CN102186665A - 改善的复合材料 - Google Patents

改善的复合材料 Download PDF

Info

Publication number
CN102186665A
CN102186665A CN2009801410725A CN200980141072A CN102186665A CN 102186665 A CN102186665 A CN 102186665A CN 2009801410725 A CN2009801410725 A CN 2009801410725A CN 200980141072 A CN200980141072 A CN 200980141072A CN 102186665 A CN102186665 A CN 102186665A
Authority
CN
China
Prior art keywords
assembly
sub
prepreg
layer
uppermost
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN2009801410725A
Other languages
English (en)
Other versions
CN102186665B (zh
Inventor
马克.怀特
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hexcel Composites Ltd
Original Assignee
Hexcel Composites Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hexcel Composites Ltd filed Critical Hexcel Composites Ltd
Publication of CN102186665A publication Critical patent/CN102186665A/zh
Application granted granted Critical
Publication of CN102186665B publication Critical patent/CN102186665B/zh
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/247—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using fibres of at least two types
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/72—Cured, e.g. vulcanised, cross-linked
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/414—Translucent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2331/00—Polyvinylesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2333/00—Polymers of unsaturated acids or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2361/00—Phenoplast, aminoplast
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2363/00—Epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2375/00—Polyureas; Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2377/00—Polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2603/00—Vanes, blades, propellers, rotors with blades
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23914—Interlaminar
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
    • Y10T428/2991—Coated
    • Y10T428/2993—Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
    • Y10T428/2996—Glass particles or spheres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Textile Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

一种预浸料组合件，其包括热固性树脂和纤维，并且包括最上面的可固化树脂表面层，从而使得当该组合件固化时，该最上面的表面层在超过200个循环时具有至少0.30mg/循环的打磨性能，根据ASTM D4060使用安装有H18轮和1.0kg重物的Taber 5151磨耗试验机测得。

Description

改善的复合材料
技术领域
本发明涉及具有表面整饰处理的包括树脂和纤维的预浸料组合件，和固化的复合材料。
背景技术
复合材料相对于传统的结构材料具有充分证明的优点，在以非常低的材料密度提供优异的机械性质方面尤其是这样。结果，这些材料的用途变得越来越广泛，它们的应用范围涉及工业、运动和休闲，以及高性能航空航天组件。
包括浸渍有树脂例如环氧树脂的纤维排列的预浸料广泛地用于产生这种复合材料。通常将许多层这些预浸料根据需要层叠，并且将得到的组合件，或者层合体，置于模具中并通常通过暴露于升高的温度而固化，从而产生固化的复合材料层合体。
但是，在没有施加任何表面处理的情况下，这种复合材料常常具有粗糙的，或者有针孔的表面。这种形成不平表面的倾向似乎与下层纤维的粗糙性紧密相关，该纤维越粗糙问题就越严重。当例行地使用粗糙纤维并且高度期望光滑表面整饰时，这尤其是个问题，一个实例是在构建风机叶片(windblade)的情况时。
给这种复合材料提供光滑的表面整饰的已知技术是使用所谓的凝胶涂层。简而言之，这涉及到使可流动的组合物在该模具的内表面流过，然后使其固化形成凝胶层，将该预浸料组合件置于该凝胶层上，然后固化。在固化过程中，该预浸料和凝胶涂层融合到一起，这通常导致该形成的复合材料具有光滑的光泽表面。但是，该方法是非常劳动密集型的，需要初始的固化步骤，并且往往会产生厚度不均匀的凝胶层。此外，为了覆盖缺陷，该层需要是较厚的(例如平均0.3mm)，具有不期望的重量增加。
考虑到施加凝胶涂层的缺点，提出的可供选择的解决方式涉及到将所谓的表面整饰膜结合到该预浸料组合件中。WO 2008/007094公开了一种整饰膜，其包括表面预浸渍的微纤维片材，该片材具有也是预浸渍的玻璃纤维的下层绒布(fleece)。在固化时，该整饰膜防止形成针孔并且提供光滑表面，而不需要凝胶涂层。
因此，似乎提供良好表面整饰的问题，即使对于粗糙的纤维复合材料，也已经在很大程度上被解决了。但是，到目前为止发现在实践中已经出现了未预料的问题。
发明内容
一旦已经由固化的复合材料层合体装配成结构体，例如风机叶片，总是发生的事实情况是最终用户期望对该结构涂油漆。无论是仅仅要改变它的颜色还是要引入其它物理性质例如抵抗气候。通常的既定实践是，通过摩擦例如通过打磨结构体来制备该结构体的表面。这不仅除去该表面上的任何污物，而且容许油漆楔入到产生的微粗糙度中，得到更好的油漆粘着力并增加该结构的服务寿命。
已经发现，最终用户对包括表面整饰膜的层合体打磨至损害它的结构并且在表面中产生与整饰膜意图防止的非常相同的针孔的程度。
本发明人已经确认，在打磨时，最终用户寻求表面光泽水平的变化作为足够打磨的指示。似乎通过使用如上所述的整饰膜产生的表面比它们以前更加耐打磨，结果它们往往使用更具攻击性的打磨方法，导致了上述的损害发生。
因此，第一方面，本发明涉及一种预浸料组合件，其包括热固性树脂和纤维，并且包括最上面的可固化树脂表面层，从而使得当该组合件固化时，该最上面的表面层在超过200个循环时具有至少0.30mg/循环的打磨性能，根据ASTM D4060使用安装有H18轮和1.0kg重物的Taber 5151磨耗试验机测得。
通过设计该最上面的层来很好地响应打磨，在发生对下层纤维的任何损害之前，观察到光泽水平的变化，这使得停止打磨，并且提供干净光滑的饰面，但是该饰面具有打磨的微粗糙度，容许施加油漆层，从而赋予有吸引力的和长的服务寿命。
已经发现，优选打磨性能为0.3至2.0mg/循环，优选0.4至1.0mg/循环。
打磨性能可以以许多方式获得，例如通过将最上面的层设计为软的。但是，已经发现，这种打磨性能优选通过在最上层中包含粒状材料(例如至少10wt％)而获得。
因此，在第二方面，本发明涉及一种预浸料组合件，其包括热固性树脂和纤维，并且包括最上面的可固化树脂表面层，该层包括至少10.0wt％的粒状材料。
优选该表面层包括15至40wt％的粒状材料，更优选20至30wt％。
该粒状材料优选的平均粒度为5至50微米，优选10至30微米。
最上面的层的厚度必需使得它能够被安全地打磨，而不害怕损害下面的纤维，而也不太厚使得预浸料中的重量增加变得显著。因此，优选该最上面的层的平均厚度为10至200微米，优选20至100微米。
该粒状材料可为任何合适的材料，通常由惰性材料，或者填料制成。优选的材料由粒度为5至50微米，优选25至35微米，和颗粒密度为2.5g/cm3的玻璃球制成。
在优选的实施方式中，该最上面的层是着色的，例如通过包含染料或者颜料而着色。通过使该最上面的层着色，最终用户除了光泽变化之外，还有第二可视指示，指示何时已经进行了充分的打磨。
优选该最上面的层是半透明的，从而使得该最上面的层下面紧接着的层的颜色能够通过该最上面的层(当它足够薄时)看见。例如，随着最终用户对最上面的层进行打磨，最上面的半透明的蓝色层(其具有较浅着色的在该最上面的层下面紧接着的层)将显示出从蓝色到较浅渐变的蓝色的逐渐颜色变化。
因此，该颜色变化能够在所有的最上面的层被打磨掉之前给最终用户发出停止打磨的信号。
虽然本发明可用于一般应用，但是优选本发明的预浸料包括如以上所述的WO 2008/007094中所披露的表面整饰纤维。因此，优选该预浸料组合件包含纤维遮蔽物层(veil layer)来帮助提供光滑的表面整饰，优选其面重量为5至20gsm，更优选7至15gsm。如果存在，该纤维遮蔽物紧接着在该最上层的下面。
该遮蔽物层的合适材料包括聚酯，聚酰胺，芳族聚酰胺(aramid)，丙烯酸类聚合物和其任何组合。
优选该纤维遮蔽物受在它下方的无纺绒布支撑，例如WO 2008/007094中披露的玻璃纤维绒布。这种绒布可比面重量为30至70gsm的遮蔽物具有更重的负载(heavier duty)。
该预浸料组合件可包括各种类型和形式的树脂。例如树脂可以作为在纤维片材(包括该绒布和遮蔽物层(如果存在的话))之间离散的层存在，。但是通常，将树脂预浸渍到该纤维层的结构中，但是根据需要在所谓的半预浸料排列中，一些纤维层能够潜在地保持“干的状态”。树脂可以以图案或者作为多个层的形式存在，设计的选择由本领域技术人员自行处理。
通常，该最上面的可固化树脂层包括通常用于预浸料制造中的热固性树脂，例如以下树脂：酚醛树脂、脲醛树脂、1，3，5-三嗪-2，4，6-三胺(三聚氰胺)树脂、双马来酰亚胺树脂、环氧树脂、乙烯基酯树脂、苯并噁嗪树脂、酚树脂、
Figure BDA0000055808580000041
聚酯、不饱和聚酯、氰酸酯树脂，或其混合物。环氧树脂是优选的。可根据需要包括固化剂和任选的促进剂。
该预浸料组合件通常包括至少一层片材形式的纤维。
该预浸料组合件优选包括多层树脂和纤维，以便给固化的层合体提供机械强度。这种结构树脂和纤维的类型和设计可为本领域技术人员已知的任何一种，例如WO 2008/056123中提及的那些。
通常在该纤维层中的纤维将会延伸通过整个预浸料组合件，例如以单向的方式或者以机织织物的方式。
在优选的实施方式中，在最上面的层中的树脂的粘度大于在该最上层下面的树脂的粘度。这帮助防止树脂在存储和固化的过程中从最上面区域向下迁移到预浸料组合件中。在最上面的层中的树脂的粘度优选是最上面的层下面紧接着的树脂的至少两倍。
本发明可应用于用于广泛的各种应用的预浸料。但是，已经发现它特别适宜生产风机叶片，例如用于风能场中的那些。在这些应用中，通常该结构纤维是比较粗糙的，并且包括至少一个面重量为600至1200gsm的结构性纤维片材，例如玻璃纤维。
本发明的预浸料组合件优选通过如下方法制造：将所述最上面的层放置到模具表面上，然后放置接下来的各层，接着通过将组合件暴露于升高的温度和任选的升高的压力而使该组合件固化。
因此，该预浸料组合件通过使该最上面的层与模具表面接触而固化。通常，将随后的层放置在最上面的层的上面从而产生三明治状的结构。在优选的实施方式状，该预浸料组合件包括至少三个层，更优选至少四个层。
该预浸料组合件可通过任何合适的已知方法固化，例如真空袋，或者高压釜固化或者压力固化。但是，真空袋方法是优选的，因为这是对于风机叶片来说的优选方法。
下面将参考以下附图示例性地说明本发明，在附图中：
图1是与模具表面接触的预浸料组合件的图。
图2是另一与模具表面接触的预浸料组合件的图。
图3是另一与模具表面接触的预浸料组合件的图。
转向附图，图1至3显示与模具表面12接触的预浸料组合件10。排列该预浸料10，从而使得它的最上面表面与该模具接触，并且因此是倒着显示的。
非常详细地示出了该最上层，并且显示出最上面的树脂表面层14，其包括：
-70.1％的改性双酚A环氧树脂，
-2.0％的双氰胺
-1.0％的N，N-(4-甲基-1，3-亚苯基)二[N′N′-二甲基-脲]
-2.4％的疏水处理的融凝硅石
-24.4％的平均粒度为约30微米的玻璃微球
-0.1％的在双酚A环氧树脂中的蓝色颜料分散体
下一层是纤维遮蔽物层16，其可例如为11gsm的WrampTM遮蔽物，由65％的聚酯和35％的尼龙的共混物制成(可得自Technical Fibre Products，Kendal，UK)，下一层是30gsm无纺绒布层18。
接下来的层是所谓的结构层，并且在图1中显示为是预浸渍的玻璃纤维层20，其包括完全浸渍有M9.6树脂的LBB 1200玻璃纤维(都可得自Hexcel)。图2显示了包括LBB 1200玻璃纤维的干的玻璃纤维层22，在所谓的半预浸料排列中具有单独的树脂层24，包括M9.6。图3显示了包括LBB 1200玻璃纤维的干的玻璃纤维层22，具有单独的预浸渍纤维层26，包括预浸渍有M9.6树脂的LBB 1200。
最后，该预浸料组合件进一步通过另外的预浸渍纤维层28支撑。
实施例
试验设备和方法
为了测量磨损，固化的层合体根据ASTM D4060使用安装有H18轮和1kg重物的Taber 5151磨耗试验机测得。测量样品重量损失(磨耗的测量)，周期性地进行至至多500个磨损循环。
为了测量光泽，在样品的已经经受磨损的区域上，根据EN ISO 2813使用手持光泽计在85℃(Sheen Instruments Ltd，Tri-Glossmaster)周期性地测量层合体。
为了测量颜色，在样品的已经经受磨损的区域上，使用手持分光光度计(X-Rite SP60)使用D65标准光源和仅使用10°标准观察者镜面组件(observer specular component)和L*a*b*颜色空间周期性地测量层合体。
生产和试验
图1中所示的预浸料组合件根据以下方法制造。
为了生产最上面的树脂层，将双酚A树脂在合适的容器中加热至70℃。将每个另外的材料装入该容器中并且使用DAC 400FVZ快速混合机混合。然后将该配制物使用逆转辊Dixon涂布机以50gsm和100gsm涂膜到硅化的纸上。
该预浸料在专用的生产线上制造。该纤维遮蔽物使用该树脂的固有粘性附着，该中间绒布可通过缝编、热粘结或者通过使用所用树脂的固有粘性附着至该增强织物。或者将该最上面的树脂层从硅化的纸热转移至该表面整饰组合件的微纤维遮蔽物侧，或者可将其在该微纤维绒布侧直接涂覆到优选的重量。
在叠置本发明的材料和另外的层压层之前，使用合适的脱模剂(例如Zyvax Watershield)预处理模具(通常具有复合材料结构)。然后将该组合件密封在真空袋的内侧，排空空气并施加真空，并且在合适的炉中固化。通常的固化进度表是：25-80℃，1℃/min；在80℃120分钟；80-120℃，1℃/min；在120℃60分钟。
在固化之后，将该层合体切成100 x 100mm样品，并且粘结到相同尺寸的铝片，从而露出表面整饰侧。使用Redux 810膏状粘合剂(Hexcel，Duxford，UK)来将该片粘结到该样品上，并且在60℃固化60分钟。通过每个样品的中心钻出6.5mm的孔，以便它可被安装到该Taber磨耗试验机上。
周期性地停止该Taber试验，记录磨损循环的数目，并且取出样品来测量重量损失，光泽和颜色。然后将样品再安装并重新开始该试验。
结果
以下表1比较了WO 2008/007094中描述的表面整饰膜复合材料和根据本发明的固化的复合材料层合体的磨损重量损失。磨损重量损失越高，对打磨的响应就越大。
表1
  对照-表面整饰膜复合材料   本发明的表面整饰复合材料
磨损循环数 磨损重量损失(g) 磨损重量损失(g)
  0   0   0
  20   0.0049   0.0035
  40   0.0106   0.0135
  60   0.0159   0.0269
  80   0.0206   0.0451
  100   0.0256   0.0622
  200   0.0441   0.1193
  300   0.0547   0.1579
  400   0.086   0.1980
  500   0.1143   0.2548
以下表2显示本发明是如何给用户说明在打磨时的清晰终点的，从而避免使该表面过度打磨和损伤。
表2
Figure BDA0000055808580000081

Claims (21)

1.一种预浸料组合件，其包括热固性树脂和纤维，并且包括最上面的可固化树脂表面层，从而使得当该组合件固化时，该最上面的表面层在超过200个循环时具有至少0.30mg/循环的打磨性能，根据ASTM D4060使用安装有H18轮和1.0kg重物的Taber 5151磨耗试验机测得。
2.根据权利要求1的预浸料组合件，其中所述最上面的层包括至少10.0wt％的粒状材料。
3.一种预浸料组合件，其包括热固性树脂和纤维，并且包括最上面的可固化树脂表面层，该层包括至少10.0wt％的粒状材料。
4.根据权利要求2或3的预浸料组合件，其中所述最上面的层包括15至40wt％的粒状材料。
5.根据权利要求2至4的预浸料组合件，其中所述粒状材料的平均粒度为5至50微米。
6.根据前述权利要求中任一项的预浸料组合件，其中所述最上面的层的平均厚度为10至200微米。
7.根据前述权利要求中任一项的预浸料组合件，其中所述最上面的层与该最上面的层之下紧接着的层在颜色上有明显差别。
8.根据前述权利要求中任一项的预浸料组合件，其中所述最上面的层是半透明的。
9.根据前述权利要求中任一项的预浸料组合件，其包括在所述最上层下面的纤维遮蔽物层。
10.根据权利要求9的预浸料组合件，其包括在所述纤维遮蔽物下面的无纺绒布。
11.根据前述权利要求中任一项的预浸料组合件，其包括至少一个纤维层。
12.根据权利要求11的预浸料组合件，其包括至少一个没有用树脂浸渍的纤维层，由此形成半预浸料排列。
13.根据前述权利要求中任一项的预浸料组合件，其包括包含所述最上层在内的至少三个层。
14.根据前述权利要求中任一项的预浸料组合件，其中在所述最上面的层中的树脂的粘度大于该最上面的层之下紧接着的树脂的粘度。
15.根据前述权利要求中任一项的预浸料组合件，其包括至少一个面重量为600至1200gsm的纤维层。
16.根据前述权利要求中任一项的预浸料组合件，其中所述最上面的层与模具表面接触。
17.制造根据前述权利要求中任一项的预浸料组合件的方法，其包括将所述最上面的层放置到模具表面上，然后放置接下来的各层，和通过将组合件暴露于升高的温度而使该组合件固化。
18.通过使根据权利要求1至16中任一项的预浸料组合件固化而形成的复合材料层合体。
19.制备根据权利要求17的复合材料层合体或者通过权利要求17的方法可获得的复合材料层合体的表面的方法，其包括打磨所述表面。
20.可通过权利要求19的方法获得的复合材料层合体。
21.一种风机叶片组件，其包括至少一个根据权利要求18或者20的复合材料层合体或者可通过权利要求17的方法获得的复合材料层合体。
CN200980141072.5A 2008-10-20 2009-10-07 改善的复合材料 Active CN102186665B (zh)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB0819186A GB2464539B (en) 2008-10-20 2008-10-20 Composite Materials with Improved Sandability
GB0819186.8 2008-10-20
PCT/GB2009/051329 WO2010046682A1 (en) 2008-10-20 2009-10-07 Improved composite materials

Publications (2)

Publication Number Publication Date
CN102186665A true CN102186665A (zh) 2011-09-14
CN102186665B CN102186665B (zh) 2016-08-03

Family

ID=40097692

Family Applications (1)

Application Number Title Priority Date Filing Date
CN200980141072.5A Active CN102186665B (zh) 2008-10-20 2009-10-07 改善的复合材料

Country Status (9)

Country Link
US (1) US8906481B2 (zh)
EP (2) EP3572224A1 (zh)
CN (1) CN102186665B (zh)
BR (1) BRPI0920361B1 (zh)
CA (1) CA2739689C (zh)
DK (1) DK2346679T3 (zh)
ES (1) ES2750333T3 (zh)
GB (1) GB2464539B (zh)
WO (1) WO2010046682A1 (zh)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106457693A (zh) * 2014-06-09 2017-02-22 赫克赛尔公司 用于单向不连续纤维复合材料模制复合物的压塑的示踪物
CN114728448A (zh) * 2019-11-20 2022-07-08 赫克塞尔合成有限公司 表面整理模制材料
CN114746266A (zh) * 2019-11-20 2022-07-12 赫克塞尔合成有限公司 模制材料

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2464539B (en) * 2008-10-20 2014-01-08 Hexcel Composites Ltd Composite Materials with Improved Sandability
GB201308284D0 (en) * 2013-05-08 2013-06-12 Gpfone Ltd Coloured Carbon-Fibre Composite Materials
US9897065B2 (en) 2015-06-29 2018-02-20 General Electric Company Modular wind turbine rotor blades and methods of assembling same
US10337490B2 (en) 2015-06-29 2019-07-02 General Electric Company Structural component for a modular rotor blade
CN105965911A (zh) * 2016-06-16 2016-09-28 悌埃保温制品（上海）有限公司 保温层外玻璃钢保护层的制作工艺
US11254793B2 (en) * 2016-09-13 2022-02-22 Dow Global Technologies Llc Catalyst-doped sizing agent for preparation of high areal weight fiber shelf-stable prepreg or molding compound intermediates
CN109952182A (zh) * 2016-10-26 2019-06-28 东丽株式会社 预浸料坯层叠体、纤维增强复合材料及纤维增强复合材料的制造方法

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6042936A (en) * 1997-09-23 2000-03-28 Fibermark, Inc. Microsphere containing circuit board paper
CN1295596A (zh) * 1997-11-26 2001-05-16 住友电木株式会社 生产预浸料和层板的方法
CN1336869A (zh) * 1999-01-14 2002-02-20 帕诺拉姆工业国际公司 耐磨损叠层及其制造工艺
CN1348485A (zh) * 1999-03-03 2002-05-08 利利工业有限公司 耐磨损涂料
US20020079052A1 (en) * 2000-05-18 2002-06-27 Ligui Zhou Self-adhesive prepreg face sheets for sandwich panels
CN1634698A (zh) * 2003-12-26 2005-07-06 叶炽凡 玻纤增强型高分子复合材料井盖
CN101104328A (zh) * 2007-01-25 2008-01-16 庄启程 一种真木皮热固性树脂浸渍高压装饰层积防火板制造方法
CN101229815A (zh) * 2007-01-25 2008-07-30 宁波曙翔铁路设备制造有限公司 高强度树脂基复合材料轨道绝缘组件

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1262522A1 (en) * 2001-06-01 2002-12-04 Dsm N.V. Granite-look reinforced laminar product of a thermosetting aminoplast
US20020136862A1 (en) * 2000-12-11 2002-09-26 Daojie Dong Decorative and/or flame retardant laminates and processes of manufacture thereof
GB0613834D0 (en) * 2006-07-12 2006-08-23 Hexcel Composites Ltd Composite material assembly
GB0622060D0 (en) * 2006-11-06 2006-12-13 Hexcel Composites Ltd Improved composite materials
GB2464539B (en) * 2008-10-20 2014-01-08 Hexcel Composites Ltd Composite Materials with Improved Sandability

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6042936A (en) * 1997-09-23 2000-03-28 Fibermark, Inc. Microsphere containing circuit board paper
CN1295596A (zh) * 1997-11-26 2001-05-16 住友电木株式会社 生产预浸料和层板的方法
CN1336869A (zh) * 1999-01-14 2002-02-20 帕诺拉姆工业国际公司 耐磨损叠层及其制造工艺
CN1348485A (zh) * 1999-03-03 2002-05-08 利利工业有限公司 耐磨损涂料
US20020079052A1 (en) * 2000-05-18 2002-06-27 Ligui Zhou Self-adhesive prepreg face sheets for sandwich panels
CN1634698A (zh) * 2003-12-26 2005-07-06 叶炽凡 玻纤增强型高分子复合材料井盖
CN101104328A (zh) * 2007-01-25 2008-01-16 庄启程 一种真木皮热固性树脂浸渍高压装饰层积防火板制造方法
CN101229815A (zh) * 2007-01-25 2008-07-30 宁波曙翔铁路设备制造有限公司 高强度树脂基复合材料轨道绝缘组件

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106457693A (zh) * 2014-06-09 2017-02-22 赫克赛尔公司 用于单向不连续纤维复合材料模制复合物的压塑的示踪物
CN106457693B (zh) * 2014-06-09 2019-12-06 赫克赛尔公司 用于单向不连续纤维复合材料模制复合物的压塑的示踪物
CN114728448A (zh) * 2019-11-20 2022-07-08 赫克塞尔合成有限公司 表面整理模制材料
CN114746266A (zh) * 2019-11-20 2022-07-12 赫克塞尔合成有限公司 模制材料

Also Published As

Publication number Publication date
ES2750333T3 (es) 2020-03-25
BRPI0920361B1 (pt) 2019-10-29
CN102186665B (zh) 2016-08-03
DK2346679T3 (da) 2019-11-18
GB0819186D0 (en) 2008-11-26
GB2464539A (en) 2010-04-28
WO2010046682A1 (en) 2010-04-29
EP2346679B1 (en) 2019-08-28
EP3572224A1 (en) 2019-11-27
US20110194942A1 (en) 2011-08-11
BRPI0920361A2 (pt) 2016-08-02
US8906481B2 (en) 2014-12-09
GB2464539B (en) 2014-01-08
CA2739689C (en) 2017-09-26
CA2739689A1 (en) 2010-04-29
EP2346679A1 (en) 2011-07-27

Similar Documents

Publication Publication Date Title
CN102186665B (zh) 改善的复合材料
TWI343854B (en) High-performance resin for abrasive products
JP5320742B2 (ja) 複合プリプレグ基材の製造方法、積層基材および繊維強化プラスチック
JP6651780B2 (ja) 繊維強化複合材料の製造方法、樹脂基材およびプリフォーム
JP5815501B2 (ja) プリプレグ、及び前記プリプレグから製造される成形体
US7771837B2 (en) Derived timber board with a surface coating applied at least in parts
KR0175713B1 (ko) 장식용 적층 시이트 제조방법 및 이 방법에 사용되는 전사시이트
CN104972719A (zh) 使用聚合物-纳米颗粒共聚物制造的无纺中间层
CN101489775A (zh) 复合材料组件
US3525664A (en) Abrasion resistant plastic laminate and method of making same
US8778039B2 (en) Composite material for further processing into sheet-like abrasive products and process for the production thereof
CN110561865A (zh) 一种充气冲浪板复合材料及其制备方法
JP4480445B2 (ja) 着色パネル組立部品
CN110682639B (zh) 一种环保型充气冲浪板复合材料及其制备方法
CN111890771A (zh) 一种强界面宽温域的阻尼插层及连续纤维增强复合材料
US11787129B2 (en) Surface-coated film, surface-coated fiber-reinforced resin molded product, and manufacturing method thereof
DK2442965T3 (en) METHOD FOR PRODUCING a textile HALF MAKE WITH IMPROVED toughness and textile HALF MAKE
US20220289924A1 (en) Surface finishing moulding material
CN1177686C (zh) 高耐磨耗性反光材料的制法
CN115610047A (zh) 一种复合薄膜及其应用
JP3623346B2 (ja) 木質仕上材

Legal Events

Date Code Title Description
C06 Publication
PB01 Publication
C10 Entry into substantive examination
SE01 Entry into force of request for substantive examination
C14 Grant of patent or utility model
GR01 Patent grant