
如果碳纳米管可以以相对于彼此的适当的浓度生长，则由于各管之间的范德华相互作用，可以实现自排列。
因此在纤维之间可以形成排列整齐的CNT结构。但是，目前还没有实际生产具有这种结构的复合部件的方法。
发明内容
一方面，本发明提供一种制造复合部件的方法，所述方法包括以下步骤：将预成型体装入部件成型框架中，用溶液或悬浮液形式的含有催化剂物质的溶剂填充所述框架，将该液体从模具中排出，由此使剩余的催化剂物质保留在预成型体上和/或成型框架的内表面上，加热所述成型框架并随后或者同时在此条件下引入含碳气体，从而在所述预成型体上和/或所述成型框架表面上生长碳纳米管结构，除去所述含碳气体，并将液体树脂材料引入所述成型框架中，由此使所述树脂通过所述预成型体和碳纳米管结构分散，从而在所述树脂固化或固定后形成最终复合部件。
所述成型框架优选是模具、真空袋树脂-传递模塑组件或其它能够用于树脂-传递模塑过程的限制性框架。在一个优选实施方式中，所述成型框架是金属模具。
优选的是，所述催化剂是溶液或悬浮液形式的金属催化剂物质。
优选的是，所述预成型体是碳纤维预成型体结构(如干燥纤维预成型体)或任何使得碳纳米管结构形成或沉积在碳纤维预成型体结构的填隙结构内或碳纤维的外表面上的类似的预成型体。
优选的是，通过以惰性气体冲洗所述模具而除去所述含碳气体。
优选的是，通过常规的树脂传递模塑技术或类似技术将树脂引入预成型体和碳纳米管结构中。
附图说明
下面将仅通过实施例并参照附图对本发明进行说明，附图中：
图1表示根据本发明的一个方面的空模具；
图2表示模具和预成型体；
图3表示模具内的预成型体；
图4表示闭合的模具工具；
图5表示将催化剂引入模具中；
图6表示催化剂被排出模具；
图7表示加热模具工具；
图8表示将含碳气体引入模具工具中；
图9表示加热模具工具；
图10表示所得的模具工具中的基质；和
图11表示正被加热的模具和正被固化的基质。
具体实施方式
虽然在树脂-传递模塑的情形下描述本实例，但本发明基本上可以在任何遵从树脂-传递模塑的成型框架构造中实施。优选的模具通常是金属模具，但也可以使用其它特定的模具材料。在本发明的一个实施方式中，将碳预成型体装入闭合模具中，所述碳预成型体优选为干纤维预成型体，例如稀松组织碳纤维织物或其它三维干纤维碳纤维结构(参见图1至4)。
模具工具密封或闭合(图3)后，填充入溶液或悬浮液形式的含有催化剂物质的液体溶剂(参见图5)。该物质优选为金属催化剂，选择该金属催化剂来提供碳纳米管生长的开始位置。
在适当的时间后，将液体溶剂排出。该过程使得剩余的催化剂物质沉积在碳预成型体纤维上和/或模具工具表面上，如图6所示。
然后，加热模具工具并引入含碳气体(参见图7和8)。在特定的条件下，加热所述含碳气体，使得在预成型体表面上和/或模具工具表面上在催化剂处生长碳纳米管阵列(参见图9)。通常，在此条件下，预成型体结构上和模具内壁上都会生长碳纳米管。如果碳纳米管以适当的浓度生长，则纳米管之间的范德华相互作用可以理想地使碳纳米管以自排列的几何形状生长。
然后，通过用惰性气体冲洗模具来去除框架内的含碳气体。对于常规的树脂传递模塑，随即将液体树脂材料引入到模具中(参见图10)。
通过毛细管作用过程，液体树脂被传送到碳纳米管网络中，这有助于预成型体的湿润和渗透。
根据所得结构，碳纳米管将不仅存在于碳纤维预成型体上，而且还存在于模具工具壁上，从而对否则就会被认为是“富含树脂”的区域提供增强作用。树脂渗透进去后，用常规方式加热模具以使部件固化，然后脱模(参见图11)。
因此，最终部件会有显著程度的“平面外”增强作用，并含有分散且局部排列整齐的碳纳米管阵列，提供“纳米裂纹阻挡物”网络。可以设想，根据该技术制得的复合结构将具有有益的各向同性应力吸收特性，并且在通常被认为富含树脂并因此缺乏耐久性的区域具有增强的韧性。
虽然已经通过实施例并参考特定的实施方式对本发明进行了描述，但应该了解，可以进行不脱离本发明的范围和要旨的改变和/或改进。例如，树脂注入过程可参考其它的液体树脂过程：树脂膜注入和多粘度注入等。
上文描述中提到了具有已知等效物的整体或者要素，这种等效物如同单独列举一样被并入本文。

Claims (8)

1.一种制造复合部件的方法，所述方法包括以下步骤：将预成型体装入部件成型框架中，用溶液或悬浮液形式的含有催化剂物质的溶剂填充所述成型框架，将所述液体从所述成型框架中排出，从而使剩余的所述催化剂物质保留在所述预成型体上和/或所述成型框架的内表面上，加热所述成型框架并随后或者同时在此条件下引入含碳气体，从而在所述预成型体上和/或所述成型框架表面上生长碳纳米管结构，除去所述含碳气体，并将液态树脂材料引入所述成型框架中，由此使所述树脂通过所述预成型体和所述碳纳米管结构分散，从而在所述树脂固化或固定后形成最终复合部件。
2.如权利要求1所述的方法，其中，所述成型框架是模具、真空袋树脂-传递模塑组件或其它能够用于树脂-传递模塑过程的限制性框架。
3.如权利要求1所述的方法，其中，所述成型框架是金属模具。
4.如权利要求1～3中任一项所述的方法，其中，所述催化剂物质是金属催化剂物质。
5.如权利要求1～3中任一项所述的方法，其中，所述预成型体是碳纤维预成型体结构，所述碳纤维预成型体结构经排列使得所述碳纳米管结构形成或沉积在所述碳纤维预成型体结构的填隙结构内或所述碳纤维的外表面上。
6.如权利要求1～3中任一项所述的方法，其中，通过以惰性气体冲洗所述成型框架而除去所述含碳气体。
7.如权利要求1～3中任一项所述的方法，其中，通过树脂传递模塑技术将所述树脂引入所述预成型体碳纳米管结构中。
8.根据权利要求1～7中任一项所述的方法制造的复合部件，其中在所述预成型体上和所述成型框架表面上沉积催化剂物质和生长碳纳米管结构。
CN2007800439642A 2006-11-29 2007-11-21 制造复合部件的改进方法 Expired - Fee Related CN101541514B (zh)

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US20100068527A1 (en) 2010-03-18
BRPI0719655A2 (pt) 2013-12-17
CA2667561C (en) 2015-10-13
US8137602B2 (en) 2012-03-20
JP5351037B2 (ja) 2013-11-27
RU2451601C2 (ru) 2012-05-27
GB0623738D0 (en) 2007-01-10
EP2091721B1 (en) 2015-09-30
CA2667561A1 (en) 2008-06-05
EP2091721A1 (en) 2009-08-26
JP2010510913A (ja) 2010-04-08
WO2008065446A1 (en) 2008-06-05
RU2009124106A (ru) 2011-01-10

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